Patent Grant
11589654
This nonprovisional application is based on Japanese Patent Application No. 2020-077797 filed on Apr. 24, 2020 with the Japan Patent Office, the entire contents of which are hereby incorporated by reference.
The present disclosure relates to a last, a method for manufacturing a last, and a method for manufacturing a footwear upper.
When an article of footwear is produced, a last (or a footwear model) for being covered with a cloth configuring a footwear upper is used in order to form the footwear upper into a predetermined shape.
U.S. Patent Application Publication No. 2018/0014609 discloses manufacturing an article of footwear in a portable housing. U.S. Patent Application Publication No. 2016/0206049 discloses a last preform reformable with a shape memory polymer. Chinese Patent No. 109732913 discloses forming a last by 3D printing.
When making a made-to-order article of footwear fitting a user's feet, a dedicated last reflecting the shape of the feet of each individual is produced. Manufacturing a user-dedicated last in a conventional manner employs dedicated large-size equipment and requires time and cost.
The present disclosure proposes a last having a simple configuration and matching a user's foot, a method for manufacturing the last, and a method for manufacturing a footwear upper using the last.
According to an aspect of the present disclosure, a last for forming a footwear upper configuring an article of footwear is proposed. The last comprises a common portion invariable in shape and position, a movable portion invariable in shape and positionally variable with respect to the common portion, and a position adjustment mechanism that changes a position of the movable portion with respect to the common portion and fixes the movable portion in a predetermined position.
According to an aspect of the present disclosure, a method for manufacturing a last for forming a footwear upper configuring an article of footwear is proposed. The present method for manufacturing a last comprises the following steps. A first step is a step of preparing a last including a common portion invariable in shape and position, a movable portion invariable in shape and positionally variable with respect to the common portion, and a position adjustment mechanism that changes a position of the movable portion with respect to the common portion and fixes the movable portion in a predetermined position. A second step is a step of adjusting the position adjustment mechanism to change the position of the movable portion with respect to the common portion.
According to an aspect of the present disclosure, a method for manufacturing a footwear upper is proposed. The method for manufacturing a footwear upper comprises the following steps. A first step is a step of covering the above-mentioned last with an unformed upper made of a fiber sheet including a heat-shrinkable yarn. A second step is a step of applying heat to form the unformed upper along the shape of the last to be a formed upper.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
Hereinafter, embodiments will be described with reference to the drawings. In the following description, identical components are identically denoted. Their names and functions are also identical. Accordingly, such components will not be described repeatedly.
A last (or a footwear model) of an embodiment described below is mainly a last for a made-to-order article of footwear made to fit a user's foot. It should be noted, however, that the last of the embodiment is also applicable to a last for articles of footwear in mass production.
Foot model FM may be formed in the same shape as the user's foot F. Alternatively, for some reason in design or functionality, foot model FM may have a specific portion corrected from the shape of the user's foot F by a desired dimension.
Last 1 shown in
Position adjustment mechanism 82A includes an engagement portion 84. Engagement portion 84 switches through a fitting structure, a screwing structure or the like between a first state in which movable portion 80A is fixed in the predetermined position and a second state in which movable portion 80A is movable. For example, position adjustment mechanism 82A may include a tube of a larger diameter and a tube of a smaller diameter accommodated in the tube of the larger diameter and capable of reciprocating with respect to the tube of the larger diameter, and engagement portion 84 may switch between a state in which engagement portion 84 is not engaged with at least one of the tube of the larger diameter and the tube of the smaller diameter to allow the tube of the smaller diameter to be movable with respect to the tube of the larger diameter and a state in which engagement portion 84 is engaged with both the tube of the larger diameter and the tube of the smaller diameter to make the tube of the smaller diameter immovable with respect to the tube of the larger diameter. In this case, engagement portion 84 may be implemented as a snap lock, a pin lock, a lock nut, or the like.
As a component configuring position adjustment mechanism 82A, an electrically driven mechanism component such as a stepping motor may be detachably accommodated in common portion 70. After movable portion 80A is positionally changed and fixed in the predetermined position, the mechanism component may be removed from common portion 70.
Movable portion 80A is positionally variable in the middle foot portion widthwise of last 1. When position adjustment mechanism 82A changes a position of movable portion 80A to increase a distance between the paired, right and left movable portions 80A, last 1 has a middle foot portion having an increased dimension in width. When position adjustment mechanism 82A changes a position of movable portion 80A to decrease a distance between the paired, right and left movable portions 80A, last 1 has a middle foot portion having a decreased dimension in width.
Movable portion 80B is positionally variable in the middle foot portion along the height of last 1. When position adjustment mechanism 82B moves movable portion 80B upward to increase a distance between movable portion 80B and common portion 70, last 1 has a middle foot portion having a dimension increased in height. When position adjustment mechanism 82B moves movable portion 80B downward to decrease a distance between movable portion 809 and common portion 70, last 1 has a middle foot portion having a dimension decreased in height.
Position adjustment mechanism 82B may have a transversely extending rotary shaft, and movable portion 80B may be supported by the rotary shaft and thus rotatable about the rotary shaft, as indicated in
Cover 90 may be a film that shrinks when it is heated, such as polystyrene film. In this case, last 1 can be covered with the film, which can in turn be heated and thus deformed to form cover 90 to cover a surface of last 1. In thermally deforming cover 90, air (warm air) may be sent from the inside of cover 90. This can suppress excessive inward shrinkage of cover 90 at a portion of connection of movable portion 80 and common portion 70 and can thus increase precision of forming a footwear upper.
Cover 90 may be metal foil represented by aluminum foil, and in this case, covering a surface of last 1 with metal enhances thermal conductivity, which is advantageous in heating and thus forming a footwear upper, as will be described hereinafter. Alternatively, cover 90 may be a sock.
Hereinafter, although there will be a description partially overlapping with the above description, a characteristic configuration as well as function and effect of the present embodiment will be listed below.
As shown in
Last 1 is divided, and movable portion 80 is used at a portion that is unlikely to vary in shape with different users and positionally varies with different users to make the portion positionally variable. Adjusting position adjustment mechanism 82 based on foot model FM of a target user to change a position of movable portion 80 with respect to common portion 70 and fix movable portion 80 in the changed position, allows last 1 corresponding to the shape of foot F of each user to be provided in a short time. Thus, last 1 matching the user's foot F can be provided through a simple configuration.
For a portion where it is unlikely that there is a difference between feet of users in shape and it is unnecessary to change last 1 in shape and position, common portion 70 that is invariable in shape and position can be used to allow last 1 to be further simplified in configuration, and thus reduce a period of time required to adjust last 1 in shape to match the user's foot in shape.
As shown in
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While incorporable last portion 88 shown in
As shown in
As shown in
Thus defining common portion 70 and movable portion 80A in shape allows last 1 to be formed to match the user's foot in shape with better precision.
Incorporable last portion 10 shown in
Foot length forming member 20 and foot width forming member 40 can be formed by cutting them out of a sheet-shaped base member. Foot length forming member 20 and foot width forming member 40 may be made of paper such as cardboard, or may be made of resin such as thermoplastic resin. Foot length forming member 20 and foot width forming member 40 may have engagement grooves for incorporating the members into each other.
A portion of the middle foot portion corresponding to the instep is a portion having a largest difference in shape among feet of users. Forming a groove or a space at this portion and using incorporable last portion 10 therein allow last 1 to be formed to match the user's foot in shape with better precision. Incorporable last portion 10 personalized for and thus dedicated to each user may be fabricated. Alternatively, a plurality of incorporable last portions 10 different in shape may previously be prepared, and incorporable last portion 10 corresponding to foot model FM of the user and having a shape closest thereto may be selected and used.
By passing rod-shaped foot length forming member 20 through throughhole 42, foot width forming member 40 is assembled to foot length forming member 20. Thus, incorporable last portion 10 can be simplified in configuration, stabilized in shape, and assembled faster. The number of rod-shaped foot length forming members 20 and that of throughholes 42 of foot width forming member 40 are not limited to two such members and two throughholes, as illustrated, and one or more such members and one or more throughholes may be provided. Throughhole 42 may be replaced with a groove formed in foot width forming member 40 and allowing rod-shaped foot length forming member 20 to be fitted therein.
While a plurality of foot width forming members 40 aligned in the longitudinal direction may be plates equal in thickness, the plurality of foot width forming members 40 may be plates different in thickness, as shown in
Preventing foot width forming member 40 from being excessively reduced in thickness on a side closer to the toes where a foot does not have an instep significantly varying in shape can reduce the number of parts configuring incorporable last portion 10. This allows last 1 to be manufactured faster.
While a plurality of foot width forming members 40 may be aligned in the longitudinal direction without a gap, as shown in
Since common portion 70 has receiving hole 72 for receiving rod-shaped foot length forming member 20 therein and supporting it in a predetermined position, foot length forming member 20 can be supported in common portion 70 in an appropriate position. Thus, incorporable last portion 10 in which plate-shaped foot width forming member 40 is assembled to rod-shaped foot length forming member 20 can be fixed in an appropriate position with respect to common portion 70.
While incorporable last portion 10 is composed of plate-shaped foot length forming member 20 and plate-shaped foot width forming member 40 combined together, as described in the third embodiment, and rod-shaped foot length forming member 20 and plate-shaped foot width forming member 40 assembled thereto, as described in the fourth embodiment, incorporable last portion 10 may be a block-shaped member obtained by solidifying resin or pulp. Block-shaped incorporable last portion 10 may be solid or hollow. Incorporable last portion 10 may be a solid molded article manufactured using a 3D printer.
In the above embodiments is described an example of last 1 in which a portion extending from a middle foot portion to a heel portion is formed as common portion 70. Instead of this example, last 1 may also comprise movable portion 80 in the heel portion.
As shown in
In last 1 shown in
In a sixth embodiment will be described a method for manufacturing a footwear upper using last 1 described in the above embodiments.
Through such a manufacturing process, a footwear upper matching a user's foot F in shape and thus dedicated to the user can be manufactured without using large-scale facilities.
Heating box 210 may be a steam oven. While unformed upper 200 is heated with steam, unformed upper 200 may be heated with hot air, warm water or the like. Unformed upper 200 may be heated partially rather than entirely. The thus formed upper is attached to a separately formed footwear sole through adhesion, thermal fusion bonding, or the like.
While each step is performed or after the whole process is completed, a shoe tongue is formed, a footwear opening is processed, eyelets are attached for passing a shoelace therethrough, an ornament and a tag are attached, a logo is printed, an insole is attached and the like to manufacture an article of footwear.
The method for manufacturing the footwear upper is not limited to thermal shrinkage of a fiber sheet including a heat-shrinkable yarn, as described above, and a variety of methods may be employed, for example, knitting a material around last 1 directly, additive manufacturing with a 3D printer, or the like. It is also possible to use last 1 of the embodiments in a conventionally known process of forming a footwear upper in a factory.
The characteristic configurations disclosed in the above-described embodiments and modifications thereof will be summarized as follows.
A last according to an embodiment of the present disclosure is directed to forming a footwear upper configuring an article of footwear. The last comprises a common portion invariable in shape and position, a movable portion invariable in shape and positionally variable with respect to the common portion, and a position adjustment mechanism that changes a position of the movable portion with respect to the common portion and fixes the movable portion in a predetermined position.
In the last according to an embodiment of the present disclosure, the movable portion may allow the last to have a middle foot portion positionally variable widthwise of an article of footwear.
In the last according to an embodiment of the present disclosure, the movable portion may allow the last to have a middle foot portion positionally variable in level.
In the last according to an embodiment of the present disclosure, the movable portion may allow the last to have a middle foot portion angularly variable with respect to the common portion.
In the last according to an embodiment of the present disclosure, the position adjustment mechanism may have an engagement portion that switches between a first state in which the movable portion is fixed in a predetermined position and a second state in which the movable portion is movable.
In the last according to an embodiment of the present disclosure, a line along a boundary portion of the common portion and the movable portion may be a straight or curved line corresponding to a line extending along a metatarsal bone of a foot of a wearer of an article of footwear.
The last according to an embodiment of the present disclosure may further comprise an incorporable last portion incorporated into a groove formed in the common portion or a space formed between the common portion and the movable portion.
In the last according to an embodiment of the present disclosure, the incorporable last portion may include a plurality of plate-shaped members extending widthwise of the article of footwear.
In the last according to an embodiment of the present disclosure, the incorporable last portion may include a rod-shaped member extending longitudinally of the article of footwear, and the plate-shaped member may have a through hole formed therein to pass the rod-shaped member therethrough.
In the last according to an embodiment of the present disclosure, the common portion may have a receiving hole formed therein to receive an end portion of the plate-shaped member.
The last according to an embodiment of the present disclosure may further comprise an incorporable last portion disposed in a gap formed between the movable portion and the common portion after the movable portion is positionally changed with respect to the common portion.
The last according to an embodiment of the present disclosure may further comprise a cover in the form of a sheet or a plate to externally cover at least a portion of the last or a gap formed in the last.
A method for manufacturing a last according to an embodiment of the present disclosure is a method for manufacturing a last for forming a footwear upper configuring an article of footwear. The method for manufacturing a last comprises the following steps. A first step is a step of preparing a last including a common portion invariable in shape and position, a movable portion invariable in shape and positionally variable with respect to the common portion, and a position adjustment mechanism that changes a position of the movable portion with respect to the common portion and fixes the movable portion in a predetermined position. A second step is a step of adjusting the position adjustment mechanism to change the position of the movable portion with respect to the common portion.
In the method for manufacturing a last according to an embodiment of the present disclosure, the second step of adjusting the position adjustment mechanism to change the position of the movable portion with respect to the common portion may include the steps of: generating a foot model for a user; generating from the foot model appropriate-position data indicating an appropriate position of the movable portion with respect to the common portion; and moving the movable portion to the appropriate position based on the appropriate-position data.
A method for manufacturing a footwear upper according to an embodiment of the present disclosure comprises the following steps. A first step is a step of covering the last of any one of the above aspects with an unformed upper made of a fiber sheet including a heat-shrinkable yarn. A second step is a step of applying heat to form the unformed upper along the shape of the last to be a formed upper.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the scope of the present invention being interpreted by the terms of the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| JP2020-077797 | Apr 2020 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 1691054 | Galterio | Nov 1928 | A |
| 1753857 | Galterio | Apr 1930 | A |
| 20070033750 | Cook | Feb 2007 | A1 |
| 20140082905 | Wen | Mar 2014 | A1 |
| 20160206049 | Kallayil | Jul 2016 | A1 |
| 20180014609 | Bruce et al. | Jan 2018 | A1 |
| 20200113291 | Smith | Apr 2020 | A1 |
| Number | Date | Country |
|---|---|---|
| 108158134 | Jun 2018 | CN |
| 109732913 | May 2019 | CN |
| 234317 | May 1911 | DE |
| 0 237 831 | Sep 1987 | EP |
| 2016146859 | Sep 2016 | WO |
| Entry |
|---|
| Communication pursuant to Article 94(3) EPC issued by the European Patent Office dated Apr. 13, 2022, which corresponds to European Patent Application No. 21167892.5-1015 and is related to U.S. Appl. No. 17/235,316. |
| The extended European search report issued by the European Patent Office dated Sep. 23, 2021, which corresponds to European Patent Application No. 21167892.5-1005 and is related to U.S. Appl. No. 17/235,316. |
| Communication pursuant to Article 94(3) EPC issued by the European Patent Office dated Oct. 17, 2022, which corresponds to European Patent Application No. 21167892.5-1015 and is related to U.S. Appl. No. 17/235,316. |
| Number | Date | Country | |
|---|---|---|---|
| 20210330040 A1 | Oct 2021 | US |
