Patent Application
20150013187
The present invention relates to a shoe using a sock-shaped upper member, and a manufacturing method therefor.
In recent years, it has been proposed to form a sock-shaped upper member by a knitting machine or a weaving machine (the first patent document).
First Patent Document: JP2004-105323A (Abstract)
A sock-shaped upper member of this type typically has a small rigidity and needs to be reinforced. However, since the upper member is sock-shaped, it is difficult to sew a reinforcement member thereto.
Such a problem arises also with members other than the upper members produced by a knitting machine, or the like, as long as they are sock-shaped upper members having a small rigidity.
It is therefore an object of the present invention to provide a shoe using a sock-shaped upper member having a small rigidity having such a structure that the upper member can be easily reinforced, and a manufacturing method therefor.
A shoe according to a first aspect of the present invention includes an upper 12, the upper 12 including:
a sock-shaped base member 1 of a knit fabric, a knit-like fabric and/or a woven fabric; and
a reinforcement member 2 integral with the base member 1, the reinforcement member 2 being substantially not sewn (substantially without sewn) to the base member 1, and the reinforcement member 2 being bonded and/or welded to a surface of the base member 1. Herein, “substantially not sewn to (substantially without sewn to)” means that “portions of the reinforcement member around or near eyelets or portions thereof around or near loops may be sewn to the base member 1”. Where there is a plurality of reinforcement members, only some of them may be sewn.
In the present aspect, the upper 12 is reinforced by the reinforcement member 2, with the reinforcement member 2 being bonded or welded to, but not sewn to, the sock-shaped base member 1. Therefore, the sock-shaped base member 1 of a knit fabric, a knit-like fabric and/or a woven fabric, which is difficult to retain its shape, can be attached to the last, and the reinforcement member 2 can easily be integrated with the base member 1 via bonding or welding, thereby facilitating the production of the upper 12.
In the present invention, a sock-shaped knit fabric or woven fabric can be produced by a well-known knitting machine or weaving machine.
A knit-like fabric means a fabric having a macroscopically-reticulated fabric structure, i.e., a lattice structure, and such a case is also encompassed by the present invention because the base member 1 is flexible and has a small rigidity.
Sock-shaped means a tubular shape that is open at least at the top line (mouth), while it may be open also in portions other than the top line, e.g., instep or toe portions, as long as it is shaped so that it can be attached to the last.
The reinforcement member 2 is less stretchable than the sock-shaped base member 1, and may typically be a non-stretchable member.
A shoe according to a second aspect of the present invention includes a sock-shaped base member 1 of a knit fabric, a knit-like fabric and/or a woven fabric forming a portion of an upper 12, and a sole member 3, 4 made of a resin bonded and/or welded to a bottom surface of the base member 1.
In the second aspect, the sole member 3, 4 is bonded or welded to the bottom surface of the sock-shaped base member 1. This facilitates the production of the shoe.
In a preferred embodiment of the first aspect, the reinforcement member 2 covers a portion of a side surface of a foot.
In a further preferred embodiment of the first aspect, the reinforcement member 2 covers a portion of each of a front foot section, a middle foot section and a rear foot section on the opposite side surfaces.
In this case, the side surface of the base member 1 is reinforced by the reinforcement member 2 in the front foot section, the middle foot section and the rear foot section, thereby making it possible to support the foot by the upper 12 even if the base member 1 has a small rigidity.
In a further preferred embodiment of the first aspect, the reinforcement member 2 covers a portion of the bottom surface of the foot and continuously extends from the bottom surface onto the opposite side surfaces.
In this case, the reinforcement member 2 continuously extending from the bottom surface onto the side surfaces is continuous in the foot-circumference direction, thereby stabilizing the support of the foot.
In a further preferred embodiment of the first aspect, the reinforcement member 2 covers the bottom surface of the middle foot section.
In a further preferred embodiment of the first aspect, in the middle foot section, the reinforcement member 2 continuously extends from the bottom surface onto the opposite side surfaces.
In this case, the reinforcement member 2, which is continuous in the foot-circumference direction in the middle foot section, further stabilizes the support of the foot.
In a further preferred embodiment of the first aspect, the reinforcement member 2 includes a lacing loop 20 integrally formed along an upper edge of the reinforcement member 2.
In this case, a shoelace is passed through a loop 20 along the upper edge of the middle foot section, and the upper member 12 is fitted to the foot via the reinforcement member 2, which continuously extends from the bottom surface onto the opposite side surfaces in the middle foot section. Therefore, even if the rigidity of the base member 1 is small, the support of the foot is stabilized by the upper member 12.
In a further preferred embodiment of the first aspect, the reinforcement member 2 includes an ornamental eyelet 21 integrally formed along an upper edge of the reinforcement member 2.
In this case, a shoelace is passed through a lacing aperture formed in the ornamental eyelet along the upper edge of the middle foot section, and the upper member 12 is fitted to the foot via the reinforcement member 2, which continuously extends from the bottom surface onto the opposite side surfaces in the middle foot section. Therefore, even if the rigidity of the base member 1 is small, the support of the foot is stabilized by the upper member 12.
In a further preferred embodiment of the first aspect, the reinforcement member 2 covers a circumference of a top line.
In this case, the circumference of the top line is reinforced by the reinforcement member 2, thereby making the top line less deformable and further stabilizing the support of the foot.
In a further preferred embodiment of the first aspect, the reinforcement member 2 includes a pair of side surface portions 2f and 2f extending in an up-down direction along each of a medial-side surface and a lateral-side surface of a middle foot section, a lower portion 2e extending in a front-rear direction in a lower portion of the side surfaces, and an ornamental eyelet 21 extending in the front-rear direction along an instep of the foot and having a plurality of lacing apertures 20A; and a portion of the base member 1 is enclosed, over an entire circumference thereof, by the pair of side surface portions 2f and 2f, the lower portion 2e and the ornamental eyelet 21.
In this case, a portion of the base member 1 is enclosed by the reinforcement member 2 in the middle foot section, thereby stabilizing the support in the middle foot section.
In this case, in a further preferred embodiment, the lacing apertures 20A are provided near upper ends of side surface portions 2f and 2f extending from the lower portion 2e toward the ornamental eyelet 21.
A shoelace passed through the lacing apertures 20A pulls up the lower portion 2e via the side surface portions 2f and 2f. As described above, since a portion of the base member 1 is enclosed by the reinforcement member 2, the upper 12 including the base member 1 and the reinforcement member 2 is likely to fit to the foot in the middle foot section.
In a preferred embodiment of the second aspect, the resin is a foamed material such as ethylene-vinyl acetate copolymer (EVA), a urethane-based material, a styrene-based material, an olefin-based material, etc., and the sole member is a midsole member 3.
In this case, the midsole member 3 made of EVA, or the like, can be easily formed on the bottom surface of the upper.
In a further preferred embodiment of the second aspect, the midsole member 3 covers a portion of each side surface of the foot.
In this case, the midsole member 3 supports the opposite side surfaces of the foot, thereby stabilizing the support of the foot, and it is possible to easily produce a shoe in which the midsole member 3 is rolled up on the side surface of the foot.
In a further preferred embodiment of the second aspect, the midsole member covers opposite side surfaces of a middle foot section, and a lacing aperture is formed along an upper edge of the midsole member 3.
In this case, since the midsole member 3 typically has a greater rigidity than the base member 1, and the lacing aperture is formed along an upper edge of the midsole member 3 having a great rigidity, the base member 1 can be fitted to the foot together with the midsole member 3 by pulling up the midsole member 3 by means of a shoelace, or the like. Therefore, even with the base member 1 having a small rigidity, the upper and the sole are likely to fit to the foot, and the foot is supported from the opposite side surfaces by means of the midsole member 3, thereby stabilizing the support of the foot.
In a further preferred embodiment of the second aspect, a heel counter 33 is integrally formed with the midsole member 3.
In this case, since the heel counter 33 is formed integrally continuously with the sole by means of the midsole member 3, it is possible to realize a stable support of the heel of the foot even with the base member 1 having a small rigidity.
In a further preferred embodiment of the second aspect, the midsole member 3 covers a circumference of a top line.
In this case, since the circumference of the top line is covered by the midsole member 3 having a greater rigidity than the base member 1, the shape of the top line is more likely to be retained.
In a further preferred embodiment of the second aspect, the sole member 3 includes a pair of side surface portions 3f and 3f extending in an up-down direction along each of a medial-side surface and a lateral-side surface of a middle foot section of a foot, a roll-up lower portion 3e rolled up from a bottom surface and extending in a front-rear direction in a lower portion of the side surfaces, and an upper edge portion 31 extending in a front-rear direction along an instep of the foot and having a plurality of lacing apertures 30A; and a portion of the base member 1 is enclosed, over an entire circumference thereof, by the pair of side surface portions 3f and 3f, the roll-up lower portion 3e and the upper edge portion 31.
In this case, since a portion of the base member 1 is enclosed by the sole member 3 in the middle foot section, the support of the middle foot section is stabilized.
In this case, in a further preferred embodiment, the lacing apertures 20A are provided near upper ends of the side surface portions 3f and 3f extending from the lower portion 3e toward the upper edge portion 31.
A shoelace passed through the lacing apertures 30A pulls up the lower portion 3e via the side surface portions 3f and 3f. As described above, since a portion of the base member 1 is enclosed by the sole member 3, the upper 12 including the base member 1 and the sole member 3 is likely to fit to the foot in the middle foot section.
Each of the shoes described above is produced by the following manufacturing method, for example.
That is, an aspect of the method of the present invention includes the steps of:
attaching a sock-shaped base member 1 forming a portion of an upper to a last portion 52 of a core 50, the core 50 including a core print 51 and the last portion 52;
loading the core 50 onto an outer mold 61, 62;
supplying a molten resin 71, 72 to be a reinforcement member 2 and/or a sole member 3, 4 into between the outer mold 61, 62 and the base member 1; and
allowing the molten resin 71, 72 to cure, thereby forming the reinforcement member 2 and/or the sole member 3, 4 integral with the base member 1.
In this case, it is possible to manufacture a shoe in which the reinforcement member 2 or the midsole member 3 is integral with the base member 1 only by performing the process of attaching the base member 1 to the last (the core 50) having the core print 51, and further loading the core 50 onto the outer mold 61, 62. Therefore, the shoe manufacture can be automated, and it is therefore possible to reduce the manufacturing cost.
Note that the base member 1 may be a sock that is stretchable and that does not shrink by heat. That is, the base member 1 may be any member as long as it can be attached to the last and it fits to the last.
Note that in the present aspect, the base member 1 may be a sock of a woven cotton that is stretchable and that does not shrink by heat. That is, the present aspect can be used as long as the upper member can be attached to the last and it fits to the last.
Preferably, in the step of loading the core 50, the core print 51 of the core 50 is supported by the outer mold 61, 62, with the core print 51 protruding from a top line of the base member 1.
More preferably, the loading step is performed with the core 50 positioned so that the core print 51 is below the last portion 52.
In this case, the core print 51 is supported by the outer mold 61, and the core 50 is stably supported by the outer mold 61.
More preferably, the outer mold 61, 62 includes a first outer mold 61, to which the core print 51 is attached, and a second outer mold 62 meshing with the first outer mold 61, the method including:
a first supply step of supplying a first molten resin 71 to be the reinforcement member 2 into between the first outer mold 61 and the second outer mold 62 and the last portion 52;
a step of allowing the first molten resin 71 to cure, thereby forming the reinforcement member 2 integral with the base member 1;
a step of meshing a third outer mold 63, which meshes with the first outer mold 61, onto the first outer mold 61, replacing the second outer mold 62;
a second supply step of supplying a second molten resin 72 to be the sole member 3, 4 into between the third outer mold 63 and the last portion 52; and a step of allowing the second molten resin 72 to cure, thereby forming the sole member 3, 4 integral with the base member 1.
In this case, the manufacture of a shoe in which the reinforcement member 2 and the midsole member 3 are formed integral with the base member 1 can be automated, and it is therefore possible to significantly reduce the manufacturing cost.
More preferably, in the meshing step after the first supply step, the second outer mold 62 is removed, with the core print 51 remaining attached to the first outer mold 61, and the third outer mold 63 is meshed onto the first outer mold 61, replacing the second outer mold 62.
In this case, it is possible to form the midsole member 3, following the reinforcement member 2, integral with the base member 1, with the core print 51 remaining attached to the first outer mold 61.
Another aspect of the present invention includes the steps of;
attaching a sock-shaped base member 1 made of a knit fabric and/or a woven fabric forming a portion of an upper to a last and heating the sock-shaped base member 1, thereby forming a sock portion; and
heating a sole member 3A made of a knit fabric and/or a woven fabric integral with the base member 1 during the heating of the base member 1, thereby melting the sole member 3A.
In this case, it is possible to manufacture a shoe in which the sole is integral with the base member 1 only by attaching the base member 1 to the last and heating the base member 1, and it is therefore possible to further reduce the manufacturing cost.
The present invention will be understood more clearly from the following description of preferred examples taken in conjunction with the accompanying drawings. Note however that the examples and the drawings are merely illustrative and should not be taken to define the scope of the present invention. The scope of the present invention shall be defined only by the appended claims. In the accompanying drawings, like reference numerals denote like components throughout the plurality of figures.
Examples of the present invention will now be described with reference to the drawings.
As shown in
The base member 1 of
Herein, a knit fabric or a woven fabric can be produced by a well-known knitting machine or weaving machine, and can be formed by a synthetic resin fiber that shrinks by heat. An example of the base member 1 is disclosed in JP2004-105323A, the content of which is herein incorporated by reference in its entirety.
For example, the base member 1 may be obtained by weaving a member into a sock shape by a weaving machine, attaching the member to the last and heating the member so as to thermally shrink the member into a shape conforming to the last, and such a member is used as a portion of the upper.
The knit-like fabric is a web molded into a knit-like configuration, in which case it easily fits to the shape of the last because it is knit-like.
The reinforcement member 2 is not substantially sewn to the base member 1, and the reinforcement member 2 is bonded and/or welded to the surface of the base member 1, thereby forming the upper 12 of
The reinforcement member 2 may be bonded to the base member 1 with an adhesive or welded thereto, or a portion of the reinforcement member 2 may be bonded to the base member 1 while another portion of the reinforcement member 2 is welded to the base member 1.
The reinforcement member 2 may be of a stretchable material or a less stretchable material, or it may also be of a foamed material such as EVA, which is used in the midsole. Typically, the reinforcement member 2 uses a material that is less stretchable than the base member 1.
That is, the reinforcement member 2 has a greater rigidity than the base member 1, and the tensile rigidity of the reinforcement member 2, for example, is greater than that of the base member 1.
As shown in
Note that where the reinforcement member 2 is welded to the base member 1 by molding, the reinforcement member 2 may cover the entire surface of the base member 1.
As shown in
Note that the structure of the medial-side surface and that of the lateral-side surface are substantially approximate to each other, and only one of the side surfaces is shown in each side view.
Note that as shown in
In the example of
Each loop-shaped portion of the reinforcement member 2 is formed by the ornamental eyelet 21, the lower portion 2e, and a pair of side surface portions 2f connecting between the ornamental eyelet 21 and the lower portion 2e, thereby enclosing the circumference of an enclosed portion 11 of the base member 1.
As shown in
As shown in
In
The heel counter 33 is formed integral with the midsole member 3. The heel counter 33 covers the rear surface and the opposite side surfaces of the foot in the rear foot section of the foot. The midsole member 3 has a greater rigidity than the base member 1, and the tensile rigidity of the midsole member 3, for example, is greater than that of the base member 1.
As shown in
In the example of
Each loop-shaped portion of the midsole member 3 is formed by the upper edge portion 31, a roll-up lower portion 3e, and a pair of side surface portions 3f connecting between the upper edge portion 31 and the roll-up lower portion 3e, thereby enclosing the circumference of an enclosed portion 11 of the base member 1.
As shown in
On the other hand, as shown in
Note that a shoelace 8 is denoted by a two-dot chain line in
In the example of
As shown in
Next, a method for manufacturing a shoe having such a structure as described above will be described.
First, the sock-shaped base member 1 forming a portion of the upper shown in
Note that where the base member 1 is of a material that thermally shrinks, the base member 1 may be heated after the attachment, thereby fitting the base member 1 to the core 50.
In this state, the core 50 of
Note that the core 50 is loaded onto the lower outer mold 61 with the core 50 positioned so that the core print 51 (
After the clamping, a molten resin 71 or 72 to be the reinforcement member 2 or the midsole member 3 is supplied into between the outer mold 61, 62 and the base member 1 as shown in
In this case, the base member 1 may become buried in the inner surface of the reinforcement member 2 or the midsole member 3. Therefore, if a reinforcement fiber is provided woven in portions of the base member 1, the reinforcement member 2 or the midsole member 3 may be reinforced by the fiber.
Note that after the molding, the lacing apertures 20A may be formed by a machining process in the area of the ornamental eyelet 21.
Next, an example of a method for manufacturing a shoe in which the reinforcement member 2 is welded to the base member 1, and the midsole member 3 is further welded to the reinforcement member 2, as shown in
In this case, steps similar to those shown in
That is, as shown in
Then, as shown in
In the step of meshing the third outer mold 63 after the first supply step, the second outer mold 62 of
After the meshing, a second supply step of supplying the second molten resin 72 to be the midsole member 3 or the outsole member 4 into between the third outer mold 63 and the last portion 52 is performed as shown in
In the manufacturing method, in a case where the upper edge portion 31 of the midsole member 3 is left unwelded to the base member 1 as shown in
On the other hand, in a case where the upper edge portion 31 of the midsole member 3 is welded to the base member 1 as shown in
Next, another manufacturing method will be described with reference to
First, a sock-shaped shoe member is provided, including a sock-shaped base member 1 made of a knit fabric and/or a woven fabric and forming a portion of an upper, and a sole member 3A made of a knit fabric and/or a woven fabric and integral with the base member 1.
The sock-shaped shoe member is attached to a last and heated, thereby forming a sock portion and heating and welding the sole member 3A during the heating. Then, the shoe member is removed from the last, thereby producing a shoe reinforced with a fiber.
While preferred examples have been described above with reference to the drawings, various obvious changes and modifications will readily occur to those skilled in the art upon reading the present specification.
For example, after molding and welding the midsole member 3 of
The outsole member 4, instead of the midsole member 3, may be welded, through molding, to the base member 1.
The reinforcement member 2 and the midsole member 3 may be an FRP containing a reinforcement fiber.
For the molding method of
Thus, such changes and modifications are deemed to fall within the scope of the present invention, which is defined by the appended claims.
The present invention is applicable to shoes having the base member 1 of a small rigidity.
1: Base member
10A: Lacing aperture, 11: Enclosed portion, 12: Upper
2: Reinforcement member, 2a: Front foot portion, 2b: Middle foot portion, 2c: Rear foot portion, 2d: Bottom portion, 2e: Lower portion
2
f: Side surface portion, 2g: Top line portion
20: Loop, 20A: Lacing aperture, 21: Ornamental eyelet
22: Top line portion
3: Midsole member, 3e: Roll-up lower portion, 3f: Side surface portion
30A: Lacing aperture, 31: Upper edge portion, 32: Top line portion, 33: Heel counter
4: Outsole member
50: Core, 51: Core print, 52: Last portion
61: First outer mold, 62: Second outer mold, 63: Third outer mold
71: First molten resin, 72: Second molten resin
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/053817 | 2/17/2012 | WO | 00 | 7/30/2014 |
