This application claims priority to Japanese Patent Applications No. 2019-229047 filed on Dec. 19, 2019 and No. 2020-084990, filed on May 14, 2020, the disclosures of which are incorporated herein by reference in their entirety.
The present invention relates to a last for shaping a shoe upper, a method for producing the last, and a method for producing the shoe upper.
In producing custom-made shoes tailored to a user's feet, lasts are exclusive for the user. Thus, after shoe uppers are shaped using lasts to produce shoes, the lasts are no longer used unless stored for future use.
US 2018/0014609 A discloses that footwear is produced in a portable housing. US 2016/0206049 A discloses a last pre-form that is composed of a shape memory polymer and thereby re-shapeable. CN 109732913 A discloses that a last is formed by 3D printing.
However, none of the abovementioned prior art documents specifically and explicitly discloses reuse of lasts that are no longer used.
It is therefore an object of the present invention to provide a reusable last, a method for producing the last, and a method for producing a shoe upper.
The following presents a simplified summary of the invention disclosed herein in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
The present invention provides a last for shaping a shoe upper, the last including: at least an outer peripheral portion including an aggregate of a plurality of blocks, the plurality of blocks being joinable together and separable from each other.
The present invention further provides a method for producing a last for shaping a shoe upper, the method including forming the last by joining a plurality of blocks together to form an aggregate.
The foregoing and other features of the present invention will become apparent from the following description and drawings of an illustrative embodiment of the invention in which:
An embodiment of the present invention will be exemplified with reference to the drawings. Hereinafter, regarding the term representing the direction “inward and outward direction”, the inward direction is a direction toward a foot of a shoe wearer, and the outward direction is a direction toward the outside of the shoe. Further, when a description is given below on a shoe upper 2 before and after being shaped, the shoe upper 2 before being shaped can be referred to as an unshaped upper 2A while the shoe upper 2 after being shaped can be referred to as a shaped upper 2B for separate identification of the respective states.
A last (shoe last) 1 of this embodiment is mainly not a last for shoes for mass production, but a custom-made last 1 tailored to a user's foot F. However, the present invention does not intend to completely deny its application to a last for shoes for mass production, but can be applicable thereto. The last 1 can be produced at a shoe retailer, or can be produced at a factory located away from the retailer by transmission and reception of block joining data and data on a user's foot using a communication device, as will be described later. As shown in
As shown in
The plurality of blocks 11 are configured to be joinable together and separable from each other. As a joining device, various devices can be used, such as a recess and projection fitting device or a magnet. As shown in
Each of the plurality of blocks 11 can have at least an outer peripheral surface formed of a material of high heat conductivity. For example, the outer peripheral surface can be a surface with a metal (e.g. an aluminum alloy) exposed. In this case, the surface of the metal material may be exposed to the outer peripheral surface, or a metal layer may be formed on the outer peripheral surface by plating or coating. The material of high heat conductivity is used to form the outer peripheral surface, which is a portion directly in contact with the shoe upper 2 unless a cover part 15 is provided on a body 12 of the last 1 as will be described later. This configuration allows heat to be easily transferred to the shoe upper 2 particularly in the case where the shoe upper 2 having heat-shrinkability is shaped.
The plurality of blocks 11 may have different shapes. In this case, the plurality of blocks 11 have different sizes, as shown, for example, in
Another example of the case where the plurality of blocks 11 have different shapes can be such that the relatively small blocks 11S are arranged at a portion of the last 1 corresponding to a forefoot portion of a user's foot, the shape of which is likely to vary by user, while the relatively large blocks 11L1 to 11L3 are arranged at other portions. Still another example may be such that the relatively small blocks 11S are arranged around a portion of the last 1 corresponding to a wearing opening of the shoe upper 2 while the relatively large blocks 11L1 to 11L3 are arranged at other portions. Each of these examples may be combined with the aforementioned configuration in which the relatively large blocks 11L1 to 11L3 are arranged on the inner side of the body 12 while the relatively small blocks 11S are arranged on the outer side thereof.
The “forefoot portion” herein is intended to be a portion of the human (wearer's) foot anatomy as encircled in
In the case where the plurality of blocks 11 have different shapes, each block 11 can have an identifier 112 for allowing its shape to be externally identifiable, as shown in
The last 1 configured as above can be disassembled back into the plurality of individual blocks 11 after being used for shaping the shoe upper 2. Thereafter, the plurality of blocks 11 can be reassembled to form the aggregate. This allows the last 1 to be reusable. The last 1 is not essentially disassembled into the individual blocks 11, and may be disassembled into a plurality of aggregates each formed of a plurality of blocks 11 connected together.
The last 1 may be solid, but is preferably hollow inside, as shown in
As shown in
The central part 13 may have a fixed shape as shown in
In the case where the last 1 includes the central part 13, the peripheral part 14 can be formed of a material of higher heat conductivity than that of the central part 13. For example, the plurality of blocks 11 constituting the peripheral part 14 can be formed of metal (e.g., an aluminum alloy) while the central part 13 can be formed of a heat-resistant resin (for example a resin resistant to heat of 200° C. or higher). This configuration causes the peripheral part 14 of the last 1 to be heated when the shoe upper 2 is heated for shaping (see
The aggregate of the plurality of blocks 11 constituting the outer peripheral portion may be at least partially covered with a sheet-shaped or a plate-shaped cover part 15 from outside. The material of the cover part 15 is not particularly limited, and can be, for example, the same material as that of the blocks 11. The cover part 15 can, for example, have a shape having a curved surface, as shown in
As shown in
Next, a method for producing the last 1 will be described. The last 1 is formed by joining the plurality of blocks 11 together into the aggregate. Thus, the last 1 can be easily formed without use of a forming mold as compared with, for example, the case where the last is formed of a resin material.
Before the last 1 is formed, a data acquiring step of acquiring the user's foot shape data, and a data generating step of generating block joining data from the user's foot shape data acquired are performed. Thereafter, a last forming step of joining the plurality of blocks 11 together based on the generated block joining data is performed. Performing these steps enables forming the custom-made last 1 tailored to the user's foot F.
The block joining data is created based on the user's foot shape data, which is individually generated for each of a plurality of users. The block joining data thus generated allows the shoe upper 2 to be finely customized for each user. The block joining data includes information on how the blocks 11 are to be stacked on each other. In the case where the plurality of blocks 11 having different shapes (including sizes) are used, the block joining data includes information on which shape (size) of the blocks 11 are used and at which position of the last 1 those blocks 11 are arranged.
The last forming step is performed by joining the plurality of blocks 11 by a human hand or a robot hand. In the case where the last forming step is performed particularly by a robot hand, a sensor or a camera reads the identifier 112 of each block 11, and a controller configured to control the robot hand thereby recognizes the shape (size) and position or orientation of the block 11. In the case where the cover part 15 is provided as shown in
The user's foot shape data refers to, for example, measurement data of each part of the user's foot F generated from image data obtained by capturing an image of the user's foot F as shown in
The image data can be acquired at the user's home or at a retailer (dealer) the user visits. In this case, the image data is transmitted to the server of a shoemaker and the foot shape data is generated at a factory of the shoemaker, so that the lasts 1 and shoes conforming thereto can be subsequently produced at the factory. It is also possible to acquire the image data at a retailer and produce the lasts 1 and shoes conforming thereto at the retailer. It is of course possible to produce the lasts 1 and shoes conforming thereto respectively at different places. The retailer is not limited to a fixed store but may be a mobile store using a car or a trailer.
A disassembling step is performed when the last 1 is no longer required after being used for shaping the shoe upper 2. In the disassembling step, the aggregate of the plurality of blocks 11 constituting the last 1 after being used is disassembled into individual blocks 11 or into small-unit aggregates each having a smaller number of blocks 11 than that of the aforementioned aggregate. The disassembling step can be performed by a human hand or a robot hand. A device configured to unjoin the blocks 11 by applying impact on the aggregate of the plurality of blocks 11 or by demagnetizing the blocks 11 in the case where they are joined together by magnetic force can also be used. Performing the disassembling step as described above allows the plurality of disassembled blocks 11 or the small-unit aggregates to be reused to produce a new last 1. The last 1 after being used can be thus reused as a last 1 for another user.
Next, a method for producing the shoe upper 2 using the last 1 will be briefly described. For example, a material of the shoe upper 2 (i.e., the unshaped upper 2A) composed of a fiber sheet including heat-shrinkable yarns is prepared. Then, carried out are a first shaping step of placing the unshaped upper 2A on the last 1, and a second shaping step of shaping the unshaped upper 2A in conformity with the shape of the last 1 by heating to obtain the shaped upper 2B as shown in
Performed after the second shaping step is a sole attaching step, in which the shaped upper 2B is attached to a separately prepared sole by, for example, adhesive. Other than adhesive, heat fusion bonding, for example, can be applied to perform the sole attaching step simultaneously with the second shaping step. In this case, the heat fusion bonding can be efficiently performed using the last 1 having the central part 13 formed of a material of high heat conductivity (for example, a metal such as aluminum, copper, or stainless steel). Forming a shoe tongue, trimming a wearing opening, making eyelets for passing shoelace therethrough, attaching decoration members and tags, printing a logo, and attaching an insole can be performed as appropriate, during any of the aforementioned steps or after all the steps.
Hereinafter, the configurations and operational effects according to the embodiment of the present invention will be summarized. Provided in this embodiment is a last 1 for shaping a shoe upper 2, the last 1 including: at least an outer peripheral portion including an aggregate of a plurality of blocks 11, the plurality of blocks 11 being joinable together and separable from each other.
This configuration allows the aggregate to be disassembled into the individual blocks 11 after the shoe upper 2 is shaped, thereby allowing the last 1 to be reusable.
The last 1 can have a hollow interior.
This configuration can reduce the number of blocks 11 constituting the last 1 by the number equivalent to the volume of an internal portion of the last 1, thereby enabling the shaping time of the last 1 to be shortened.
The last 1 can further include: a central part 13 formed in advance as a core; and a peripheral part 14 that is constituted by the aggregate of the plurality of blocks 11 formed on an outer peripheral portion of the central part 13.
This configuration can reduce the number of blocks 11 included in the last 1, thereby enabling the shaping time to be shortened.
Each of the plurality of blocks 11 can have at least an outer peripheral surface formed of a material of high heat conductivity.
This configuration allows heat to be easily transferred to the shoe upper 2 particularly in the case where the shoe upper 2 having heat-shrinkability is shaped.
The configuration can be such that the plurality of blocks 11 include blocks 11 of different shapes, and that each of the blocks 11 of different shapes has an identifier 112 for allowing a shape of the each of the blocks 11 of different shapes to be externally identifiable.
This configuration makes it easy to sort the plurality of blocks 11 by shape or to join together the blocks 11 having the same shape.
The configuration can be such that the plurality of blocks 11 include blocks 11 of different sizes, and that relatively large blocks 11L1 to 11L3 are arranged on an inner side of the last 1 and relatively small blocks 11S, which are smaller than the relatively large blocks 11L1 to 11L3, are arranged on an outer side of the last 1.
This configuration allows the large blocks 11L1 to 11L3 to be used for roughly shaping the inner side of the last 1, and then allows the small blocks 11S to be used for finely shaping the outer side of the last 1.
Each of the plurality of blocks 11 can have a hollow interior.
This configuration can save the weight of the last 1.
The aggregate of the plurality of blocks 11 can have an outer peripheral portion at least partially covered by a sheet-shaped cover part 15 or a plate-shaped cover part 15 from outside.
This configuration allows the cover part 15 to be used for arranging the outer peripheral shape of the last 1.
The configuration can be such that the aggregate of the plurality of blocks 11 is provided on an upper side of a plate shaped base part 16 for shaping a lower part of the shoe upper 2.
This configuration allows the lower part of the shoe upper 2 to be shaped into a constant shape by using the base part 16.
Provided in this embodiment is a method for producing a last 1 for shaping a shoe upper 2, the method including: forming the last 1 by joining a plurality of blocks 11 together to form an aggregate.
This configuration allows the last 1 to be easily formed without a use of a forming mold.
The method for producing the last 1 can further include: acquiring a user's foot shape data; generating block joining data from the user's foot shape data; and joining the plurality of blocks 11 together based on the block joining data to form the last 1.
The production method thus configured allows the last 1 to be formed tailored to the user's foot.
The method for producing the last 1 can further include creating the block joining data based on the user's foot shape data individually generated for each of a plurality of users.
The production method thus configured allows the shoe upper 2 to be customized for each user.
The user's foot shape data can be generated from image data obtained by capturing an image of the user's foot.
The production method thus configured allows the foot shape data to be easily generated using, for example, a digital camera or a smartphone P.
The method for producing the last 1 can further include: disassembling the last 1, after being used, into the plurality of blocks 11.
The production method thus configured allows the last 1 after being used to be reusable as a last 1 for another user.
Provided in the aforementioned embodiment is a method for producing a shoe upper 2, including: placing an unshaped upper 2A on the last 1, the unshaped upper 2A composed of a fiber sheet including heat-shrinkable yarns; and shaping the unshaped upper 2A in conformity with the shape of the last 1 by heating to obtain a shaped upper 2B.
The production method thus configured allows the shoe upper 2 to be produced using a reusable last 1.
The present invention has been described by taking an embodiment, but the description is merely an exemplification. The last 1, the method for producing the last 1, and the method for producing the shoe upper 2, according to the present invention, are not limited to the aforementioned embodiment. Thus, various modifications can be made for the last 1, the method for producing the last 1, and the method for producing the shoe upper 2, according to the present invention, without departing from a gist of the present invention. The modifications include, for example, partially replacing or partially omitting a plurality of elements constituting the aforementioned embodiments, and combining an element pertaining to an embodiment with an element pertaining to another embodiment as appropriate. The modifications also include combining matters pertaining to common technical knowledge regarding the last 1, the method for producing the last 1, and the method for producing the shoe upper 2.
For example, the configuration can be such that each block 11 is a cylindrical bead 11a having a through hole 114 as shown in
As shown in
The last 1 may be formed to entirely conform to the shape of the user's foot F, but may be formed to have a specific portion having a desired dimension inconsistent with the shape of the user's foot F for design or functional reasons.
The method for producing the shoe upper 2 is not limited to the aforementioned embodiment in which the fiber sheet including heat-shrinkable yarns are heat-shrunk, but various methods such as: knitting yarns to form fabric surrounding the last 1; or layering a material using a 3D printer can be employed.
The last, the method for producing the last, and the method for producing the shoe upper, of this embodiment are as described above, but the present invention is not limited to the aforementioned embodiment, and the design can be appropriately modified within the scope intended by the present invention. The operational advantages of the present invention are also not limited to the foregoing embodiments. The embodiments disclosed herein should be construed in all respects as illustrative but not limiting. The scope of the present invention is not indicated by the foregoing description but by the scope of the claims. Further, the scope of the present invention is intended to include all the modifications equivalent in the sense and the scope of the claims.
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JP2019-229047 | Dec 2019 | JP | national |
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