Method for manufacturing shoe fitted to foot of user

Abstract

[Problem] To provide a shoe that fits the foot of a user. [Solution] This method for manufacturing a shoe that fits the foot of a user is characterized by comprising: a first step of installing an outsole part 12 having a shoe sole that can contact a ground surface; a second step of layering a flexible sheet part 14 onto the outsole part 12; a third step of layering a foot-shaped resin part 16 formed from a thermoplastic resin that melts at a prescribed temperature onto the flexible sheet part 14; a fourth step of layering a fabric part 18 formed from a fabric in contact with the foot of the user onto the foot-shaped resin part 16; a fifth step of heating the shoe produced through the first step, the second step, the third step, and the fourth step at a prescribed temperature; and a sixth step of curing the foot-shaped resin part 16 by having the user place their foot on and apply their bodyweight to the foot-shaped resin part 16 melted by the fifth step, and allowing a prescribed time to elapse while in this state.

Description

A method for manufacturing shoes that fit the user's feet

[0001] The present invention relates to a method for manufacturing shoes that fit a user's feet.

[0002] Conventionally, shoes have an insole layered on an outsole that is placed on the ground and has a contact surface that comes into contact with the user's foot. The insole is made of various materials, taking into consideration comfort, etc. As a technology related to the present invention, for example, Patent Document 1 discloses a shoe insole that is characterized in that a backing card about 0.5 mm thick is placed on the bottom of a mold, a silicone resin is applied to the backing card to a thickness of about 7 mm, and the surface of the silicone resin is covered with a plastic wrap, and a user of the shoe insole stands barefoot on the insole material, applies pressure to take an impression of the sole of the foot, and after the silicone resin of the insole material has hardened, the insole material that has been formed with the sole impression is cut out with scissors to fit the shape of the shoe, thereby completing the shoe insole.

[0003] Furthermore, Patent Document 2 discloses a method for manufacturing a foot shape that is characterized by the fact that, rather than simply focusing on how accurately to take a foot shape from the current foot as in the conventional example, the current foot is first returned to a normal foot, and then a shape is taken from the normal foot.

[0004] JP 2005-198921 A JP 2013-212335 A

[0005] In recent years, various insoles have been developed, but because these insoles are shaped to fit the average foot shape, they do not necessarily fit the purchaser. Also, insoles that fit the foot shape precisely have been developed, as in Patent Documents 1 and 2, but these are large-scale, time-consuming, and costly.

[0006] Furthermore, these insoles are added on top of existing insoles in shoes, which can lead to problems such as misalignment. For this reason, there is a need for the development of shoes that fit the user's feet.

[0007] An object of the present invention is to provide a shoe that fits the user's foot.

[0008] The shoe according to the present invention, which fits a user's foot, is characterized by comprising an outsole portion having a sole capable of contacting the ground, a flexible sheet portion laminated on the outsole portion and having flexibility, a foot-shaped resin portion laminated on the flexible sheet portion and made of a thermoplastic resin that melts at a predetermined temperature, and a fabric portion laminated on the foot-shaped resin portion and made of fabric that comes into contact with the user's foot.

[0009] Furthermore, in the shoe according to the present invention that fits the user's foot, the outsole portion has a wall portion that stands up to cover the ends of the flexible sheet portion and the foot-shaped resin portion, and the fabric portion is attached so as to cover the ceiling surface of the foot-shaped resin portion and the outer surface of the wall portion of the outsole portion.

[0010] The method of manufacturing shoes that fit a user's feet according to the present invention is characterized by comprising: a first step of installing an outsole portion having a sole that can come into contact with the ground; a second step of laminating a flexible sheet portion having flexibility onto the outsole portion; a third step of laminating a foot-shaped foot-shaped resin portion made of thermoplastic resin that melts at a predetermined temperature onto the flexible sheet portion; a fourth step of laminating a fabric portion made of fabric that comes into contact with the user's foot onto the foot-shaped resin portion; a fifth step of heating the shoes manufactured through the first, second, third, and fourth steps at a predetermined temperature; and a sixth step of placing the user's foot on the shoe having the foot-shaped resin portion melted in the fifth step, and leaving it in a state where the user's weight is applied for a predetermined period of time, thereby hardening the foot-shaped resin portion.

[0011] Furthermore, in the method for manufacturing shoes that fit the user's feet according to the present invention, the outsole portion has a wall portion that stands up to cover the ends of the flexible sheet portion and the foot-shaped resin portion, and the fabric portion is attached so as to cover the ceiling surface of the foot-shaped resin portion and the outer surface of the wall portion of the outsole portion.

[0012] In addition, in the method of manufacturing shoes that fit the user's feet according to the present invention, the thermoplastic resin contains polycaprolactone resin that melts at 60 to 70°C.

[0013] According to the present invention, shoes that fit the purchaser's feet can be provided.

[0014] FIG. 1 is a diagram showing a shoe manufactured by a shoe manufacturing method according to an embodiment of the present invention; FIG. 2 is a diagram showing a shoe manufactured by a shoe manufacturing method according to an embodiment of the present invention, viewed from the top and bottom; FIG. 3 is a flowchart showing a procedure for manufacturing a shoe in a shoe manufacturing method according to an embodiment of the present invention; FIG. 4 is a diagram showing another shoe manufactured by a shoe manufacturing method according to an embodiment of the present invention; and FIG. 5 is a diagram showing another shoe manufactured by a shoe manufacturing method according to an embodiment of the present invention.

[0015] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following, similar elements in all drawings will be designated by the same reference numerals, and duplicate explanations will be omitted. Furthermore, in the description below, previously described reference numerals will be used as necessary.

[0016] Fig. 1 is a diagram showing a shoe 10 manufactured by a shoe manufacturing method according to an embodiment of the present invention. Fig. 2 is a diagram showing the shoe 10 manufactured by the shoe manufacturing method according to an embodiment of the present invention, as viewed from the top and bottom.

[0017] FIG. 2(a) is a diagram showing the shoe 10 manufactured by the shoe manufacturing method of the embodiment of the present invention as viewed from the top side, and FIG. 2(b) is a diagram showing the shoe 10 manufactured by the shoe manufacturing method of the embodiment of the present invention as viewed from the bottom side.

[0018] Fig. 3 is a flowchart showing the procedure for manufacturing shoe 10 using the shoe manufacturing method according to an embodiment of the present invention. Fig. 4 is a diagram showing another shoe manufactured using the shoe manufacturing method according to an embodiment of the present invention. Fig. 5 is a diagram showing another shoe manufactured using the shoe manufacturing method according to an embodiment of the present invention.

[0019] The shoe 10 is footwear that can be adjusted to fit the shape of the user's foot 3. The shoe 10 originally functions as a sandal, but the detachable instep band is removed to facilitate vacuum packing, but the instep band can also be fixed in advance.

[0020] The shoe 10 comprises an outsole portion 12 having a sole that can come into contact with the ground, a flexible sheet portion 14 laminated on the outsole portion 12 and having flexibility, a foot-shaped resin portion 16 laminated on the flexible sheet portion 14 and made of a thermoplastic resin that melts at a predetermined temperature, and a fabric portion 18 laminated on the foot-shaped resin portion 16 and made of fabric that comes into contact with the user's foot.

[0021] The outsole 12 is a part on the bottom of the shoe that comes into direct contact with the ground. Examples of materials that can be used to form the outsole 12 include rubber, PVC (polyvinyl chloride), PU (polyurethane), EVA (ethylene vinyl acetate), and cowhide.

[0022] Rubber is non-slip and has moderate elasticity. By mixing (compounding) many materials such as reinforcing agents, vulcanizing agents, vulcanization accelerators, and antioxidants, and then applying heat and pressure to cause a chemical reaction (vulcanization), rubber with various durable properties is created. It can also be foamed and used in a sponge-like form. Rubber can be broadly classified into two types: "natural rubber" and "synthetic rubber." "Natural rubber," which is extracted from rubber trees, has excellent strength and elasticity. "Synthetic rubber," which is made from petroleum, is most commonly used in shoemaking, and is known for its excellent abrasion resistance and resistance to aging.

[0023] PVC is said to be the most widely used plastic material in the world and has excellent properties. It is one of the easiest materials to manufacture, but it tends to harden slightly at low temperatures.

[0024] PU has excellent abrasion resistance, elasticity, and oil resistance, and is lighter than rubber. There are various types, such as "TPU," a type of thermoplastic resin, and "foamed PU," which is used in a sponge-like form.

[0025] EVA is a very light material and is not often used for outsoles because it has poor abrasion resistance, slip resistance, and durability, but it can be used by blending it with rubber or other resins to improve its properties.

[0026] Cowhide leather is required to be strong, so it is tanned thicker and harder than leather for the uppers. Although it is less durable and waterproof than other sole materials, it is often used in men's shoes because it fits well to the foot, has excellent breathability, and has a luxurious appearance.

[0027] The flexible sheet portion 14 is made of a flexible material, and can be made of, for example, polyurethane foam and polyethylene foam. The flexible sheet portion 14 is adhered to the outsole portion 12 so as to be layered on top of the outsole portion 12.

[0028] Polyurethane foam is a sponge material used in a wide range of applications, including home and industrial use. It is light, soft, and has excellent cushioning properties. It also boasts excellent durability, shock absorption, thermal insulation, heat resistance, chemical resistance, and sound absorption. Polyurethane foam is used in a variety of applications, from household items such as pillows and cushions to automobiles, industrial materials, and building materials.

[0029] Polyethylene foam is a type of polyolefin foam, a sponge material used in a wide range of fields, including general merchandise and industrial applications. It is lightweight, waterproof, and has load-bearing properties. Polyethylene foam also boasts excellent insulation, weather resistance, chemical resistance, and sound absorption. Polyethylene foam is used for a variety of purposes in a wide range of fields, from sports equipment such as kickboards to displays, industrial materials, and building materials.

[0030] The foot-shaped resin portion 16 is a foot-shaped member having a predetermined thickness and made of a thermoplastic resin that melts at a predetermined temperature. The thermoplastic resin is preferably a polycaprolactone resin that melts at 60-70°C, but other thermoplastic resins may also be used. The foot-shaped resin portion 16 is adhered to the flexible sheet portion 14 so as to be layered on top of it.

[0031] As described above, the foot-shaped resin portion 16 is preferably made of polycaprolactone resin, but other resins such as polylactic acid (PLA), polyethylene (PE), high-density polyethylene (HDPE), medium-density polyethylene (MDPE), low-density polyethylene (LDPE), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene chloride, polystyrene (PS), polyvinyl acetate (PVAc), polyurethane (PUR), Teflon (registered trademark) - (polytetrafluoroethylene, PTFE), ABS resin (acrylonitrile butadiene styrene resin), AS resin, and acrylic resin (PMMA) can also be used.

[0032] The foot-shaped resin portion 16 is preferably set to a thickness of 1 mm to 3 mm, and more preferably set to 1.5 mm. The foot-shaped resin portion 16 is formed by injection molding.

[0033] The fabric portion 18 is the portion that comes into contact with the sole of the user's foot, and is therefore preferably made of a material that feels good against the skin, such as suede. The fabric portion 18 is adhered to the foot-shaped resin portion 16 so that it is layered on top of it.

[0034] The shoe 10, which is composed of the outsole portion 12, the flexible sheet portion 14, the foot shape resin portion 16, and the fabric portion 18, is preferably covered with a vacuum pack portion 20.

[0035] The vacuum packing unit 20 is formed by vacuum-packing a nylon plastic bag. The nylon plastic bag is preferably made of a material that does not shrink when heated in hot water. Here, the description is given assuming that the nylon plastic bag is formed of two layers, with nylon (NY) as the outer layer and polyethylene (PE) as the inner layer, but it may also be formed of three or more layers. For example, in addition to the two layers, linear low density polyethylene may be laminated.

[0036] It is preferable that the vacuum packing portion 20 has a notch formed therein to make it easier to open after boiling in hot water. Also, by covering the foot-shaped resin portion 16 with the vacuum packing portion 20, it is possible to protect it from dust and the like, making it convenient for storage. In the above description, the inner layer of the two-layer nylon plastic bag is made of polyethylene (PE), but it may also be made of polypropylene (PP).

[0037] Next, a procedure for manufacturing the shoe 10 using the shoe manufacturing method according to the embodiment of the present invention will be described. First, the outsole portion 12 is formed and placed at the bottom (S2). Examples of materials that can be used to form the outsole portion 12 include rubber, PVC (polyvinyl chloride), PU (polyurethane), EVA (ethylene vinyl acetate), and cowhide.

[0038] After step S2, the flexible sheet portion 14 is formed and adhered so as to be laminated on the outsole portion 12 (S4). The flexible sheet portion 14 can be made of a material such as polyurethane foam and polyethylene foam.

[0039] After step S4, the foot-shaped resin part 16 is formed and laminated onto the flexible sheet part 14 (S6). Specifically, polycaprolactone resin is mixed with other materials, and then the foot-shaped resin part 16 having a thickness of 2.5 mm is formed by injection molding.

[0040] After step S6, the fabric part 18 is formed and adhered so as to be layered on the foot-shaped resin part 16 (S8). The fabric part 18 is preferably made of a material that feels good against the skin, such as suede.

[0041] In step S8, the shoes formed through steps S2 to S8 are vacuum-packed in nylon plastic bags. Specifically, the shoes are shrink-sealed so that the entire surface is covered with polyethylene film. Using polyethylene film allows the shoes to be sealed without sticking to them.

[0042] After step S8, the shoe 10 formed through steps S2 to S8 is heated (S10). Specifically, the shoe 10 is placed in a container or the like containing hot water heated to a temperature of 60 to 70°C or higher, at which the foot-shaped resin portion 16 is believed to melt, and the foot-shaped resin portion 16 of the shoe 10 is melted by heating it in hot water.

[0043] Next, the foot-shaped resin portion 16 is hardened (S12). Specifically, the user puts on the shoe 10 including the molten foot-shaped resin portion 16. The user puts on the shoe 10, stands upright, and applies pressure to the shoe 10 by putting on the shoe 10 and putting on the user's weight. Here, because the foot-shaped resin portion 16 is liquefied, the surface side of the foot-shaped resin portion 16 deforms to fit the shape of the user's foot.

[0044] By leaving the shoe in this state for 3 to 7 minutes, the foot-shaped resin portion 16 hardens, completing the shoe 10 that fits the user's foot. An instep band is attached to the shoe 10 that fits the user's foot, completing the sandal.

[0045] Next, a modified example of the shoe 10 manufactured using the shoe manufacturing method according to the embodiment of the present invention will be described. As shown in Figure 4, the modified example of the shoe 10 is a sneaker 10a, which includes an outsole portion 12, a flexible sheet portion 14, a foot-shaped resin portion 16, and a fabric portion 18.

[0046] The sneaker 10a has an upper made up of an instep, waist, and heel portion into which the user inserts their foot, in addition to an outsole portion 12, a flexible sheet portion 14, a foot-shaped resin portion 16, and a fabric portion 18. There are a number of combinations of uppers depending on the type of sneaker, and for example, the upper may include a toe tip (rubber tip), laces, a quarter (waist), eyelets, a tongue, a quarter lining (back of the waist), a heel tape, and a counter (moon-shaped).

[0047] The sneaker 10a includes the shoe 10, but differs from the above in that it is not vacuum-packed due to the presence of an upper. Therefore, to melt the foot-shaped resin portion 16, it cannot be directly placed in a hot water bath. Therefore, as shown in Figure 4(a), a vinyl bag 9 is inserted into the sneaker 10a and the opening is exposed. Then, hot water heated to a temperature of 60 to 70°C or higher is poured into the vinyl bag 9.

[0048] After the foot-shaped resin portion 16 has been liquefied in this manner, the plastic bag 9 containing the hot water is removed, as shown in Fig. 4(b). Thereafter, similar to step S12 above, the user puts on the sneakers 10a including the molten foot-shaped resin portion 16.

[0049] When a user wears the sneakers 10a and stands upright, the user's weight is applied to the sneakers 10a, and pressure is applied to the sneakers 10a. Here, since the foot-shaped resin part 16 is liquefied, the surface side of the foot-shaped resin part 16 deforms to fit the shape of the user's foot.

[0050] By leaving the shoe in this state for 3 to 15 minutes, the foot-shaped resin portion 16 hardens, and the sneaker 10a that fits the user's foot is completed.

[0051] As described above, the sandals or sneakers 10a equipped with the shoes 10 have the flexible sheet portion 14, foot-shaped resin portion 16, and fabric portion 18 laminated and integrated onto the outsole portion 12, so they do not shift position like insoles that are placed on top of the insoles of shoes. Therefore, when a user wears the sneakers 10a and engages in exercise such as running, they can run with good grip, which has the advantage of enabling them to achieve even better times.

[0052] Next, another variation of the shoe 10 made using the shoe manufacturing method according to the embodiment of the present invention will be described. As shown in Figure 5, the other variation of the shoe 10 is a sandal 10b, which includes an outsole portion 12b, an upper fabric portion 13, a flexible sheet portion 14, a foot-shaped resin portion 16, and a fabric portion 18b.

[0053] The differences between the sandal 10b and the shoe 10 are the presence of the upper fabric portion 13 and the shape of the outsole portion 12b and the fabric portion 18b, so we will focus on these differences and omit explanations of other common parts.

[0054] The outsole portion 12b includes a substantially U-shaped first outsole portion and a plate-like second outsole portion that is installed via the upper fabric portion 13. As shown in Fig. 5, the substantially U-shaped first outsole portion includes a wall portion 12c that stands up so as to cover the ends of the flexible sheet portion 14 and the foot-shaped resin portion 16.

[0055] The flexible sheet portion 14 and the outer periphery of the foot-shaped resin portion 16 are entirely covered by the wall portion 12c, so that outward deformation is restricted even when the foot-shaped resin portion 16 is deformed by the user stepping on it with the sole of the foot.

[0056] As shown in Figure 5, the fabric portion 18b is attached so as to cover the ceiling surface of the foot-shaped resin portion 16, the entire outer surface of the wall portion 12c of the first outsole portion of the outsole portion 12b, and part of the bottom surface of the approximately U-shaped first outsole portion.

[0057] The upper fabric portion 13 is a portion that forms the band portion of the sandal, and as shown in FIG. 5, is sandwiched between a substantially U-shaped first outsole portion and a plate-shaped second outsole portion.

[0058] Next, the operation of the sandal 10b will be described. The sandal 10b has the same basic structure as the shoe 10, and therefore provides the same operational effects. Furthermore, with the sandal 10b, the outer peripheral surfaces of the foot-shaped resin portion 16 and the flexible sheet portion 14 are all covered by the wall portion 12c. Therefore, when the weight of the user's foot is applied to the fabric portion 18b, the foot-shaped resin portion 16 deforms outward, which has the advantage of being able to deform to fit the shape of the sole of the user's foot without forming unnecessary wrinkles.

[0059] The top surface of the outsole portion 12 may be flat, but may have an uneven surface in the area corresponding to the arch of the foot, for example, to serve to force the position of the foot. Also, although the molded resin portion 16 and the flexible sheet portion 14 are described here as separate entities, they may be collectively made of, for example, a sponge material that deforms with temperature or pressure.

[0060] 9 Plastic bag, 10 Shoes, 10a Sneakers, 12, 12b Outsole portion, 12c Wall portion, 13 Upper fabric portion, 14 Flexible sheet portion, 16 Foot shape resin portion, 18, 18b Fabric portion, 20 Vacuum pack portion.

Claims

1. A shoe that fits a user's foot, comprising: an outsole portion having a sole that can come into contact with the ground; a flexible sheet portion laminated on the outsole portion and having flexibility; a foot-shaped resin portion laminated on the flexible sheet portion and made of a thermoplastic resin that melts at a predetermined temperature; and a fabric portion laminated on the foot-shaped resin portion and made of fabric that comes into contact with the user's foot.

2. A shoe that fits a user's foot as described in claim 1, wherein the outsole portion has a wall portion that stands up so as to cover the ends of the flexible sheet portion and the foot-shaped resin portion, and the fabric portion is attached so as to cover the ceiling surface of the foot-shaped resin portion and the outer surface of the wall portion of the outsole portion.

3. A method for manufacturing shoes that fit a user's feet, comprising: a first step of installing an outsole portion having a sole that can come into contact with the ground; a second step of laminating a flexible sheet portion having flexibility onto the outsole portion; a third step of laminating a foot-shaped foot-shaped resin portion made of thermoplastic resin that melts at a predetermined temperature onto the flexible sheet portion; a fourth step of laminating a fabric portion made of fabric that comes into contact with the user's foot onto the foot-shaped resin portion; a fifth step of heating the shoes manufactured through the first, second, third and fourth steps at a predetermined temperature; and a sixth step of placing the user's foot on the shoe having the foot-shaped resin portion melted in the fifth step, and putting weight on it for a predetermined period of time, thereby hardening the foot-shaped resin portion.

4. A method for manufacturing shoes that fit a user's feet, as described in claim 3, wherein the outsole portion has a wall portion that stands up to cover the ends of the flexible sheet portion and the foot-shaped resin portion, and the fabric portion is attached so as to cover the ceiling surface of the foot-shaped resin portion and the outer surface of the wall portion of the outsole portion.

5. A method for manufacturing shoes that fit a user's feet according to claim 3, characterized in that the thermoplastic resin contains polycaprolactone resin that melts at 60 to 70°C.

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