Footwear equipped with a shoehorn and method for manufacturing the same

Abstract

This invention belongs to the field of footwear manufacturing technology and discloses a shoe equipped with a shoehorn and a method for manufacturing the same. [Solution] The footwear of this invention achieves the effect of hands-free shoes by cleverly incorporating a shoehorn into the back of a regular shoe, simplifying the complex manufacturing process of conventional hands-free shoes, reducing costs, and improving production efficiency. The shoehorn consists of an upper and lower half, reinforced with a pre-formed material (such as chemical sheet or hot melt), and the upper half forms a gliding path for the heel to slide into, improving comfort. The manufacturing method of this invention is simple, does not require complex structural changes or cumbersome processes, is suitable for large-scale production, and has the potential for a wide range of applications.

Description

Technical Field

[0001] The present invention relates to the field of shoemaking technology, particularly to footwear provided with shoehorns and a method for manufacturing the same.

Background Art

[0002] Currently, various types of hands-free shoe products (shoes that can be worn without using hands) have emerged in the market. In particular, the elderly, disabled, and people in special occupations need shoes that are easy to put on and take off and convenient. The emergence of hands-free shoe products has been very helpful to these consumers.

[0003] However, due to structural reasons, current hands-free shoe products have several problems in the manufacturing process. For example, in the heel structure of the shoes with easy on and off disclosed in Patent Document 1, the heel panel, fixed panel, support panel, and attachment panel are made of thermoplastic plastic, and a hot melt net is heated and covered on each panel. Using this structure, there are problems such as complex operation, high labor cost, inability to cope with heels of different sizes, and low manufacturing efficiency.

[0004] Furthermore, for the medical shoes with easy on and off without using hands disclosed in Patent Document 2, the footwear including a heel cup disclosed in Patent Document 3, the heel core for shoes disclosed in Patent Document 4, etc., these technologies are actually support components for the heels to be worn hands-free. In the manufacturing process, it is necessary to go through complex wrapping processes for the heels such as glue pressing, adhesion, and turning inside out, and then fix it to the heel of the shoe. In the heel part where the first core material and the second core material using hot melt resin are arranged as disclosed in Patent Document 5, the second core material located above is configured to be narrower in width than the lower part. However, due to the characteristics of this hot melt resin, it cannot provide sufficient support force to the heel of the foot, and there is a possibility that it will break and cannot recover to its original shape when subjected to pressure. Therefore, doubts arise about the reliability in actual use.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] Chinese Patent Application No. CN2023236593269 [Patent Document 2] Chinese Patent Application No. CN2023227668482 [Patent Document 3] Chinese Patent Application No. CN2022900002255 [Patent Document 4] Patent Application No. 2023-075620 [Patent Document 5] Patent Application No. 2024-095658 [Overview of the project] [Problems that the invention aims to solve]

[0006] While these hands-free shoes offer a certain level of convenience, they increase manufacturing difficulty and cost, reduce production efficiency, and raise concerns about materials. Furthermore, the complex heel-wrapping process can compromise product quality consistency, affecting the shoe's appearance and performance. For shoemakers, simplifying the manufacturing process, reducing costs, and improving wearability while maintaining hands-free functionality are critical issues that need to be addressed.

[0007] This invention aims to improve upon the problems of conventional hands-free shoes. By combining innovative design with traditional manufacturing techniques, it provides hands-free shoes that are easy to produce, highly practical, and cost-effective while maintaining a good appearance, thereby meeting the technical needs of the shoemaking industry and the demands of many hands-free shoe consumers. [Means for solving the problem]

[0008] To address the complexities, high costs, and practical limitations of existing hands-free shoes, this invention provides footwear equipped with a shoehorn. Its innovative aspect lies in its unique manufacturing method, the specific technical details of which are as follows.

[0009] Footwear typically includes structural components such as the opening, upper sides, upper front, heel, insole, midsole, and outsole, but this invention does not require any complex structural modifications. In the heel area, a unique manufacturing method cleverly incorporates multiple curved shoehorn shapes with different radii of curvature, thereby achieving the effect of hands-free shoes.

[0010] In some embodiments of the present invention, the shoehorn comprises an upper and a lower half, the upper half being inclined to the right at the top when viewed from the right side, and inclined downward on both sides in a bracket-like arc shape when viewed from above, forming a guide structure for the heel to slide smoothly into the shoe. The lower half is spherically bulging to the right when viewed from the right side, and inclined upward on both sides in a bracket-like arc shape when viewed from below, forming a shape that fits the heel. The shoehorn comprises a structure fixed to the heel.

[0011] The method for attaching the shoehorn is simple and does not require a complex heel-wrapping process. In the manufacturing process, the sewn portion at the top of the shoehorn is fixed to the upper end of the heel by machine sewing or hand sewing, and in the subsequent turning process, the lower half of the shoehorn is sewn together with the upper material and the lining material to firmly attach the shoehorn to the heel.

[0012] The lower part of the shoehorn is reinforced using a shaping material such as a chemically treated sheet material or hot melt (a material that functions as an adhesive when heated) to ensure the stability and support of the shoehorn's shape, and at the same time, the lower part of the shoehorn is sewn to the lower part of the heel of the upper material to further fix its position.

[0013] The aforementioned shoehorn is made of a resin material that has support and elasticity, such as a new high-elasticity material like TPU, TPE, or TPEE, which has good elasticity and toughness characteristics and can provide sufficient support, and further has advantages such as wear resistance, durability and high temperature resistance, ensuring the durability and longevity of the shoehorn.

[0014] The height of the upper half is less than half the height of the lower half, and the connection between the upper and lower half transitions in an arc shape, forming a projection in the direction toward the inside of the shoe. In a front view, the upper part of the shoehorn is arc-shaped, and both side edges have a shape that widens diagonally downward from the upper half to the lower half. [Effects of the Invention]

[0015] Compared to existing hands-free shoe technologies, footwear equipped with the shoehorn of the present invention has the following beneficial effects. 1. By simply adding a shoehorn to the heel of a regular shoe, the same effects as other hands-free shoe technologies can be achieved, for example, by improving the convenience and comfort of putting on shoes and meeting consumer demand for hands-free shoes. 2. The manufacturing process has been significantly simplified, reducing the traditional hands-free shoe bonding and turning process to just the turning process, drastically shortening working time. This lowers the difficulty and cost of manufacturing, increases production efficiency, and allows for the production of hands-free shoes at a lower cost. 3. Product quality is more stable, and the simplification of the manufacturing process reduces the complexity and error rate of human operation, ensuring consistency in the appearance and performance of the shoes. 4. It is suitable for large-scale production, and by simplifying the manufacturing process and reducing costs, it is possible to significantly increase production volume and meet the high demand for hands-free shoes in the market. 5. The shoehorn is made of resin materials such as TPU, TPE, and TPEE, which have both support and elasticity. This ensures sufficient support for the heel during everyday wear, eliminating concerns about breakage and ensuring quality. [Brief explanation of the drawing]

[0016] To more clearly illustrate the technology in the embodiments of the present invention, a brief explanation will be given using the following drawings. The drawings in the following explanation are some embodiments of the present invention, and those with ordinary skill in the art can use these drawings to obtain other drawings without requiring any creative effort. [Figure 1] A side view of a footwear provided with a shoehorn according to an embodiment of the present invention. [Figure 2] A right side view of a shoehorn provided by an embodiment of the present invention. [Figure 3] A front view of a shoehorn provided by an embodiment of the present invention. [Figure 4] A perspective view of a shoehorn provided by an embodiment of the present invention. [Figure 5] A plan view of a shoehorn provided by an embodiment of the present invention. [Figure 6] A bottom view of a shoehorn provided by an embodiment of the present invention. [Figure 7] A longitudinal sectional view of the heel part of a footwear provided with a shoehorn according to an embodiment of the present invention, wherein the shaded part in the figure indicates the filling material, clearly showing the arrangement of the shoehorn and the shaping material. [Figure 8] A three-dimensional structural view of a shoehorn and a shaping material provided by an embodiment of the present invention, showing how the shaping material is incorporated into the shoehorn. [Figure 9] A comparison image diagram of the width between the opening of the heel part of a footwear provided with a shoehorn according to an embodiment of the present invention and the heel of the foot. The dotted line in the figure indicates the heel of the foot. A is an image where the opening of the heel part forms a polygonal shape, and B is an image where the opening of the heel part forms a curved shape.

Modes for Carrying Out the Invention

[0017] Hereinafter, referring to the drawings in the embodiments of the present invention, the technology in the embodiments of the present invention will be clearly and completely described. Obviously, the described embodiments are some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments that can be obtained by those with ordinary knowledge in this field without creative efforts belong to the protection scope of the present invention. Hereinafter, embodiments of the present invention will be described with reference to FIGS. 1 to 8.

[0018] As shown in Figure 1, an embodiment of the present invention provides footwear equipped with a shoehorn, which consists of a heel portion 10 of the shoe and a shoehorn 100 provided between the upper material and lining material of the heel portion.

[0019] Furthermore, referring to Figures 2 to 6, the shoehorn 100 includes an upper half 101 and a lower half 102. In Figure 2, the upper half 101 is inclined to the right at the top, and in Figure 5, both sides are inclined downward in a bracketed arc shape, forming a guide structure for the heel of the foot to slide smoothly into the shoe. In Figure 2, the lower half 102 is spherically bulging to the right, and in Figure 6, both sides are inclined upward in a bracketed arc shape, forming a shape that fits the heel of the foot.

[0020] Furthermore, by changing the inclination angle of the upper part 101 from 10 degrees to 30 degrees, the heel sliding effect can be optimized.

[0021] Furthermore, the shoehorn 100 includes a structure for fixing to the heel. In some embodiments of the present invention, as shown in Figure 3, a sewn portion 104 for fixing to the upper end of the heel of footwear is provided in the left-right central part of the upper part of the shoehorn 100. In embodiments of the present invention, the horizontal width of the sewn portion 104 is preferably 0.5 cm or more, and the thickness is preferably approximately 0.05 cm.

[0022] Furthermore, the horizontal width of the upper half 101 in the left-right direction is smaller than the horizontal width of the heel of a human body. In the embodiment of the present invention, considering support capacity and aesthetics, the width of the upper half 101 is preferably 3 to 4.5 cm and the thickness is preferably 0.15 to 0.25 cm.

[0023] Furthermore, in order to prevent the heel portion of the footwear from appearing unnecessarily high in appearance, in the embodiments of the present invention, it is desirable that the height of the upper half 101 be less than half the height of the lower half 102. Of course, it is also possible to adjust the height of the upper half 101 depending on the specifications of the footwear.

[0024] Furthermore, to avoid any visual incongruity at the heel of the footwear, it is desirable to gradually thin the thickness of the shoehorn 100 from the center in the vertical direction downwards.

[0025] Furthermore, the connection between the upper half 101 and the lower half 102 transitions in an arc shape, forming a projection 103 in the direction toward the inside of the shoe. As shown in Figures 2 and 7, the projection 103 is positioned laterally to the upper half 101 and the lower half 102, with at least a portion of it located furthest to the left. When the footwear is worn, as shown in Figure 5, the projection 103 takes on a shape that surrounds the Achilles tendon, fitting snugly to the heel of the foot in an integral manner with the lower half 102, preventing the shoe from slipping off during walking or exercise.

[0026] Furthermore, as shown in Figure 3, the upper part of the shoehorn 100 is arc-shaped, and both side edges of the upper part have a shape that widens diagonally downward from the upper half 101 to the lower half 102. From the viewpoint of the overall stability of the shoehorn 100 and supporting the upper half 101, it is desirable to set the width of the lower half 102 to 1.5 times that of the upper half 101.

[0027] In existing shoe heel shaping methods, to make the shoe body look good and aesthetically pleasing, a shaping material 105 such as a chemical sheet or hot melt is usually added inside the heel 10. Chemical sheets are softened with a solvent, then molded, and hardened by drying on the shoemaking line. Hot melt is softened at the high temperature of the shoemaking line, then molded, and after cooling, it maintains the shape of the heel of the last. Both chemical sheets and hot melt need to be fixed between the upper material and the lining material during the upper manufacturing process. In the heel upper manufacturing process, the upper material and lining material are first sewn together right sides together at the opening, and then turned inside out along the seam, i.e., a turning process is performed. After turning inside out, the shaping material 105 is sandwiched between the upper material and the lining material.

[0028] In this embodiment of the present invention, when sewing the upper material and the lining material together with the right sides facing each other at the opening, the shoehorn 100 is placed facing the lining material, and the sewing portion 104 is sewn together with the upper material and the lining material simultaneously. After turning the shoe inside out, the bracket-shaped recess of the lower half 102 adheres to the lining material, and the spherically bulging portion adheres to the upper material. This process is easy to perform and does not require a troublesome spray bonding process.

[0029] In this embodiment of the present invention, after turning the shoe inside out, the pre-formed material 105 is placed between the upper material and the lining material, and positioned towards the upper material side, that is, on the back of the shoehorn 100.

[0030] In this embodiment of the present invention, after turning the shoe inside out, the upper material, the lower half of the lower part 102 of the shoehorn 100, the shape material 105, and the lining material are tightened and overlapped at the lower part of the upper material, sewn together to form a lasting allowance. This is to ensure that the lasting allowances of the upper material and the lining material are aligned during the subsequent lasting process and when attaching the midsole fabric. Of course, the lower part of the lower half 102 that is exposed from the lasting allowance needs to be trimmed.

[0031] In embodiments of the present invention, as shown in Figures 1 and 8, the mold material 105 is adhesive, and when the upper material is molded after the upper is completed, the mold material 105 adheres tightly to the shoehorn 100 and becomes one with it. In practice, the heel support component of hands-free shoes currently on the market is formed in a shape that semi-encloses the heel of the foot. The three-dimensional support structure formed by the inner and outer sides of the mold material 105 extending forward provides the effect of reinforcing the shoehorn 100 while making it less likely to collapse or deform, similar to a normal heel support component.

[0032] In the embodiment of the present invention, when the shoehorn 100 and the molded material 105 are integrated, the thickness of the shoehorn 100 in the overlapping portion can be appropriately reduced so that the thickness of the overlapping portion does not give an unnatural appearance to the footwear. For example, by setting the thickness of the upper half 101 of the shoehorn 100 to 0.2 cm and adjusting the thickness of the shoehorn 100 in the overlapping portion within the range of 0.05 cm to 0.1 cm, the unnatural appearance can be minimized. With this configuration, the joint between the shoehorn 100 and the molded material 105 becomes smooth, improving the aesthetic appearance and comfort of the footwear.

[0033] In the embodiment of the present invention, as shown in Figures 1 and 7, the shoe body manufactured by the process of the present invention has an upper end portion 11 of the heel portion that extends posteriorly and upward, widening the space for inserting the foot at the opening and making it easier to insert the foot. Inside the shoe, the projection 103 and the filling material form a raised structure 12 on the underside of the heel portion, which fits the heel of the foot when wearing the shoe and makes it less likely for the shoe to slip off.

[0034] In embodiments of the present invention, in order to improve comfort for the feet, a cushioning material such as sponge can be placed on the back of the lining material, or a cushioning filling material can be applied to the foot-side portion of the shoehorn 100.

[0035] In other embodiments of the invention, different sizes of chemical sheets and hot melt adhesives are used to accommodate different shoe sizes. The shoehorn 100 is fixed to the upper end 11 of the heel portion via a sewn portion 104, and the lower part of the lower half 102 may not reach the bottom of the instep. As shown in Figures 7 and 8, this structure allows the lower half 102 of the shoehorn 100 to remain suspended in mid-air without reaching the height of the heel. While in this suspended state, the inclination of the shoehorn 100 is confirmed using a positioning point, and then the molding process is performed, causing the molding material 105 to adhere completely to the shoehorn 100 and become one with it. This design makes the shoehorn 100 applicable to the heel portions of shoes of different sizes and shapes. In particular, it has the flexibility to accommodate various shoe types even when the shoehorn 100 does not reach the height of the heel.

[0036] In an embodiment of the present invention, referring to Figure 1, the upper half 101 of the shoehorn 100 is inclined upward and backward. The upper half 101 is a support for the upper end 11 of the heel portion, meaning that the upper end 11 of the heel portion is also inclined upward and backward, widening the space for inserting the foot into the opening. At the same time, because the width of the upper half 101 of the shoehorn 100 is set to be narrow, the width of the heel opening is smaller than the horizontal width of the human heel. In other words, as shown in Figure 9, if the shape of the heel opening formed inside the shoe is curved, its radius of curvature is smaller than the natural radius of curvature of the human heel, but if the formed shape is polygonal, its interior angles are formed at acute angles compared to the anatomical angles of the human heel.

[0037] In an embodiment of the present invention, referring to Figures 2 to 6, the upper part of the upper half 101 is inclined backward, and both sides are inclined forward in a bracket-like arc shape, forming a slide for the heel to slide into the shoe. This design allows the heel of the foot to slide smoothly into the shoe, avoiding friction and obstruction between the heel and the heel portion 10, thereby improving the smoothness and comfort of putting on the shoe.

[0038] In embodiments of the present invention, the shoehorn 100 is manufactured from a polymer material, such as a resin or plastic material, that possesses a certain degree of support strength and tough elasticity. For material selection, highly elastic new materials such as TPU (polyurethane), TPE (thermoplastic elastomer), and TPEE (thermoplastic polyester elastomer) are recommended. These materials possess good elasticity and toughness, can provide sufficient support, and further have advantages such as abrasion resistance, durability, and high-temperature resistance. Therefore, shoehorns manufactured from these highly elastic new materials can effectively meet the structural requirements of shoes while simultaneously ensuring comfort and durability during wear.

[0039] In the embodiment of the present invention, the shoehorn 100 is integrally molded by injection molding using a metal mold. The metal mold uses 738H molded steel, which is resistant to damage, aging, and deformation, resulting in a long service life and thus saving on maintenance costs. This means that the mold does not need to be frequently replaced or maintained during the production process, further reducing production costs.

[0040] In other embodiments of the present invention, the shoehorn 100 can be made of a moldable material such as a chemical sheet or hot melt adhesive, and the same hands-free putting-on effect can be achieved. Specifically, the shoehorn 100 made of the above material is first attached to the upper end of the heel portion by sewing or adhesive, and then molded by sandwiching it between the conventional moldable material 105, the upper material and the lining material. The shoehorn 100 made by this method does not have the same durability as TPU, but it is suitable for short-lived footwear (for example, event shoes intended for temporary use or shoes intended for short-term use).

[0041] In an embodiment of the present invention, when a person puts on a shoe, the tip of the foot is placed inside the shoe and the heel is pressed down, causing the heel to slide into the shoe along the inclined upper end portion 11 of the heel section. After the heel is inside the shoe, the raised structure 12 fits the heel, making it difficult for the heel to slip out.

[0042] In embodiments of the present invention, the shoehorn 100 includes a center position mark at a location corresponding to the center of the heel. The center position mark is a geometrically shaped mark with raised and recessed areas, and during the manufacturing process, the center position mark can be identified visually and tactilely to accurately align the shoehorn 100 to the center of the heel. The position mark employs a geometrically shaped structure with raised and recessed areas, forming a clear position indicator. Its shape is circular or linear, with a diameter of 1 millimeter and a height and depth of 0.5 millimeters, making it identifiable without pushing the foot up.

[0043] In one embodiment of the present invention, a fine texture is applied to the surface of the shoehorn 100. The depth of these textures is 0.5 millimeters or less, and their shape can be linear, mesh-like, dotted, matte, rough, wavy, spotted, uneven, spiral, granular, etc. These textures are distributed on the surface of the shoehorn and are used to increase the contact area and frictional force.

[0044] In embodiments of the present invention, the shoehorn 100 can be used in multiple manufacturing processes, including cementing, sewing, crimping, injection molding, vulcanization, Goodyear welding, and California welding. These can be selected based on the characteristics of the material, the suitability of the production equipment, and the differences in the production environment. The structure formed by the shoehorn 100 and the molded material 105 is effectively fixed inside the heel portion 10, providing the necessary performance and stability for the entire footwear.

[0045] In embodiments of the present invention, the method for manufacturing footwear equipped with a shoehorn includes the following steps.

[0046] a. Preparation of the shoehorn: A shoehorn is manufactured using a resin material with support and elasticity (e.g., polyurethane, TPU, TPE, TPEE, Chemisheet, hot melt, etc.) through a molding process (e.g., injection molding, compression molding, cutting, or processing molding).

[0047] b. Attaching the shoehorn: Secure the shoehorn up to the top of the heel of the shoe. Specifically, sew or glue the upper seam of the shoehorn to the top of the heel to ensure that the shoehorn is accurately positioned on the heel and that the heel slides in effectively and fits snugly when wearing the shoe.

[0048] c. Turning inside out process: The specific procedure is as follows. First, the upper material and the lining material are sewn together facing each other at the opening of the shoe, and then the shoe is turned inside out along the seam. After turning inside out, the shoehorn and the shaper are placed between the upper material and the lining material.

[0049] d. Reinforcement by molding: The molded material is molded (e.g., by heating or pressurizing) to ensure that it adheres closely to the shoehorn and becomes one with it, thereby ensuring the stability and support of the shoehorn's shape, and allowing the shoe to maintain a good shape and performance when worn. [Explanation of Symbols]

[0050] 1. Footwear 10 Heel 11 Upper end of the heel 12 Raised structure 100 shoehorns 101 Upper half 102 Lower half 103 Protrusion 104 Sewing department 105 Fixed material

Claims

1. Footwear equipped with a shoehorn, including a heel portion having multiple curved surfaces with different radii of curvature, The shoehorn includes an upper half and a lower half, and a projection connecting the upper half and the lower half. The upper half is tilted to the right at the top when viewed from the right side, and both sides are curved downwards when viewed from above, forming a guide structure for the heel of the foot to slide into the shoe. The aforementioned lower half bulges to the right when viewed from the right side, and when viewed from the bottom, both sides are curved and inclined upward, forming a shape that fits the heel of the foot. In a right-side view, the projection is positioned laterally to the upper and lower halves, with at least a portion of it located as far left as possible. The edges on both sides of the upper part of the shoehorn are designed to widen diagonally downward from the upper half to the lower half. The aforementioned shoehorn is integrated and reinforced with a standard material such as a chemical sheet or hot melt. Footwear characterized in that, when the user puts on the footwear, the heel of the foot slides into the heel portion along the sloping upper portion, and the protrusion fits the heel of the foot, making it difficult to slip off.

2. The footwear according to claim 1, characterized in that a sewn portion is provided at the upper end of the heel portion, and the shoehorn is fixed to the heel portion.

3. Footwear equipped with a shoehorn, including a heel portion having multiple curved surfaces with different radii of curvature, The upper half of the aforementioned shoehorn is set so that its horizontal width in the left-right direction is smaller than the horizontal width of a human heel, and its height is smaller than that of the lower half. The upper end of the heel portion extends upward and backward, widening the space for inserting the foot into the opening. The width of the heel opening is set to be smaller than the horizontal width of the human heel. Therefore, if the heel opening is curved, its radius of curvature is smaller than the natural radius of curvature of the human heel. Furthermore, if the heel opening is polygonal, its interior angles are formed to be acuter than the anatomical angles of the human heel. The aforementioned raised structure is characterized by fitting snugly around the heel of the foot when the footwear is worn, preventing the shoe from slipping off during walking or exercise.

4. The aforementioned shoehorn includes a projection, When the aforementioned protrusion is attached to the footwear, it forms a raised structure that fits the heel of the foot and prevents slipping. Footwear according to claim 3, characterized by being less likely to slip.

5. A method for manufacturing footwear equipped with a shoehorn, a. Preparation of the shoehorn: A shoehorn is manufactured using a resin material with support and elasticity (e.g., polyurethane, TPU, chemisheet, hot melt, etc.) through a molding process (e.g., injection molding, compression molding, cutting, or processing molding). b. Attaching the shoehorn: Secure the shoehorn up to the top of the heel of the footwear. c. Reinforcement of the mold: The mold is prepared so that the molded material adheres tightly to the shoehorn and becomes one with it. A method for manufacturing footwear, including the process.

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