Patent Application
20230255322
The present invention relates generally to a shoe last and method, and specifically to a shoe last and sole and a method of manufacture of footwear wherein the shoe last comprises forefoot and heel cavities adapted to receive shoe sole foot pads such that the sole is maintained in proper position during assembly of an article of footwear.
A shoe-making last is a critical component in the manufacture of footwear. Conventional lasts are solid pieces of wood, metal, plastic or other resilient materials that serve as molds for the footwear to be formed. The last is sized and shaped for the desired footwear to be produced. Traditionally, pieces of shoe material which may include a shoe upper or a sole member are positioned around the last and carefully attached to one another. More recently, the shoe upper and shoe sole are formed separately and joined together by inserting the last into the upper and attaching the sole to the upper. Whether using traditional build-up techniques or more modern approaches, this process generally includes centering the sole member and the last before attaching joining the sole and shoe upper together.
The interior space of the footwear reflects the exterior shape of the last. Lasts are reused many times. Footwear built on the same last should have consistent interior dimensions. If such dimensions should vary from shoe to shoe, the fit of each shoe will also vary. Therefore, the last and sole must be precisely shaped and sized. Even with precisely shaped and sized lasts and soles, it is imperative that the shoemaker be able to consistently align the sole with the last while forming the footwear. Faulty centering of the sole member on the last can result in an ill-fitting, uncomfortable shoe.
Over the years, attempts have been provided to assist the shoemaker in properly centering the sole member on the last. For example, U.S. Pat. No. 1,470,651, to Stewart, teaches locating the sole in relation to the last by engaging peg-like last projections into sole recesses. U.S. Pat. No. 2,129,112, Ayers, discloses a last comprising a metal heel plate having a marginal flange adapted to receive a sole during the lasting operation to maintain the sole in proper position. Ponce, U.S. Pat. No. 3,060,470 provides a last that includes a heel portion and heel plate. The bottom of the heel portion is cut away to receive the heel plate. The heel plate includes an outwardly directed flange around the sides and rear of the bottom of the plate. Field, U.S. Pat. No. 3,088,147 provides wooden last inserts that permits a tack or nail to be inserted. Gumbert, U.S. Pat. No. 6,014,824 provides a last and shoemaking method wherein the last has contours resembling a human foot.
However, the shoe lasts discussed above are intended for conventional shoes having conventional soles. Modern shoe soles often comprise complex arrangements of cushions and supports. In some cases, such cushions and supports are raised in relation to the perimeter surface of the sole. What is needed is a shoe last and sole and a method of manufacture adapted to permit a sole member comprising forefoot and heel pads to be correctly positioned during manufacture of an article of footwear.
Referring to the figures, the shoe last of the preferred embodiment generally comprises a front portion and a heel portion. The heel portion is pivotally associated with the front portion in the customary manner. An underside of the last comprises forefoot and heel cavities. The shoe last of the preferred embodiment is adapted for use with a specially configured sole and foot pad arrangement.
The shoe last forefoot cavity is adapted to receive an upper portion of a forefoot pad. The heel cavity is adapted to receive an upper portion of an upper heel pad. In use, a footbed fabric integrated within a shoe upper is positioned between the shoe last and the sole. The respective pads as covered by the footbed fabric may, thus, be received by the forefoot and heel cavities.
The forefoot pad of the preferred embodiment is positioned within a forefoot recess of the sole (“sole” or “shoe sole”). The upper heel pad and a lower heel pad are positioned within a heel recess of the sole member.
The shoe last can be formed of an appropriate solid material such as wood, metal, or plastic. In the preferred embodiment, the shoe last is formed from polycarbonate material. The last is utilized with conventional and commercially available footwear-making equipment and will consistently produce footwear well adapted for a variety of activities. The last of the present invention is adapted for limited production runs as well as mass-production runs for a variety of footwear types. The footwear includes shoes, boots and so on. Examples of footwear include casual shoes, recreational shoes, athletic shoes, outdoor shoes and dress shoes. Further examples of footwear include cowboy boots, western boots, riding boots, outdoor boots, hiking boots and work boots. Additional examples of footwear include specialty footwear such as military boots.
In the preferred embodiment, there are two heel pads, the upper heel pad and lower heel pad. However, there need not be two pads. Rather, a single heel pad may be used, for example, comprising the combined dimensions of the upper heel pad and lower heel pad. In the preferred embodiment, the upper heel pad and lower heel pad each comprise an oval outside configuration when viewed in plan view. Thus, the upper heel pad and lower heel pad each have a greater length than width. In the preferred embodiment, the upper heel pad and lower heel pad have the same length and width dimensions. The lower heel pad of the preferred embodiment comprises a depth that is greater at a heel pad rearward portion than at a heel pad forward portion.
In the preferred embodiment, the forefoot pad comprises an oval outside configuration when viewed in plan view. Thus, the forefoot pad has a greater length than width.
The sole comprises an upper surface, a lower surface, a heel, the heel recess, and the forefoot recess. The heel recess of the sole comprises an opening in the upper surface corresponding to the heel such that the heel is partially hollow. The heel recess comprises a depth that is greater at a heel recess rearward portion than at a heel recess forward portion. A heel recess perimeter is partially defined by a series of posts. The heel recess perimeter comprises a generally oval configuration. Thus, the perimeter has a greater length than width. In the preferred embodiment, the heel recess perimeter has slightly larger length and width dimensions than those of the upper heel pad and lower heel pad.
The forefoot recess of the sole comprises an opening in the upper surface. The forefoot recess has an oval outside configuration when viewed in plan view. Thus, the forefoot recess has a greater length than width. In the preferred embodiment, the forefoot recess has slightly larger length and width dimensions than those of the forefoot pad.
Optionally, the sole comprises an arch support recess adapted to receive an arch support. In the preferred embodiment, the arch support, when nesting within the arch support recess is flush with the upper surface of the sole. In the preferred embodiment, the arch support and arch support recess each comprise an expanded “X” configuration. A foremost end of the “X” is wider than a rearward portion. Flex slots or “V” shaped cutouts are positioned in the crotch of the rearward portion of the arch support. These slots permit lateral flexion of the sole.
The shoe last heel cavity of the preferred embodiment comprises an oval outside configuration when viewed in plan view. Thus, the heel cavity comprises a greater overall length than overall width. The overall length of the heel cavity is slightly larger than the overall length of the upper heel pad. Similarly, the overall width of the heel cavity is slightly larger than the overall width of the upper heel pad. The heel cavity has a depth that permits the upper portion of the upper heel pad to nest within the heel cavity.
The forefoot cavity of the preferred embodiment comprises an oval outside configuration when viewed in plan view. Thus, the forefoot cavity comprises a greater overall length than overall width. The overall length of the forefoot cavity is slightly larger than the overall length of the forefoot pad. Similarly, the overall width of the forefoot cavity is slightly larger than the overall width of the forefoot pad. The heel cavity has a depth that permits the upper portion of the upper heel pad to nest within the forefoot cavity.
In some embodiments, the forefoot pad and upper heel pad contain balls or spheres. The balls are solid and are made of a resilient material such as thermoplastic rubber (TPR), polyurethane (PU), polyethylene or ethylene-vinyl acetate rubber (EVA). The balls in the forefoot pad are smaller than the balls in the upper heel pad. In some embodiments, actual size of the balls depends on the sole size which is a function of shoe size (with larger sole sizes having larger balls than smaller sole sizes). The balls may be separated from one another or connected to one another at edges or by a pin or rod.
The balls (or parts of balls) are encased in a flexible resilient matrix material. The matrix material fills the spaces between the balls thereby preventing the balls from moving with respect to one another. In preferred embodiments, the tops and bottoms of the balls are visible at the respective top and bottom surfaces of the forefoot and upper heal pads. This allows the resiliency of the balls to be utilized when foot pressure is applied.
In use, the forefoot pad is inserted within the forefoot recess. The lower heel pad and upper heal pad are inserted within the heel recess with the lower heel pad below the upper heel pad, the heel pad rearward portion being closer to the rear of the sole than the heel pad forward portion. The shoe last is positioned in a shoe upper. Then, using the forefoot and heel pads the sole and the shoe last are centered such that the upper portion of the upper heel pad nests within the heel cavity and the upper portion of the forward heel pad nests within the forefoot cavity. The shoe upper is then attached to the sole either mechanically such as with nails, threads, or other conventional coupling device or adhesively, such as with glue or cement. The shoe last is then removed from the upper.
The method of the preferred embodiment comprises the steps of providing a shoe last, the shoe last comprising a front portion and a heel portion, the heel portion being pivotally associated with the front portion; an underside of the shoe last comprising forefoot and heel cavities; providing a sole comprising heel and forefoot recesses, the heel recess being adapted to receive one or more heel pads, the forefoot recess being adapted to receive one or more forefoot pads; providing a shoe upper; positioning the shoe last in the shoe upper; using the forefoot and heel pads centering the sole and the shoe last such that the upper portion of the upper heel pad nests within the heel cavity and the upper portion of the forward heel pad nests within the forefoot cavity; attaching the shoe upper to the sole; removing the shoe last from the shoe upper.
In preferred embodiments, the shoe upper comprises a footbed fabric. In such embodiments, respective portions of the footbed fabric are pressed by the respective forefoot and heel pads into the respective forefoot and heel cavities.
In some embodiments, the front portion comprises a protective toe strip on the underside of the shoe last. In other embodiments, the heel recess comprises a sloped bottom.
In other embodiments, the heel recess comprises vertical posts defining a perimeter.
In other embodiments the heel pad comprises balls.
In other embodiments the forefoot pad comprises balls.
In other embodiments the balls are surrounded by a matrix material.
In other embodiments, the sole comprises an arch support.
In other embodiments, the arch support comprises an “X” configuration.
In other embodiments, the arch support is positioned in an arch support recess.
Referring to
Reference throughout this document to “one embodiment,” “certain embodiments,” “an embodiment,” or similar term means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of such phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner on one or more embodiments without limitation. The detailed description illustrates by way of example, not by way of limitation, the principles of the invention. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives, and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.
Referring to the figures, the shoe last 12 of the preferred embodiment generally comprises a front portion 14 and a heel portion 16. The heel portion 16 is pivotally associated at 18 with the front portion 14 in the customary manner. An underside of the last 12 comprises forefoot and heel cavities 20, 22. In some embodiments, the front portion 14 comprises a protective toe strip 68 on the underside of the shoe last 12. The shoe last 12 of the preferred embodiment is adapted for use with the specially configured sole 26 and foot pad arrangement 24, 28, 34.
The shoe last 12 forefoot cavity 20 is adapted to receive an upper portion of a forefoot pad 24 (
The forefoot pad 24 of the preferred embodiment is positioned within a forefoot recess 30 of the sole member (“sole” or “shoe sole”) 26. The upper heel pad 28 and a lower heel pad 34 are positioned within a heel recess 32 of the sole 26. As used herein, the terms “upper” (except when referring the shoe upper 70 itself), “lower”, “forward”, “rearward”, “front”, “rear”, “top”, “underside”, and “bottom” and similar terms are used to describe spatial relationships between components of the last, sole, footwear and/or between a component of the last, sole, and/or footwear and the ground. Such terms are relative to footwear positioned in an upright orientation on a ground surface. “Ground” includes interior floors and exterior surfaces such as streets, sidewalks, soil, etc.
The shoe last 12 can be formed of an appropriate solid material such as wood, metal, or plastic. In the preferred embodiment, the shoe last 12 is formed from polycarbonate material. The last 12 is utilized with conventional and commercially available footwear-making equipment and will consistently produce footwear well adapted for a variety of activities. The last 12 of the present invention is adapted for limited production runs as well as mass-production runs for a variety of footwear types. The footwear includes shoes, boots and so on. Examples of footwear include casual shoes, recreational shoes, athletic shoes, outdoor shoes and dress shoes. Further examples of footwear include cowboy boots, western boots, riding boots, outdoor boots, hiking boots and work boots. Additional examples of footwear include specialty footwear such as military boots.
In the preferred embodiment, there are two heel pads 28, 34, the upper heel pad 28 and lower heel pad 34. However, there need not be two pads 28, 34. Rather, a single heel pad may be used, for example, comprising the combined dimensions of the upper heel pad 28 and lower heel pad 34. In the preferred embodiment, the upper heel pad 28 and lower heel pad 34 each comprise an oval outside configuration when viewed in plan view. Thus, the upper heel pad 28 and lower heel pad 34 each have a greater length than width. In the preferred embodiment, the upper heel pad 28 and lower heel pad 34 have the same length and width dimensions. As best shown in
In the preferred embodiment, the forefoot pad 24 comprises an oval outside configuration when viewed in plan view. Thus, the forefoot pad 24 has a greater length than width. In the preferred embodiment, the overall length of forefoot pad 24 is approximately 116 mm. The overall forefoot pad 24 is approximately 74 mm. The forefoot pad 24 of the preferred embodiment has a thickness of approximately 6 mm. However, the length, width, and thickness of the forefoot pad 24 need not be confined to these dimensions. Rather, the forefoot pad 24 can comprise a greater or lesser length, width, and/or thickness.
As shown, for example, in
The heel recess 32 of the sole 26 comprises an opening in the upper surface 54 corresponding to the heel 50 such that the heel 50 is partially hollow. The heel recess 32 comprises a depth that is greater at a heel recess rearward portion 44 than at a heel recess forward portion 46. In the preferred embodiment, the depth of the heel recess 32 at the heel recess forward portion 46 is approximately 47 mm and 22 mm at the heel recess forward portion 46. An upper surface 48 of the heel recess 32 (the bottom of the heel recess 32) is preferably approximately parallel-planar with a lower outside surface 52 of the heel 50. A heel recess perimeter 62 is partially defined by a series of posts 60. The heel recess perimeter 62 comprises a generally oval configuration. Thus, the perimeter 62 has a greater length than width. In the preferred embodiment, the heel recess 32 perimeter 62 has slightly larger length and width dimensions than those of the upper heel pad 28 and lower heel pad 34.
The forefoot recess 30 of the sole 26 comprises an opening in the upper surface 54. The forefoot recess 30 comprises a depth. In the preferred embodiment, the depth of the forefoot recess 30 is approximately 2 mm. The forefoot recess 30 has an oval outside configuration when viewed in plan view. Thus, the forefoot recess 30 has a greater length than width. In the preferred embodiment, the forefoot recess 30 has slightly larger length and width dimensions than those of the forefoot pad 24.
In the preferred embodiment, portions of the forefoot pad 24 and the upper heel pad 28 are above the upper surface 54 of the shoe sole 26. As discussed herein, this positioning permits portions of the pads 24, 28 to nest within the respective cavities 20, 22 of the shoe last 12.
Referring, for example, to
Regarding the shoe last 12, the heel cavity 22 of the preferred embodiment comprises an oval outside configuration when viewed in plan view. Thus, the heel cavity 22 comprises a greater overall length than overall width. The overall length of the heel cavity 22 is slightly larger than the overall length of the upper heel pad 28. Similarly, the overall width of the heel cavity 22 is slightly larger than the overall width of the upper heel pad 28. The heel cavity 22 has a depth that permits the upper portion of the upper heel pad 28 to nest within the heel cavity 22. In the preferred embodiment, the depth of the heel cavity 22 is approximately 2 mm. However, the depth of the heel cavity 22 need not be 2 mm. Rather, the depth of the heel cavity 22 can be more or less than 2 mm. For example, the depth of the heel cavity 22 can range from 1 mm to 17 mm or more. The heel cavity 22 of the preferred embodiment has an overall length of approximately 69 mm and an overall width of approximately 47 mm. However, these dimensions may vary depending on a number of factors, including, for example, shoe size.
The forefoot cavity 20 of the preferred embodiment comprises an oval outside configuration when viewed in plan view. Thus, the forefoot cavity 20 comprises a greater overall length than overall width. The overall length of the forefoot cavity 20 is slightly larger than the overall length of the forefoot pad 24. Similarly, the overall width of the forefoot cavity 20 is slightly larger than the overall width of the forefoot pad 28. The heel cavity 22 has a depth that permits the upper portion of the upper heel pad 28 to nest within the forefoot cavity 20. In the preferred embodiment, the depth of the forefoot cavity 20 is approximately 2 mm. However, the depth of the forefoot cavity 20 need not be 2 mm. Rather, the depth of the forefoot cavity 20 can be more or less than 2 mm. For example, the depth of the forefoot cavity 20 can range from 1 mm to 17 mms or more. The heel cavity 22 of the preferred embodiment has an overall length of approximately 120 mm and an overall width of approximately 77 mm. However, these dimensions may vary depending on such factors as those discussed above.
Referring to
The balls 36 (or parts of balls) are encased in a flexible resilient matrix material 38. The matrix material 38 fills the spaces between the balls 36 thereby preventing the balls 36 from moving with respect to one another. In preferred embodiments, the tops and bottoms of the balls 36 are visible at the respective top and bottom surfaces of the forefoot and upper heal pads 24, 28. This allows the resiliency of the balls 36 to be utilized when foot pressure is applied. The matrix material 38 is made of a flexible and resilient material such as polyurethane.
In use, the forefoot pad 24 is inserted within the forefoot recess 30. The lower heel pad 34 and upper heal pad 28 are inserted within the heel recess 32 with the lower heel pad 34 below the upper heel pad 28, the heel pad rearward portion 40 being closer to the rear of the sole 26 than the heel pad forward portion 42. The shoe last 26 is positioned in a shoe upper 70. Then, using the forefoot and heel pads 24, 28 the sole 26 and the shoe last 26 are centered such that the upper portion of the upper heel pad 28 nests within the heel cavity 22 and the upper portion of the forward heel pad 24 nests within the forefoot cavity 20. The shoe upper 70 is then attached to the sole 26 either mechanically such as with nails, threads, or other conventional coupling device or adhesively, such as with glue or cement. The shoe last 12 is then removed from the upper 70.
The method of the preferred embodiment comprises the steps of providing a shoe last 12, the shoe last 12 comprising a front portion 14 and a heel portion 16, the heel portion 16 being pivotally associated with the front portion 14; an underside of the shoe last 12 comprising forefoot and heel cavities 20, 22; providing a sole 26 comprising heel and forefoot recesses 32, 30, the heel recess 32 being adapted to receive one or more heel pads 34, 28, the forefoot recess 30 being adapted to receive one or more forefoot pads 24; providing a shoe upper 70; positioning the shoe last 26 in the shoe upper 70; using the forefoot and heel pads 24, 28 centering the sole 26 and the shoe last 26 such that the upper portion of the upper heel pad 28 nests within the heel cavity 22 and the upper portion of the forward heel pad 24 nests within the forefoot cavity 20; attaching the shoe upper 70 to the sole 26; removing the shoe last 12 from the shoe upper 70.
In preferred embodiments, the shoe upper 70 comprises a footbed fabric 72. In such embodiments, respective portions of the footbed fabric 72 are pressed by the respective forefoot and heel pads 24, 28 into the respective forefoot and heel cavities 20, 22.
In other embodiments, the heel recess 32 comprises a sloped bottom 48.
In other embodiments, the heel recess 32 comprises vertical posts 60 defining a perimeter.
In other embodiments the heel pad 28 comprises balls 36.
In other embodiments the forefoot pad 24 comprises balls 36.
In other embodiments the balls 36 are surrounded by a matrix material 38.
In other embodiments, the sole comprises an arch support 64.
In other embodiments, the arch support 64 comprises an “X” configuration.
In other embodiments, the arch support 64 is positioned in an arch support recess 58.
While there has been illustrated and described what is, at present, considered to be a preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for elements thereof without departing from the true scope of the invention. Therefore, it is intended that this invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the invention, but that the invention will include all embodiments falling within the scope of this disclosure.
