Insole manufacturing system, insole manufacturing method, and insole

Abstract

Provided are: an insole manufacturing system and manufacturing method which enable anyone in any area to manufacture a desired insole according to their needs; and an insole manufactured by the same. This manufacturing system for manufacturing a desired insole composed of a plurality of parts from thousands of patterns or more, preferably hundreds of thousands of patterns or more, even more preferably hundreds of billions of patterns or more, includes a design unit which is configured by a computer, and which selects a plurality of parts from a predetermined part list according to an input design specification and designs the insole by arranging the plurality of selected parts.

Description

Insole manufacturing system, insole manufacturing method, and insole

[0001] The present disclosure relates to an insole manufacturing system, an insole manufacturing method, and an insole for footwear such as shoes.

[0002] As an insole (also referred to as a footbed or orthotic insole) to be worn inside footwear such as shoes, those formed in a three-dimensional shape according to the shape of the sole of the foot are known (for example, see Patent Document 1). As this type of insole, many commercially available insoles (for example, see Patent Document 2) designed and manufactured according to the average sole shape of a person are in circulation.

[0003] On the other hand, not only off-the-shelf products, but also made-to-order insoles manufactured according to the characteristics of the user have been commercialized (for example, see Patent Document 3).

[0004] Made-to-order insoles are in higher demand, for example, in the medical field and the sports industry, as devices for improving and preventing symptoms, preventing injuries, maintaining and improving performance, etc.

[0005] When manufacturing a made-to-order insole, conventionally, a technician (such as a doctor or a person who works based on the instructions of a doctor) has needed to perform face-to-face foot measurement and foot molding of the user. The insole is manufactured based on the measured and molded foot shape of the user (a static foot shape, such as the foot shape in a standing, lying, or sitting position). In the technology according to Patent Document 3, an insole is manufactured to have an arch support portion that supports the arch of the user's sole based on the measured static foot shape of the user.

[0006] Conventional general insoles are premised on being manufactured to support the entire sole or the arch of the sole in accordance with the static foot shape of the user.

[0007] In the case of made-to-order insoles, it is necessary to perform foot measurement and foot molding of the user, and space and time are required for such measurement.

[0008] In particular, when measurements were taken in person, the reality was that insoles could only be manufactured in specific regions where the technicians or manufacturers (hereinafter referred to as "technicians, etc.") who made the insoles were based. This limitation to specific regions meant that custom-made insoles were subject to supply and demand imbalances, leading to higher prices. Furthermore, this price issue made production and acquisition even more difficult.

[0009] To address the challenge that custom-made insoles cannot be manufactured without skilled technicians, in recent years, insoles categorized as semi-custom-made have emerged (see, for example, Patent Documents 4-6).

[0010] Japanese Patent No. 5498631, Japanese Unexamined Patent Publication No. 2008-62005, Japanese Patent Publication No. 2022-528573, Japanese Unexamined Patent Publication No. 2003-088405, Japanese Unexamined Patent Publication No. 2008-048863, Utility Model Registration No. 3210276

[0011] Semi-custom insoles allow for the creation of insoles tailored to each customer by combining several parts, making it relatively easy to produce insoles that are customized to the customer's needs, even for those who are not skilled in insole manufacturing, such as technicians.

[0012] However, in conventional technologies such as those described in Patent Documents 4 to 6, the shape patterns of the parts were limited to a practical range from the perspective of commercialization, meaning that they lacked technical significance. As a result, the number of shape patterns was limited to at most a few dozen to a few hundred, which was far from sufficient considering that the characteristics of each customer's feet are completely different.

[0013] For reference, biometric authentication methods such as fingerprints and retinal scans are known, but it is said that identical patterns cannot exist for fingerprints and retinal scans. Furthermore, the error rate in current biometric authentication systems is approximately one in a million.

[0014] Regarding the feet of living human beings, it is theoretically and practically impossible to consider any two pairs of feet to be completely identical in terms of their characteristics (shape, sole characteristics, and other characteristics of the foot as a living organism).

[0015] Considering these points, conventional semi-custom insoles, as described above, absolutely lacked product patterns to accommodate the unique characteristics of each individual's foot, where no two patterns are identical.

[0016] Thus, with conventional insoles, especially custom-made (specifically, fully custom-made) insoles, there were limitations such as the need for technicians to manufacture them and the requirement for face-to-face measurements.

[0017] In an effort to address these challenges, semi-custom-made insoles have been proposed. However, given the vastly different characteristics of each individual's feet, the number of product patterns is practically limited to only a few dozen to a few hundred, making it impossible to provide the optimal insole for each individual.

[0018] A further challenge is that conventional insoles, whether ready-made, semi-custom, or custom-made, are manufactured based on a static foot shape. However, during use, insoles are typically subjected to dynamic loads on the feet, such as during standing or walking. In these situations, the shape of the foot also changes dynamically, but conventional insoles do not take this into consideration.

[0019] Furthermore, while specialized software and systems are used in the design of semi-custom insoles, in some cases, knowledge and design skills are required to maximize the software's functionality and create the best possible design. Additionally, setting up a manufacturing environment for insoles generally requires relatively high costs and physical space.

[0020] Several complex challenges exist that prevent the creation of a situation where people can easily, affordably, and without disparity in the production of insoles that are perfectly suited to their individual needs.

[0021] Let's re-examine the issues.

[0022] Regarding custom-made insoles, the conventional face-to-face manufacturing method had the following challenges:

[0023] It is difficult to produce them regardless of the region (there are service disparities from region to region).

[0024] It is difficult to produce easily.

[0025] It is difficult to manufacture it inexpensively.

[0026] Thus, conventionally, the desired form of service delivery had not been achieved.

[0027] In recent times, emergencies such as pandemics caused by viral infections and wars have occurred, affecting the production and distribution of goods, resulting in chronic shortages and price increases. These problems have brought the aforementioned challenges to the forefront even more clearly.

[0028] Given these challenges, there was a strong desire for a situation where anyone, regardless of their location, could easily have insoles manufactured and obtain them at a reasonable cost according to their needs.

[0029] In response to this, advancements in the internet have led to the proposal of systems that allow for the exchange of information via the internet to create insoles. According to this system, it is possible to create insoles by obtaining information about the feet or taking images of the feet, without the need for face-to-face measurements.

[0030] However, even in such cases, as mentioned above, the insoles were only made to fit the static shape of the user's foot. In other words, there was little to no consideration given to the dynamic shape of the foot during movement (dynamic deformation of the foot shape) or to guiding weight transfer.

[0031] Conventional insoles have focused on simply supporting the entire sole of the foot or the arch, but have not focused on supporting dynamic changes and movements, specifically supporting (controlling) the movement (trajectory) of the "center of pressure (COP)," which is an important element in exercise. Even if it is mentioned, there is room for improvement and refinement in terms of technical solutions.

[0032] With conventional insoles, in some cases, foot movement during exercise may be hindered, potentially leading to impaired overall physical movement that originates from the feet. In this case, contrary to the original intention, there are concerns about worsening symptoms, increased risk of injury, and decreased performance.

[0033] This disclosure aims to increase the freedom and versatility of insole manufacturing, while also providing insoles with superior functionality.

[0034] Specifically, this disclosure provides an insole manufacturing system and manufacturing method that enable anyone, regardless of their location, to manufacture insoles according to their needs.

[0035] This disclosure provides an insole capable of supporting the movement (trajectory) of the center of pressure (COP), a manufacturing system for the insole, and a manufacturing method for the insole.

[0036] This disclosure provides an insole that not only has the function of supporting the foot as a structure, but also, in addition to such function, elicits muscle activity in the foot and creates whole-body movement from the movement of the foot (sole), as well as a manufacturing system and method for the insole.

[0037] The manufacturing system of this disclosure is a manufacturing system for insoles composed of multiple parts. There are several thousand patterns, preferably several hundred thousand patterns, and more preferably several hundred billion patterns, of insoles that can be created with the manufacturing system of this disclosure. The manufacturing system includes a design unit configured as a computer, which selects the multiple parts from a predetermined parts list according to the input design specifications, and designs the insole by arranging the selected multiple parts.

[0038] Here, "selection" means that essential or sufficient parts are chosen so that the combination of multiple parts satisfies practicality and functionality. "Placement" means that the selected parts are not placed randomly but in an intended positional relationship (a positional relationship according to a predetermined placement logic). In other words, selection and placement are carried out according to predetermined rules or logic.

[0039] This manufacturing system allows engineers (insole manufacturers) to design insoles simply by inputting design specifications, which are then handled by a design unit. The design unit is configured to select multiple parts from a predetermined parts list according to the input design specifications, and then arrange these selected parts to design the insole. This makes it possible to design insoles that are suitable for each customer (insole user). The algorithm for selecting parts according to the design specifications can be pre-programmed and implemented in the manufacturing system.

[0040] This algorithm incorporates and reflects calculation and simulation results, knowledge and data presented in research and papers, and knowledge and data based on empirical rules. Calculation and simulation results include, for example, data and results derived from trial and error in designing according to various programs on a computer. Knowledge and data presented in research and papers may include, for example, data and results found in various studies, theoretical knowledge (for example, knowledge derived from the characteristics of human anatomy), and clinical trial data. Knowledge and data based on empirical rules may include, for example, the actual user experience, impressions, and results from continued use by consumers (insole users). By modifying the design algorithm based on this feedback from consumers (insole users), knowledge and data based on empirical rules are reflected in the algorithm.

[0041] In addition to the types of parts, the algorithms for selecting and arranging the parts make it possible for the manufacturing system of this disclosure to design thousands of patterns, preferably hundreds of thousands of patterns, and even more preferably hundreds of billions of patterns of insoles.

[0042] The manufacturing system of this disclosure may include an output unit that outputs to an external source information on the actual-scale form or relative form of multiple parts selected and placed by the design unit in their placed state.

[0043] "Form" includes at least shape, size, and positional relationships. "Form" may also include thickness, material, hardness, etc. "Information on form at actual size" means at least information on the shape, size, and positional relationships between parts at actual size. "Information on relative form" refers to information on similar form to actual parts, rather than the shape, size, and positional relationships at actual size. Specifically, it means at least information on the relative shape, size, and positional relationships when all multiple parts and their positional relationships are enlarged or reduced by the same ratio.

[0044] "Outputting externally" includes, for example, displaying on a display screen, projecting onto a projection surface by a projector or the like, printing and outputting on paper, and outputting in a form recognizable to others.

[0045] Information output by the output unit enables engineers (manufacturers of the console) and others to easily recognize how the multiple parts constituting the console are arranged in what positional relationships.

[0046] In particular, when information in the form of actual size is output externally, engineers (manufacturers of the console) and others can recognize the parts in a form corresponding to the actual object, so they can more naturally grasp the types of parts and the positional relationships between the parts, and thus can recognize them more easily and clearly. For this reason, the production of the console can be made easier and more reliable.

[0047] Also, when information in a relative form is output externally, especially when it is output externally in an enlarged form, recognition of the types of parts and the positional relationships between the parts becomes easier due to the enlargement. For example, it becomes easier for those with symptoms such as nearsightedness or presbyopia to recognize.

[0048] Also, when output externally in a reduced form, the output area can be saved, and the merit that a production system can be introduced even when there are physical restrictions on the production location of the console can be enjoyed. For example, in the case of projecting an image of the form of a part, even when there are restrictions on the size of the projection surface, the problem of the size of the projection surface can be solved by reducing the image and projecting it. Also, in the case of printing and outputting the form of a part on paper, it can be printed and output on a relatively small piece of paper, which can be advantageous from the viewpoints of convenience and resource saving.

[0049] The manufacturing system of this disclosure may include a display unit that superimposes the individual parts in a recognizable manner for multiple parts selected and placed by the design unit. "Superimposing in a recognizable manner" means, for example, displaying the outline of a part that is hidden by another part when that part is placed underneath it. In this case, the outline of the hidden part can be displayed with a dashed line. This makes it easier and more reliable to recognize multiple parts, and makes it easy to recognize where to place the multiple parts and in what positional relationship they should be placed. As a result, it may be easier and more reliable for engineers (insole manufacturers), etc., to manufacture insoles.

[0050] Here, the display unit may be included in the output unit. In other words, the output unit may have a display unit. Alternatively, the output unit may have the functions of a display unit.

[0051] Furthermore, the display unit may be configured to display multiple parts in a way that allows recognition of their superposition order. When we say "display in a way that allows recognition of the superposition order," for example, this could involve changing the thickness, shading, or line type of the outline lines in the order of superposition, or changing the overall color and shading of the parts (for example, by applying a gradient). Not only is the superposition display done in a way that allows recognition of the superposition order, so engineers (insole manufacturers, etc.) can recognize the order in which the multiple parts should be arranged. This can lead to a smoother insole manufacturing process.

[0052] The manufacturing system of this disclosure may include a comparison unit that compares the arrangement of multiple parts arranged by a design unit (hereinafter referred to as "model arrangement") with the arrangement of multiple parts as actual objects placed in predetermined locations (hereinafter referred to as "actual arrangement"), and a determination unit that determines whether the model arrangement and the actual arrangement match based on the results of the comparison by the comparison unit.

[0053] The comparison unit may include a detection unit or detection function that detects multiple parts as actual objects placed in predetermined locations. One example of a detection unit or detection function is a camera unit that images the parts.

[0054] A manufacturing system comprising a comparison unit and a judgment unit can determine whether the type and placement of parts match the design specifications with respect to the actual parts that are actually placed. This helps to suppress or prevent manufacturing errors. More specifically, by feeding the judgment results back to engineers (insole manufacturers), it is possible to suppress or prevent manufacturing errors by engineers (insole manufacturers). The comparison and / or judgment may be performed at predetermined time intervals, in real time, or, for example, each time a part is placed or each predetermined number of parts is placed, after detecting that a part has been placed.

[0055] By performing comparisons and / or judgments at predetermined time intervals rather than in real time, the resources (computer processing load) of the manufacturing system can be reduced. On the other hand, performing comparisons and / or judgments in real time allows for the suppression or prevention of manufacturing errors in real time. Furthermore, providing real-time feedback of the judgment results can lead to smoother insole production.

[0056] In the manufacturing system of this disclosure, the insole includes at least one of a base part and an additional part, and the base part and the additional part may be selected from a plurality of parts prepared according to each area arbitrarily divided in the approximate shape of a human foot. Furthermore, the additional part may be arbitrarily selected from a plurality of types of parts in which at least one element selected from the group of elements of shape, size, thickness, and hardness is different. Here, the base part may be a part having the shape of an approximate shape of a human foot. When both the base part and the additional part are used, the additional part may be used in combination with the base part.

[0057] In this case, the insole may include at least a base sole layer, a parts layer placed on the base sole layer, and an intermediate layer placed adjacent to at least one of the two surfaces of the parts layer.

[0058] The parts layer may be a layer in which multiple parts that make up the insole are arranged in any combination and in any positional relationship.

[0059] For multiple parts, it is preferable to chamfer the edges, such as by beveling, to soften the contact with the soles of the feet. On the other hand, with a configuration that includes an intermediate layer, the intermediate layer prevents the edges of individual parts from directly contacting the soles of the feet. Therefore, the intermediate layer can soften the contact with the soles of the feet. Furthermore, by providing an intermediate layer, it is possible to obtain the same effect as chamfering the edges of the parts. Therefore, such chamfering can be omitted. When chamfering is performed, additional equipment and labor are required, which significantly increases costs, but if only an intermediate layer is provided, additional equipment for chamfering is not required, and labor is also significantly reduced by not performing chamfering. Therefore, it is possible to significantly reduce overall costs and cycle time.

[0060] In the manufacturing system of this disclosure, the parts list may include a list of parts groups that are pre-composed by combining any multiple parts, and the design unit may be configured to select one or more parts groups from the list of parts groups as parts to be selected.

[0061] For multiple parts, the combinations can be patterned to some extent in order to achieve the desired effect. Therefore, by pre-registering the multiple parts that make up the patterned combination as a group of parts, and including that group of parts in the parts list so that it can be selected, the design burden can be reduced. More specifically, instead of selecting and combining parts one by one, selecting a group of parts that are already assembled simplifies computer processing and can reduce the processing load.

[0062] This disclosure also includes a method for manufacturing insoles. The manufacturing method may be as follows:

[0063] Specifically, the method for manufacturing an insole composed of multiple parts, wherein a desired insole is produced from thousands of patterns, preferably hundreds of thousands of patterns, and more preferably hundreds of billions of patterns, and the method for manufacturing the insole is a design unit configured on a computer, which selects the multiple parts from a predetermined parts list according to the input design specifications, and designs the insole by arranging the selected multiple parts.

[0064] Furthermore, this disclosure includes insoles manufactured by the manufacturing system and / or manufacturing method described above.

[0065] Furthermore, this disclosure may also include a computer program for implementing the above-mentioned manufacturing system and / or manufacturing method on a computer, and a recording medium for storing the computer program.

[0066] The insole manufacturing system, manufacturing method, and insoles manufactured therein described herein make it possible to manufacture insoles without the customer (insole user) and the technician (insole manufacturer) having to meet in person. Specifically, as long as communication is possible via a communication network, insoles can be manufactured regardless of geographical location. Therefore, anyone who desires insoles, regardless of location, can have the desired insoles manufactured and obtain them according to their needs.

[0067] Furthermore, according to the insole manufacturing system and method disclosed herein, it is only necessary to arrange the insole parts according to the output information (e.g., projected image), and no advanced skills or knowledge are required for manufacturing. Therefore, the range of personnel who can be involved in manufacturing as technicians can be greatly broadened. Anyone with even a minimum level of general dexterity can be involved in the manufacturing of insoles.

[0068] The insole manufacturing system, manufacturing method, and insoles manufactured therein according to this disclosure are superior in terms of ease of manufacture, versatility, etc., due to the inclusion of a computer-based design unit, and as described above, it is possible to manufacture desired insoles from thousands of patterns, preferably hundreds of thousands of patterns, and even more preferably hundreds of billions of patterns. In addition, by including a computer-based design unit, it is possible to implement unique algorithms. Due to these unique features, it is possible to realize a design focused on COP (Coefficient of Performance).

[0069] Regarding optimal walking and running motion, it is said that walking or running should be performed in such a way that the foot lands on the heel, the coping mechanism (COP) moves from the heel towards the fourth toe, then smoothly transitions between the big toe and the second toe, and finally exits from near the ball of the foot towards the front in the direction of walking or running. This reduces the load on the bones and muscles of the legs and hips, and allows for smooth and rapid movement with minimal energy loss.

[0070] In any movement, the strength and direction of the kick are determined according to the trajectory and endpoint of the center of gravity (COP), and the resulting forces determine the direction and speed of the body's center of gravity, thereby forming the movement of the entire body.

[0071] The insole manufacturing system, manufacturing method, and insoles manufactured therein according to this disclosure make it possible to optimize the trajectory and endpoint of the COP, and ultimately the movement of the entire body, to a desired state. Furthermore, it is possible to manufacture such insoles with a greater degree of freedom, without constraints on place, time, etc. for manufacturing. Moreover, it is possible to make it possible for anyone to easily and reliably manufacture insoles by simply assembling parts, without requiring advanced expertise or a high level of skill. The insole manufacturing system, manufacturing method, and insoles manufactured therein according to this disclosure not only have the function of supporting the foot as a structure, but in addition to such function, it is possible to provide insoles that draw out muscle activity in the foot and create whole-body movement from the movement of the foot (sole)

[0072] Figure 1A is a schematic diagram illustrating the human body's center of gravity and ground reaction force, and Figure 1B is a schematic diagram showing a general example of the movement trajectory of the COP and the body's center of gravity. Figure 2A shows the ideal movement trajectory of the COP, Figure 2B shows a typical example of the movement trajectory of the COP in the case of flat feet, and Figure 2C shows a typical example of the movement trajectory of the COP in the case of hallux valgus. This is a schematic diagram showing the configuration of the insole manufacturing system. This is a perspective view showing the installation configuration of the manufacturing terminal and projector. This is a perspective view showing the installation configuration of the manufacturing terminal and projector. This is a schematic diagram showing the case when a short-throw projector is used. This is a drawing showing the interface screen (menu screen) for designing (manufacturing) insoles. This is a drawing showing the interface screen (pattern template registration screen) for registering pattern templates. This is a drawing showing an example of area division of an insole. This is an example of an insole parts diagram. This is an example of an insole parts diagram. This is an example of an insole parts diagram. This is a diagram showing an example of combination of insole parts. This is a diagram showing an example of combination of insole parts. This is a diagram showing an example of layering. This is a diagram showing an example of layering. Figures 17A to 17C are diagrams illustrating the parts. These are diagrams illustrating an example of the specific structure of an insole. Figures 19A and 19B are diagrams showing examples of parts processing. These are diagrams showing examples of parts processing. Figure 21A is a diagram illustrating the intermediate layer, and Figure 21B is a diagram illustrating the state in which each layer is tightly bonded (adhered).

[0073] Insoles are used in footwear such as shoes (hereinafter also simply referred to as "shoes, etc."). Insoles may include those that are manufactured separately from shoes, etc., as well as those that are sewn into shoes, etc., during the manufacturing process.

[0074] This disclosure explains the basic concepts (basic design philosophy) of the insole. Figure 1A is a schematic diagram illustrating the human body's center of gravity and ground reaction force.

[0075] Figure 1A schematically shows a simulated body, with the upper body removed, resting on an object with a shape close to a semi-ellipse, in order to facilitate a visual understanding of the relationship between the body's center of gravity 26 and the COP (Center of Pressure) in a standing human position.

[0076] It can be said that all movements a person performs in daily life are movements that control the body's center of gravity 26. The COP (Center of Particle) is biomechanically important for controlling the body's center of gravity 26.

[0077] As shown in Figure 1A, the force W1 acting in the direction of gravity from the center of gravity 26 of the human body is transmitted to the foot 25 via the simulated hip joint 22, simulated knee joint 23, and simulated ankle joint 24, and then acts on the floor from the foot 25 via the object on the sole of the foot. On the other hand, a reaction force (hereinafter referred to as ground reaction force W2) is received from the floor via the object on the sole of the foot and acts on the entire sole of the foot 25.

[0078] COP (Coefficient of Precipitation) is widely used in scientific calculations as the starting point for the resultant vector of forces (ground reaction force W2) acting across the entire contact surface between the sole of the foot 25 and the object. The magnitude and direction of this ground reaction force W2, based on COP, physically determine the movement of each joint in the entire body, including the movement of the body's center of gravity.

[0079] Figure 1B is a schematic diagram showing a typical example of the movement trajectory of the COP and the body's center of gravity.

[0080] The ideal trajectory of the center of gravity (COP) during walking is shown in Figure 1B by the line Y, which connects the left foot's left foot (LF) and the right foot's right foot (RF). The arrow Z represents the trajectory of the body's center of gravity. COP varies from person to person, and optimizing this COP trajectory Y can not only improve walking and reduce pain, but also potentially enhance athletic performance.

[0081] For most sports and everyday movements, the COP (Critical Point of Pressure) typically originates in or near the heel of the foot (hereinafter referred to as the COP origin) and ends in the toes (hereinafter referred to as the COP endpoint).

[0082] Figure 2A shows the ideal COP movement trajectory, Figure 2B shows a typical example of the COP movement trajectory in the case of flat feet, and Figure 2C shows a typical example of the COP movement trajectory in the case of hallux valgus.

[0083] In normal walking, it is considered ideal for the heel to make contact with the ground, and for the COP (Center of Pace) to end in the space between the big toe and the second toe. The same applies to jogging and running.

[0084] Furthermore, in golf, for example, it is said that ideally, the endpoint of the COP (Center of Pace) should be on the medial side of the big toe of the foot distal to the target during the golf swing (usually the right foot).

[0085] In addition, ideal COP (Coefficient of Motion) movement trajectories have been identified depending on the type of sport, or the type and characteristics of the movement.

[0086] The strength and direction of the push-off are determined by which toe or specific part of the toe the COP (Center of Pose) endpoint is located on, and the resulting force determines the direction and speed of the body's center of gravity, thereby shaping the body's movement.

[0087] Anatomically and kinematically, the most efficient endpoint for the center of pressure (COP) is considered to be near the big toe. This is because the metatarsal bone, proximal phalanx, and distal phalanx of the big toe are larger than those of the other toes, and the big toe has a unique arrangement of muscles that function independently of the other toes.

[0088] If the COP (Coronary Optic Pathway) endpoint is located in an inappropriate area, it can lead to impairments and pain in all movements, including walking, and can also result in decreased athletic performance.

[0089] In bipedal humans, differences in the position of the COP endpoint, or differences in the speed of COP movement, can cause differences in the push-off force between the left and right feet, which can then affect the entire lower limb, pelvis, and trunk as twisting, potentially leading to various types of pain and other disorders.

[0090] By guiding the endpoint of the COP (Coefficient of Motion) to a specific area near the big toe, it becomes possible to improve the push-off force in that specific area near the big toe, or to increase or decrease the push-off force in the left and right feet, thereby creating a movement that is more suited to the purpose.

[0091] This disclosure focuses on the COP (Coefficient of Motion) (specifically, its movement trajectory) and discloses a technical concept for guiding the COP's movement trajectory to a desired trajectory. Based on this concept, the insole of this disclosure is designed to guide the COP's movement trajectory to a desired trajectory. Specifically, the shape, size, thickness, hardness, and combinations thereof of the insole and the parts that make up the insole are designed to guide the movement from foot contact to push-off.

[0092] Figure 3 is a schematic diagram showing the configuration of the insole manufacturing system 10 of this disclosure.

[0093] The insole manufacturing system 10 comprises a manufacturing terminal 11, a projector 12, and a server 13. The manufacturing terminal 11 and the server 13 are connected via a communication network 14 (for example, the Internet).

[0094] The manufacturing terminal 11 is a general-purpose computer equipped with a CPU, ROM, RAM, etc. (not shown in the diagram). The manufacturing terminal 11 may be a PC (including desktop PCs and notebook PCs), or a mobile device such as a tablet or smartphone. Furthermore, the computer may be a computer equipped with AI (artificial intelligence), and may also include any computer capable of performing calculations and processing, such as a quantum computer or a quantum optical computer.

[0095] The projector 12 is a device that projects images. The projector 12 is connected to the production terminal 11 in a communicative manner and projects images according to the data transmitted from the production terminal 11.

[0096] The projector 12 can be any device that has brightness and resolution above a predetermined standard. The manufacturing system 10 is equipped with a projector 12 as an example, but it is not limited to a projector as long as it can display images and videos for manufacturing insoles in a desired form and at a desired position. For example, instead of a projector, a smartphone or tablet capable of projecting images may be used, or a display device such as a display (e.g., a sheet-type display) may be used. In this case, the parts of the insole can be arranged according to the image on the display. Such a display is an example of an output unit and display unit in this disclosure.

[0097] In addition to a projector for projecting images and videos for manufacturing insoles, the system may also be equipped with a printing device for printing drawings (design drawings, parts drawings, etc.) for manufacturing insoles, and the drawings may be printed and output on paper.

[0098] Such projectors 12, printing devices, etc., are also examples of output units and display units in this disclosure.

[0099] An example of an output unit and display unit is a device that embodies Augmented Reality (AR) (hereinafter also referred to as an AR device). Specifically, it is conceivable to use an AR device to overlay digital information of an insole (more specifically, digital information of the insole parts) onto the real world, thereby supporting the placement of parts in the real world. In this case, the worker (manufacturer) can produce the insole by placing the parts as real objects according to the digital information of the insole parts that has been overlaid on the real world.

[0100] Examples of AR devices include smartphones and / or tablet devices that project digital information onto the real world, as well as wearable devices such as smart glasses that are worn like eyeglasses. With smart glasses, digital information is superimposed onto the real world through the lenses.

[0101] Server 13 has the function of designing insoles. Server 13 designs insoles and, based on the design data of those insoles, provides the manufacturing terminal 11 with data for manufacturing the insoles.

[0102] Server 13 can be any type of server that is connected to the production terminal 11 in a communicative manner and capable of transmitting the above data to the production terminal 11. Server 13 may include, for example, an AP (application) server, a Web server, or a DB server. The AP server stores application programs and operates according to those programs to implement various functions. The Web server provides various functions and information to other computers via the network on the Web system. The DB server stores various information in a read-write manner.

[0103] The server 13 may simply transmit data (data for manufacturing insoles) to the manufacturing terminal 11. Alternatively, the server 13 may be configured to provide the manufacturing terminal 11 with functions for designing insoles (e.g., application programs) in addition to the above data. The insole design may be performed by the server 13 or by the manufacturing terminal 11. In either case, it is covered within the technical scope of this disclosure.

[0104] The location of the server 13 is irrelevant. The server 13 may be installed in the same country as the manufacturing terminal 11, or it may be installed in a different country. Even if the server 13 and the manufacturing terminal 11 are installed in different countries or regions, they are still covered within the technical scope of this disclosure. The server 13 and / or the manufacturing terminal 11 are examples of design units of this disclosure.

[0105] Furthermore, as long as data transmission and reception are achieved, the aforementioned servers do not necessarily need to be used. For example, distributed network systems where multiple computers collaborate to build a network, and communication methods using blockchain technology, which do not require a specific server, are also included within the technical scope of this disclosure.

[0106] Figures 4 and 5 are perspective views showing the installation configuration of the manufacturing terminal 11 and the projector 12. In other words, they show the hardware configuration for manufacturing insoles.

[0107] The projector 12 is mounted on the stand 15. The stand 15 has a holding mechanism 151 (see also Figure 5) that fixes and holds the projector 12 while allowing the position of the projector 12 to be adjusted, and a work base 152 that functions as a base and onto which the image from the projector 12 is projected.

[0108] See also Figure 5. The holding mechanism 151 includes a support column 151a, a first bracket 151b, two second brackets 151c, two holding brackets 151d, and a housing 151e.

[0109] The support column 151a is a member that extends vertically up and down. The support column 151a is equipped with a guide mechanism 1511a. The guide mechanism 151g is configured so that its fixed position can be adjusted along the support column 151a.

[0110] The first bracket 151b extends laterally (horizontally) when installed. The first bracket 151b is attached and fixed to the support column 151a via a guide mechanism 1511a. The mounting position can be adjusted vertically up and down by adjusting the position of the guide mechanism 1511a along the support column 151a. The first bracket 151b has a mounting groove 1511b.

[0111] The two second brackets 151c are attached and fixed to the first bracket 151b by screws via mounting grooves 1511b. The mounting position is adjustable laterally (horizontally) along the mounting grooves 1511b. In the mounted state, each of the two second brackets 151c extends vertically from the first bracket 151b.

[0112] Each of the two second brackets 151c is provided with a retaining bracket 151d at its tip. The two retaining brackets 151d fix and hold the housing 151e so that its orientation can be adjusted. Specifically, the retaining bracket 151d has an orientation adjustment screw S, and the orientation of the housing 151e can be adjusted by operating and adjusting the orientation adjustment screw S.

[0113] The housing 151e houses the projector 12. With the projector 12 housed in the housing 151e, the orientation of the housing 151e can be adjusted to hold the projector 12 in a desired orientation.

[0114] In the manufacturing system 10, a projector 12 is configured to project a life-size image of the insole onto the workbench 152. Image data of the insole is provided from the manufacturing terminal 11. The manufacturing system 10 is configured so that the worker (manufacturer) can produce an insole according to the projected specifications by arranging the insole parts according to the image projected onto the workbench 152. Further details will be described later.

[0115] Figures 4 and 5 illustrate an example of a configuration in which the up, down, left, and right position and orientation of the projector 12 can be adjusted using fixing means such as screws. However, this configuration is merely an example, and any configuration that allows for adjustment of the projector's position and orientation may be adopted.

[0116] Let's specifically discuss other configuration examples. Another configuration involves using a short-throw projector. More specifically, a short-throw projector is a projector equipped with a short-throw lens (wide-angle lens), which is capable of projecting an image with wide diffusion. Short-throw projectors are generally known to have a focal length of approximately 0 to 300 mm.

[0117] This short-throw projector allows for a relatively shorter distance from the projector to the projection surface. Therefore, the overall size and volume of the manufacturing system 10 can be reduced, decreasing the area occupied by the system. This enables the manufacturing system 10 to be constructed in a smaller area, improving ease of construction and versatility.

[0118] Furthermore, by using a short-throw projector, the placement of the projector is no longer limited to directly overhead; it can also be placed in front, to the side, or diagonally above. This is because the focal length is relatively short.

[0119] If there is ample space and the projector can be installed overhead (directly above), and a short-throw projector is not required, a relatively inexpensive projector can be used, which has the advantage of reducing the overall cost of the production system 10. Furthermore, projecting the image from a vertical direction makes it easy to project a distortion-free image, which has the advantage of making the construction of the production system 10 easier.

[0120] If I were to point out a problem, it would be that when the creator tries to look at the projected image from directly above, the projector's light may overlap with their view, potentially obstructing the image projection.

[0121] In this regard, by constructing the production system 10 using a short-throw projector to project images from positions such as the front, side, and diagonally above, it becomes possible to improve the problem of image projection being obstructed by a part of the producer's body.

[0122] Figure 6 is a schematic diagram showing a comparison between a standard projector 12 and a short-throw projector 12S.

[0123] When using the short-throw projector 12S, it is possible to install the short-throw projector 12S closer to the projection surface compared to the conventional projector 12 assumed in Figures 4 and 5. As shown in Figure 6, the installation distance can be significantly reduced compared to the conventional projector 12.

[0124] Therefore, it eliminates the possibility of the creator blocking the image projection with their own head, making the production process easier and potentially improving work efficiency.

[0125] Figure 7 is a diagram showing an interface screen (menu screen) for designing (manufacturing) the insole of this disclosure. The interface screen (menu screen) shown in Figure 7 is displayed on the terminal (server 13 or manufacturing terminal 11) used for designing the insole. The insole can be designed (manufactured) via the interface on the server 13 or manufacturing terminal 11. The interface screen (menu screen) of Figure 7 will be described below.

[0126] <(1) Data Entry> The ID is a unique number or symbol used for identification. The ID may be entered optionally. In other words, setting and entering the ID may be omitted.

[0127] The name should be the full name of the insole user. Entering the name is optional. A nickname or other identifying name is also acceptable.

[0128] The pattern code indicates the specifications of the designed insole, more specifically, it represents the insole's lineage, purpose, and constituent parts using a code. When the necessary information for designing the insole is entered and the "Generate" tab (described later) is clicked, the insole is designed according to a pre-configured logic, and a pattern code corresponding to that design is generated and displayed in display field A10.

[0129] The "Delete" tab is used to delete the pattern code currently displayed in display area A10. Clicking the "Delete" tab will delete all pattern codes at once and reset the display.

[0130] The "Paste" tab is used to paste text. When the "Paste" tab is clicked, the text stored in the clipboard is copied (pasted) to display area A10.

[0131] The "Apply" tab is used to activate the pattern code displayed in display field A10. Specifically, when the "Apply" tab is clicked, elements such as the distance from the lower edge of the ball of the foot, the distance directly below the big toe, the little toe distance, size, sole type, sole application, and area-specific patterns are entered or selected based on the entered pattern code. Note that if you have performed "(2) Preparation for Work" described below before clicking the "Apply" tab, you will need to perform "(2) Preparation for Work" again.

[0132] The "Generate" tab is used to generate pattern codes from information such as the distance from the underside of the ball of the foot, the distance directly below the big toe, the little toe distance, size, sole type, sole application, and area-specific patterns, which have been entered or selected. When the "Generate" tab is clicked, a pattern code will be generated based on the above information.

[0133] By clicking the "Generate" tab, it is possible to generate a pattern code from the entered or selected information such as the distance from the lower edge of the ball of the foot, the distance directly below the big toe, the little toe distance, size, sole type, sole application, and area-specific patterns. Furthermore, by clicking the "Apply" tab, it is possible to input (generate) elements such as the distance from the lower edge of the ball of the foot, the distance directly below the big toe, the little toe distance, size, sole type, sole application, and area-specific patterns from the pattern code displayed in display field A10. In this way, data generation and updating are possible bidirectionally between the pattern code and the information of each element. This can improve the convenience of design (manufacturing).

[0134] "Distance from the lower edge of the ball of the big toe" represents the distance from the heel to the lower edge of the ball of the big toe. This value is set for both the left and right feet (the same applies below, and explanations will be omitted as appropriate).

[0135] "Distance directly below the big toe" refers to the distance from the heel to the area around the bottom of the big toe.

[0136] "Little toe distance" refers to the distance from the heel to the little toe (fifth toe).

[0137] The "size" indicates which of the pre-prepared base soles is being used. The base sole is the foundation of the insole, and the insole is made by placing and attaching various parts to the base sole. Base soles are available in types that correspond to the manufacturers of commercially available shoes and foot sizes.

[0138] "Sole type" indicates which type of sole a shoe belongs to. More specifically, each shoe manufacturer has specifications for sole shape for each type of shoe, and these specifications have distinctive characteristics. For example, the specifications of manufacturer A might be similar to those of manufacturer B. By categorizing and aggregating these specifications, they can be grouped into a specific type of sole type. "Sole type" indicates which of these classified types the shoe belongs to.

[0139] In other words, here, we have collected and categorized a wide range of specifications for base soles from various shoe manufacturers, and it is now possible to select a specific specification from among the categorized specifications.

[0140] "Sole application" refers to the intended use of the insole, such as for walking, running, golf, or general sports.

[0141] "Pattern template" indicates the type of template. In this disclosure, an insole (in other words, a designed insole) with various values ​​set or entered can be registered as a template by assigning an identifier (name). To register, set or enter the various values ​​and then click the "Register Pattern Template" tab. This will execute the registration. Registered templates can then be called up and used.

[0142] Here, we will further explain the registration of pattern templates using Figure 8.

[0143] Figure 8 is a diagram showing the interface screen (pattern template registration screen) for registering pattern templates.

[0144] In this interface screen (pattern template registration screen), the sole application, as mentioned above, indicates the application of the insole and is configured to be selectable via a pull-down menu. However, immediately after the "Pattern Template Registration" tab in the menu screen of Figure 7 is pressed and the pattern template registration screen of Figure 8 is displayed, the item in the "Sole Application" field that was set at the time of the menu screen of Figure 7 is displayed (selected). The displayed application item (name) may be a combination of a serial number and a description indicating the application. The pattern template registration will be executed using any one item (name) displayed in the "Sole Application" field of Figure 8.

[0145] Based on the selected "sole application," the pattern corresponding to that "sole application" will be displayed in the "Selected Pattern" column. The patterns displayed in this column correspond to the pattern codes displayed in display column A10 in Figure 7, however, the codes indicating the distance from the lower edge of the ball of the foot, the distance directly below the big toe, the little toe distance, the size, the sole system, and the sole application are omitted from the pattern codes displayed in display column A10, and only the codes indicating the parts are displayed. To change the contents of the pattern, press the "Close" tab to return to the menu screen in Figure 7, and you can change it by entering or resetting the information that indicates the contents of the pattern.

[0146] In the interface shown in Figure 8, registration is performed by clicking the "Register" tab. Clicking the "Register" tab prompts you to enter a name. Entering a name here will register the template with that name. If you enter an existing name and perform registration, the existing pattern template with that name will be overwritten.

[0147] The "Registered Templates" section displays a list of templates registered for the sole application selected in "Sole Application". If you wish to delete a template from the displayed list, you can do so by selecting the template and clicking the "Delete" tab.

[0148] <(2) Preparation for work [execution]> Returning to Figure 7, we will now explain the "(2) Preparation for work [execution]" tab. When you click this tab, the following process will be executed.

[0149] Access the PowerPoint file associated with the base sole (the base insole) system specified in the "(1) Data Entry" section above (open the PowerPoint file), and select and prepare the base sole, arch pad (where the arch pad is a part applied to the arch area (the instep area)), and individual parts based on the values ​​entered in the "(1) Data Entry" section.

[0150] When you change the value of an item in "(1) Data Entry" or when you execute "Apply" in an item in "(1) Data Entry", you can execute the process by clicking the "(2) Preparation for Work [Execute]" tab to implement the process that reflects the change (selection and preparation of parts, etc.).

[0151] <(3) Area-Specific Pattern Selection> This section is for selecting and determining the part patterns for each area of ​​the right and left feet.

[0152] First, select whether you want to use the right or left foot by clicking the "Right Foot" tab or the "Left Foot" tab.

[0153] Next, select an area. Specifically, select one of the tabs A1(*) to A9(*). In Figure 7, A1(b), A2(e), A3(d), A4(d), A5(d), A6(d), A7(c), A8(none), and A9(d) are shown.

[0154] To explain this meaning using A1(b) as an example, it means that pattern (part) b is selected for area A1. In the example in Figure 7, patterns a (A15), b (A16), and c (A17) are displayed for area A1. Furthermore, it can be recognized that, with area A1 selected, pattern b (A16) is selected from patterns a (A15), b (A16), and c (A17).

[0155] "(None)" means that no pattern (part) has been selected. Depending on the required use and function, patterns (parts) may be selected or left unselected. When any area (A1 to A9) is selected, images of the selectable patterns (parts) corresponding to that area are displayed, and the tags corresponding to the selected patterns (parts) are displayed in a pressed state (i.e., so that the selected patterns (parts) are visible).

[0156] <(4) Apply Pattern [Execute]> When you click the "(4) Apply Pattern [Execute]" tab, a display image will be created based on the selected pattern. The display image is an image that represents the designed insole. For example, the information may be output to an application such as PowerPoint and the display image may be created in PowerPoint slide format. Note that this "(4) Apply Pattern [Execute]" process cannot be executed unless the "(2) Preparation for Work [Execute]" process described above has been executed.

[0157] <(5) PDF Output> Clicking the "(5) PDF Output" tab will execute the output of a PDF file. PDF file output cannot be performed unless the "(4) Apply Pattern [Execute]" process has been executed. Once the PDF file output is complete, the output destination path will be displayed. The output destination may be set in advance, or it may be configured to be set (selected) at the time of output. After the PDF file output is executed, a pattern code is automatically generated. In other words, the final pattern code at the time the PDF file output is executed is automatically generated. The generated pattern code is automatically output and saved to the specified path.

[0158] <Form Reset> Clicking the "Form Reset" tab will reset the data you are currently working on, resetting or erasing any data you are entering, selecting, etc.

[0159] <Pattern Code> A pattern code is text information that describes the specific specifications of an insole in code format. The pattern code may include information necessary for the manufacture of the insole, such as its intended use, whether it is for the right or left foot, size, and the parts / groups of parts used.

[0160] Each component of the insole is coded individually. Here, coding means that a unique code is assigned to each individual component. In other words, there is a one-to-one correspondence between each component and its unique code. Furthermore, there is a one-to-one correspondence between groups of components (groups of components arranged within a predetermined area, and groups of components arranged across multiple areas) and the unique code of those groups of components.

[0161] This makes it possible to design insoles (determine specifications) using code. Specifically, by writing code, it becomes possible to describe the necessary parts, manufacturing process, and the finished insole. This format allows for automated computer design of insoles while simultaneously outputting the necessary parts, manufacturing process, etc. Furthermore, using code simplifies a series of calculations, enabling calculations and output with relatively low load. In addition, based on the output results, insoles can be manufactured using the parts and manufacturing process specified in the output results. Therefore, it becomes possible to easily and reliably manufacture insoles according to the design.

[0162] Furthermore, if insoles are described using codes, it is theoretically possible for those managing production to recognize the insoles from the written codes without having to look at specific planar or three-dimensional drawings of the insoles' shape and appearance, which can be highly convenient in certain situations.

[0163] In addition to a unique code for each part, the code may also include a customer code indicating the customer, an application code indicating the intended use, a code indicating the design date, manufacturing date, etc., and a code indicating the lot number.

[0164] In this disclosure, the specifications of the insole are described using the code described above. Specifically, the unique code for each individual part is described in the order in which they should be attached, with the code corresponding to the base member being the first. However, the code does not have to be described in order; it is also possible to attach all the described parts. In this case, the order of description may be random. Also, in this case, the parts can be attached in any order.

[0165] In other words, first, a code indicating the base component is written. Next, the codes for the parts that should be attached to that base component first are written immediately after the base component code. When we say "written side by side," they can be arranged vertically or horizontally; any arrangement is acceptable as long as the order is understandable and recognizable. By default, they are written from left to right, just like language.

[0166] Furthermore, when a code is provided, the description may consist of the code alone, or it may include both the part name and the code. In addition, a separate description may be provided that includes the part name, quantity, and other remarks, separate from the description that contains only the code.

[0167] From the perspective of ensuring that people, such as those managing production, can roughly recognize individual parts, it is common practice to describe (either alongside or separately) the names of the parts.

[0168] By describing parts using code, parts management becomes possible via code. This allows for inventory management, order processing, and other operations to be performed using code. In this case, it becomes easy to build a system for selling and distributing parts by utilizing existing e-commerce (E-commerce) sites. By integrating the distribution of parts into existing distribution networks without having to build a separate distribution network, a more stable supply system for goods and services can be established, which is one of the major advantages of the insole manufacturing system disclosed herein.

[0169] Figure 9 is a diagram illustrating the insole of this disclosure, and illustrates the insole that is manufactured (designed) via the aforementioned interface screen.

[0170] Figure 9 shows an example of area division in an insole. The insole of this disclosure is manufactured by dividing it into predetermined areas, and selecting, arranging, and attaching predetermined parts according to the specifications to each area.

[0171] The diagram shown in Figure 9 corresponds to the right foot. The front side of the paper in the diagram is the side that touches the ground, and the back side is the side that faces the sole of a human foot. The diagram for the left foot is omitted, but the same principle applies to the left foot. The left and right insoles may be symmetrical or asymmetrical. In one example, it may be a rule that they must always be symmetrical. In another example, whether they are symmetrical or asymmetrical may be determined at the design (specification determination) stage, as a result of designing (determining specifications) according to the characteristics of the user.

[0172] The insole (or, in other words, the base sole) is formed to match the overall shape of the shoe's interior (midsole shape), and is divided into nine areas, Area 1 to Area 9, as follows. Areas 1 to 9 correspond to A1 to A9 in the menu screen shown in Figure 7.

[0173] Area 1: Anterior-lateral area Area 2: Mid-lateral area Area 3: Four toes area Area 4: Transverse arch area Area 5: Lower part of the ball of the foot Area 6: Lower medial area Area 7: Medial heel area Area 8: Lateral heel area Area 9: Tip of the big toe Area 1 corresponds to the relatively lateral region of the forefoot.

[0174] Area 2 corresponds to the relatively outer region of the midfoot.

[0175] Area 3 corresponds to the slightly outer region of the midfoot.

[0176] Area 4 corresponds to the approximately central part of the midfoot.

[0177] Area 5 corresponds to the lower part of the ball of the foot.

[0178] Area 6 corresponds to the medial and lower part of the midfoot.

[0179] Area 7 corresponds to the inner area of ​​the heel.

[0180] Area 8 corresponds to the outer region of the heel.

[0181] Area 9 corresponds to the big toe portion of the forefoot.

[0182] The number of regions to be divided, the method of dividing each region, and the specific boundaries of the regions are merely examples and are not limited to the configurations shown in the above description and diagrams.

[0183] The insoles of this disclosure can be arbitrarily configured with several to several dozen types of parts for each area, preferably several to several hundred types, and even more preferably several to several thousand types. Details of these parts will be described later, but the elements of a part may include at least shape, size, thickness, hardness, and material. In other words, at least one of these elements may differ for each part. And as for the combination patterns of parts, there may be at least several million, and if no particular restrictions are placed, there may be hundreds of millions to several trillion or more patterns.

[0184] For each area, predetermined parts are arbitrarily selected and glued onto the base sole in a predetermined order. Because the parts have thickness, the gluing process may result in unevenness due to the individual thickness of the parts. However, these unevennesses are addressed by rounding the edges and / or tapering (hereinafter referred to as tapering). This allows for a smooth and natural feel against the sole of the foot, without the user feeling any unevenness caused by the thickness of the parts. As a result, the shoes can be worn without any discomfort for the user. Details of this tapering process will be described later.

[0185] Regarding tapering, it may be done on each individual part before they are glued together. Alternatively, the tapering may be done on the entire piece after the parts have been glued together. Or, in some cases, such tapering may be omitted as long as it provides a comfortable fit without any discomfort.

[0186] Figures 19 and 20 show examples of part processing. Each part is precisely processed according to its characteristics, design specifications, and other factors.

[0187] Figure 19A shows examples of tapered and middle-edge machining. Tapered machining is a process that chamfers the corners of a part (see section A-A). As a result, the cross-sectional shape of the part can become trapezoidal. Tapered machining (in other words, chamfering) softens the contact with the sole of the foot, resulting in a softer feel. From the perspective of COP induction, the sole of the foot perceives the presence of moderately convex areas, but tapered machining can reduce the feeling of protrusion on the sole of the foot, resulting in a more natural feel.

[0188] If the surface is too rough or bumpy, it can easily cause inflammation, blisters, and other problems due to friction. However, tapering (chamfering) the surface can help prevent such problems.

[0189] Middle edge machining is a process that chamfers one sharp end over a wider area than in tapered machining. Middle edge machining involves removing material from one end over a larger area, resulting in an overall sharper angle (see section B-B). By removing material over a larger area, the overall surface becomes smoother, resulting in a more natural feel underfoot.

[0190] Figure 19B also shows an example of middle edge machining. In the example in Figure 19B, a relatively large area is machined, as shown by the cross-section C-C. The extent of the area machined can be determined according to various factors such as the desired natural feel underfoot, the size of the part (width, etc.), the desired hardness, strength, and thickness of the finished part, and the hardness, strength, and thickness of the part before machining.

[0191] Figure 20 shows an example of complete edge machining. Complete edge machining is a process of beveling the entire surface of a given area. In other words, a taper is applied to the entire surface of a given area. In this case, as shown in Figure 20, the cross-section can be beveled across the entire width of the part.

[0192] While we have explained an example of tapered processing, as mentioned earlier, tapered processing can be omitted as long as it provides a comfortable fit without any discomfort. Please refer to Figure 21 for further explanation on this point.

[0193] In Figure 21, layer 21 is the base sole layer, and will be referred to as the base sole layer 21 hereafter. Layer 23 indicates the layer of the base parts and / or additional parts, and will be referred to as the parts layer 23 hereafter. Layer 22 is an intermediate layer placed between the base sole layer 21 and the additional parts 23, and will be referred to as the intermediate layer 22 hereafter. Layer 24 is a layer that functions as a cover, and will be referred to as the cover layer 24 hereafter.

[0194] Figure 21A is a schematic diagram showing each layer separately. Figure 21B is a schematic diagram showing each layer bonded together. Although Figures 21A and 21B show four layers, this is merely for convenience; in one example, it could be composed of five to seven layers.

[0195] The base sole layer 21 serves as the base of the insole, and the parts layer 23 is placed on top of the base sole layer 21 (at the bottom in Figure 21). However, an intermediate layer 22 is interposed between the base sole layer 21 and the parts layer 23. The cover layer 24 is placed on top of the parts layer 23 (at the bottom in Figure 21).

[0196] As schematically shown in Figure 21B, the intermediate layer 22 is interposed between the base sole layer 21 and the parts layer 23, so that the edges of the parts layer 23 (more specifically, the edges of the base parts and / or additional parts that constitute the parts layer 23) are covered by the intermediate layer 22, thereby creating a predetermined rounded shape.

[0197] This reduces the pressure on the sole of the foot caused by the thickness and edges of the part layer 23, and as a result, the same effect as when the part layer 23 is tapered can be obtained. For the user of the insole, even if the part layer 23 is not tapered, the presence of the intermediate layer 22 makes it less noticeable or impossible to feel the pressure from the edges of the part layer 23, resulting in a softer feel against the foot. By interposing the intermediate layer 22 between the base sole layer 21 and the part layer 23, it is possible to avoid foot pain caused by the edges of the part layer 23 even if the tapering of the part layer 23 is omitted.

[0198] The material of the intermediate layer 22 may be a sponge-like material or an elastic rubber-like material, but it is preferable to use a material with low elasticity. If a sponge-like material or an elastic rubber-like material is used, the unevenness will be created relatively directly according to the shape of the part layer 23, and the effect of softening the contact with the edges of the part layer 23 will be reduced. On the other hand, if a material with low elasticity is used, the low elasticity will allow it to adequately cover the edges of the part layer 23, and the contact with the foot at the edges of the part layer 23 will be appropriately softened. More specifically, by using a material with low elasticity and applying a predetermined tension to cover the edges of the part layer 23, pressure can be applied to the corners of the edges of the part layer 23, and these edges can become rounded. This effectively prevents the soles of the feet from becoming painful as described above.

[0199] Furthermore, in the insole of this disclosure, a high-strength material may be used in the base sole layer 21. High strength means a strength such that it will not be punctured by foreign objects such as pebbles.

[0200] A further advantage of using the intermediate layer 22 is that the tapering of the part layer 23 can be omitted, significantly reducing the manufacturing process for the part layer 23 and, consequently, the insole. As a result of the reduced labor costs, the insole can be manufactured at a lower cost. In particular, the smaller and thinner the part layer 23, the more difficult the tapering process becomes. By omitting the tapering process, this difficulty issue no longer needs to be considered. Therefore, the insole can be manufactured more easily and at a lower cost.

[0201] Furthermore, by interposing the intermediate layer 22, peeling and detachment of the part layer 23 can be effectively suppressed. This improves the strength and lifespan of the insole.

[0202] Here, the order of the intermediate layer 22 and the parts layer 23 may be reversed. Specifically, the parts layer 23 may be placed directly on top of the base sole layer 21 (directly below the base sole layer 21 in Figure 21), and the intermediate layer 22 may be placed on top of the parts layer 23 (below the top and bottom of the drawing in Figure 21). In this case, the order from bottom to top (from the base sole layer 21 downwards in Figure 21) may be base sole layer 21, parts layer 23, intermediate layer 22, and cover layer 24.

[0203] The intermediate layer 22 may be, for example, a film with a thickness of around 0.6 mm.

[0204] Figures 10 to 12 show examples of insole parts. It should be noted that the types of parts described in the drawings and the detailed description of the invention are examples and represent only a part of the possible components. Of course, other types of parts may also exist.

[0205] Figure 10 shows the base parts of the insole (hereinafter also referred to as the basic parts).

[0206] The basic components shown are a short arch pad and a heel pad. The short arch pad is positioned approximately in the center of the insole, corresponding to the arch of the foot (the instep). The heel pad is positioned in the heel area of ​​the insole.

[0207] Each basic part has corresponding parts for the left and right feet. Furthermore, there are multiple sizes of parts to accommodate different human foot sizes. In addition, there are multiple types of parts that differ in shape, size, thickness, and hardness.

[0208] In other words, as basic components, there are multiple types of parts that differ in characteristics in at least one aspect: shape, size, thickness, and hardness.

[0209] Figures 11 and 12 show additional parts that can be placed on top of the base parts. Figure 11 shows 10 types of additional parts A as an example. Additional parts A include the following types of parts: a relatively small triangle called a "small triangle", a relatively medium-sized triangle called a "medium triangle", a relatively acute angle called a "pointed" part, a round shape called a "round", a square shape called a "square", a roughly tabi-shaped part called a "TABI", a relatively long "long heel" placed on the heel, a relatively short "short heel" placed on the heel, a relatively thick "thick heel" placed on the heel, and a relatively elongated shape called a "slender" part.

[0210] Like the base parts, some additional parts A have corresponding parts for the left and right feet. Furthermore, there are multiple sizes of parts available to accommodate different human foot sizes.

[0211] Figure 12 shows three types of additional parts B as examples of parts that can be further placed on the base parts. The additional parts B include a "banana forefoot" which is placed on the forefoot and has a roughly banana shape, a "long forefoot" which is also placed on the forefoot and has a relatively long shape, and a "short forefoot" which has a relatively short shape.

[0212] Like the base parts, add-on part B also has parts for the left and right feet. Furthermore, there are multiple sizes of parts to accommodate different human foot sizes.

[0213] Similar to the base parts, additional parts A and B consist of multiple types of parts with different characteristics in at least one aspect: shape, size, thickness, and hardness.

[0214] The desired insole is manufactured by combining the base part with additional part A and / or additional part B.

[0215] Figures 13 and 14 show examples of part combinations.

[0216] Figure 13 shows an example in which additional parts A and B are combined with a short arch pad as a basic part. Figure 14 shows an example in which additional parts A and B are combined with a base sole as a basic part.

[0217] Multiple additional parts A and B of various types are combined, and their overlapping and combination create a unique three-dimensional shape. The thickness, hardness, size, and shape created by the combination of parts (base part and additional parts A and B) can directly affect the sole of the user's foot. The three-dimensional shape characteristics and hardness of the insole directly affect the sole of the user's foot, inducing the movement (trajectory) of the COP and potentially adjusting the movement of the body's center of gravity. Here, the base part may be omitted, and only additional parts A and B may be used.

[0218] Additional parts A and B are selected from a group of parts using general computer processing. Various methods are possible for this selection, and in this disclosure, any part can be ultimately selected by the following method.

[0219] In the data processed by the computer, all placeable (selectable) parts are initially provisionally positioned for each area.

[0220] Figures 13 and 14 show, as an example, a state in which all placeable (selectable) add-on parts A and B are placed in the data. To illustrate this state, Figures 13 and 14 show each of the multiple add-on parts A and B in a recognizable shape, and also show multiple add-on parts A and B overlapping each other in multiple layers.

[0221] In the method proposed in this disclosure, all selectable parts are temporarily placed in the data, and then any desired part is selected from among these temporarily placed parts. Only the selected part is then drawn (displayed) externally. Conversely, parts that are not selected are placed in the data, but are not drawn (displayed). In this case, the creator recognizes the existence of only the selected part, and perceives the unselected parts as if they did not exist. Thus, from the creator's perspective, the situation is the same as if only the selected desired part itself were placed.

[0222] In other words, although multiple types of parts (all types of parts) exist in the data, only the parts that are ultimately selected are visible, and unnecessary parts that are not selected cannot be seen.

[0223] The advantages of this method include the fact that, in terms of data processing on a computer, only the selection of parts is required, eliminating the need to place the selected parts in their designated locations afterward, thus reducing the processing load on the computer. Furthermore, in addition to reducing the processing load on the computer, because the complex process of placing the parts in arbitrary locations after selection is not required, processing can be done with very common systems and software, rather than special systems or software, and processing speed is improved, making mass production easier. For this reason, processing is possible even offline. Of course, processing is also possible online, more specifically on servers connected to a communication network, and the processing load on such servers can also be reduced. As a result, it has the effect of increasing versatility, and the ease of system construction and system usability can be improved.

[0224] Furthermore, any unnecessary parts of the selected components that would protrude when placed are removed and finished by methods such as cutting or tapering as described above.

[0225] Figure 15 will be used to further explain the logic behind the placement of the parts (the logic of selection).

[0226] In insoles, the areas can be classified as, for example, Area 1 to Area 9, as mentioned above. In this case, a layer is prepared for each area, and parts are placed (selected) for each layer.

[0227] Specifically, as shown in Figure 15, nine layers are prepared, from Area 1 to Area 9. Then, for each layer (each area), the desired parts are selected and placed from among multiple parts that can be applied to that area. This process is carried out separately for the left foot and the right foot. Finally, the layers corresponding to Area 1 to Area 9 are superimposed to create a completed insole.

[0228] Furthermore, the parts to be selected may be chosen individually, or they may be selected as a group of parts with pre-formed combinations. Specifically, instead of selecting parts one by one, the system may be configured to have pre-prepared combinations of parts arranged in a specific pattern.

[0229] For example, depending on factors such as area, application, and size, an optimal combination of parts may already exist. This optimal combination of parts is derived from research, trials, simulations, and user feedback over a predetermined period. Alternatively, it may be theoretically derived computationally from, for example, a complete computer simulation.

[0230] In Figure 15, for example, areas 2 to 7 can be understood as showing the arrangement of parts as a combination of multiple parts.

[0231] This can be understood as the result of each individual part being selected, or, as mentioned above, as an optimal combination being pre-constructed, and one set of parts representing that combination being selected and placed.

[0232] Thus, this disclosure describes methods in which individual parts are selected one by one, as well as methods in which a pre-configured set of optimally combined parts is selected. The choice of which method to use is arbitrary.

[0233] Furthermore, a pre-configured set of optimally combined parts may be prepared and used as a single part. While the concept of a set of parts is based on the idea of ​​assembling multiple parts to form a set of parts, the idea here of preparing something equivalent to a set of parts as a single part is, as the wording suggests, a technical concept of constructing something equivalent to a set of parts as a single part. According to this technical concept, a set of parts consisting of multiple parts is constructed as a single part, and as a result, the number of parts can be reduced.

[0234] In this case, the labor required for production (specifically, the labor required for attaching parts) can be reduced. When a group of parts is constructed as a single part, attachment only needs to be done once, by attaching that single part. Of course, the production and processing of the parts can also be simplified when they are constructed as a single part. In this case, since the number of parts can be reduced, it is also advantageous in terms of inventory management, etc.

[0235] Thus, this technological approach of constructing what would normally be a group of parts as a single part offers significant advantages, such as reducing manufacturing time and simplifying inventory management.

[0236] Here, the group of parts may include different types of parts, such as a group of parts that are placed within a predetermined area (more specifically, within the range of a predetermined area among the nine areas mentioned above), and a group of parts that are placed across multiple areas.

[0237] The former group of parts may be a pattern formed by combining multiple parts. The combination (patterning) of multiple parts can be implemented within the system. In this case, it is assumed that the parts are placed within a predetermined area and do not extend into other areas, and therefore, the multiple parts may overlap each other.

[0238] The latter group of parts, due to its nature of spanning multiple areas, is configured so that they do not overlap. In other words, multiple parts are combined and arranged on the same plane without overlapping. This group of parts is a combination (fusion) of the parts that are placed in each respective area.

[0239] Figure 16 shows an example of how layers are stacked sequentially. Figure 16 shows an example where three layers, Layers 1 to 3, are stacked sequentially.

[0240] In Layer 1, a pad is placed on the base sole, extending from the heel to the arch. Layers 2 and 3 contain several parts or groups of parts, and by sequentially stacking Layers 1, 2, and 3, as well as subsequent layers (which are not shown in the illustration), a three-dimensional insole is realized. In practice, each layer or part may be color-coded to make it visually easy to recognize.

[0241] The parts will be further explained using Figure 17.

[0242] Figure 17A shows an example of attaching the add-on parts one by one, where add-on parts 30a to 30g are independent add-on parts that are each placed on the same layer.

[0243] Figure 17B shows the parts corresponding to the parts group. Part 30 in Figure 17B is a single part, and this single part 30 performs the same function as the combination of additional parts 30a to 30g. Part 30 can also be said to be a part that integrates the additional parts 30a to 30g.

[0244] Part 30 can be arranged as a single part, as shown in Figure 17C.

[0245] With this group of parts (part 30), part 30 can also serve as the additional parts 30a to 30g, thus eliminating the need to attach each of the additional parts 30a to 30g individually.

[0246] Figure 18 shows an example of a specific structure of an insole. In the example in Figure 18, there is a multi-layer structure consisting of a base sole layer 31, an intermediate layer 32, a basic parts layer 33, an additional parts layer 34, and a cover layer 35.

[0247] The base sole layer 31 is the layer that comes into contact with the sole of the foot. It also serves as a base for attaching arch pads and other additional parts during the manufacturing of the insole. This base sole layer 31 includes a first base sole layer 31a and a second base sole layer 31b. The first base sole layer 31a may be made of Excene (registered trademark). The second base sole layer 31b is bonded to the first base sole layer 31a and may be made of a shock-absorbing material. The thickness of the second base sole layer 31b is preferably about 2 mm.

[0248] The intermediate layer 32 is made of, for example, a film with a thickness of approximately 0.6 mm.

[0249] The base parts layer 33 is the layer on which basic pads such as arch pads and heel pads are placed.

[0250] The additional parts layer 34 is the layer on which the additional parts are placed, and as mentioned above, the number of possible combinations of additional parts exceeds several thousand to several hundred billion. The additional parts layer 34 is the layer that generates several thousand to several hundred billion patterns of insoles.

[0251] The cover layer 35 is a layer that functions as a cover. A non-slip material may be used for the cover layer 35. The cover layer 35 may have a first cover layer 35a and a second cover layer 35b. The first cover layer 35a and the second cover layer 35b may be made of different materials.

[0252] This disclosure describes how to create a design drawing for an insole that is relatively life-sized. Specifically, by setting the focal length, subject distance, projector angle, and focus so that it is absolutely life-sized, it becomes possible to manufacture the insole based on the projected design drawing.

[0253] Here, the projector 12 may be configured to project an image of the insole that is relatively life-sized. "Relatively life-sized" means that the design drawing has been enlarged or reduced, the positional relationships of the arrangement match the designed insole, and the absolute size of the insole (the absolute size of the parts) differs from the design specifications. However, the relative sizes of the parts match the design specifications.

[0254] In this case, instead of projecting the image with the projector 12, the system may be configured to output the image as a paper-based output, printed on paper.

[0255] Furthermore, digital information (digital images) may be superimposed onto the real world using augmented reality (AR) technology.

[0256] The insole maker simply needs to arrange and attach the parts according to the projected design. Therefore, according to the manufacturing system disclosed herein, anyone, anywhere, and with the necessary equipment, can easily and reliably produce the desired insole without requiring advanced skills.

[0257] The parts that can be combined create a three-dimensional shape through their overlapping and combination. The thickness, hardness, size, and shape of the parts themselves directly affect the sole of the foot. This three-dimensional shape of the insole acts on the sole of the foot, changing the trajectory of the COP (Center of Pressure) on the sole and adjusting the movement of the body's center of gravity. Of course, it goes without saying that it also has the function of supporting the structure of the foot itself, like conventional custom-made insoles.

[0258] This disclosure states that the detailed shape of the insole can be custom-made in consideration of the user's characteristics. Conventionally, this would have required meticulous measurement of each part of the user's foot, which was traditionally done in person with a technician.

[0259] This disclosure describes how custom-made insoles can be manufactured remotely, for example, based on data transmission, response, and exchange over the internet, using the method described below.

[0260] To enable contactless insoles, the process primarily utilizes anatomical information of the foot and information on body movement. More specifically, this includes (1) statistical models, (2) ergonomically based shape data, (3) movement data as electronic data, and (4) questionnaire data that can be answered online. By combining this information, it becomes possible to produce custom-made insoles of the same quality as those made in person, but without face-to-face interaction. In this disclosure, the shape of the insole is determined not only from the skeletal data of the foot itself (data of the user in a stationary state) but also from movement data that can be exchanged as electronic data (data of the user in a moving state).

[0261] (1) A statistical model is a model used to statistically calculate the production data necessary to create insoles tailored to the characteristics of the user's feet, based on actual data such as foot size measured from photographs of the user's feet. By comparing the actual data measured from photographs of the user's feet with the statistical model, the production data can be calculated. A more detailed explanation is as follows:

[0262] Generally, the data that can be measured from photographs is limited to the distance between anatomical landmarks of the foot (parts with distinctive shapes, such as bony protrusions), and it is practically difficult to measure the distance to parts that do not have landmarks. In contrast, by using statistical models, it becomes statistically possible to calculate the distance to parts without landmarks based on the data measured from the landmarks.

[0263] While errors can occur in values ​​calculated using statistical models, the extent of these errors (the error range) can be mathematically determined. Verification of these errors has mathematically demonstrated that even when using statistical models, it is possible to calculate data with a very small error range that does not pose practical problems.

[0264] (2) Ergonomically based shape data refers to average and neutral shape data (arch shape data) that can be used regardless of race or gender. The human foot consists of 28 bones, and it is known that the structure and shape of such a human foot fall within a certain shape range, even when considering gender and race. Based on this shape range, there is an average and neutral arch shape for functionally controlling the movement trajectory of the COP during movement. By positioning the ergonomically based shape as the average shape and deforming the shape from that shape to match the individual movements of the user, it is possible to determine the optimal shape according to the characteristics of the user.

[0265] (3) Operational data as electronic data, and (4) information obtained via the Internet, specifically consist of the following electronic data:

[0266] (A) Foot skeletal information data acquired from directly above or from various directions (hereinafter referred to as foot skeletal data) (B) Comprehensive movement data (C) Questionnaire data that can be answered on the internet (hereinafter referred to as questionnaire data) First, (A) Foot skeletal data is foot skeletal information acquired from directly above the foot or from various directions as needed. Specifically, this includes photographic and video data of the foot taken from those directions, as well as data from sensors that can acquire foot size information. Using these, foot size is measured based on anatomical landmarks of the foot (parts with distinctive shapes, such as bony prominences and joints).

[0267] Here, foot size refers to not only the general foot length (length from heel to toe), but also the foot width and the distance between each toe.

[0268] Furthermore, landmark areas include, specifically, the most prominent part of the medial aspect of the first metatarsophalangeal joint, the most prominent part of the lateral aspect of the fifth metatarsophalangeal joint, the most prominent part of the calcaneus, the most prominent parts of the toes, and the toe joints.

[0269] This foot size measurement uses foot size data based on landmarks as the independent variable, and a proprietary statistical model derived from multivariate analysis is used to calculate the foot size of areas without landmarks.

[0270] Multivariate analysis, in statistics, is a method for predicting an outcome from multiple independent variables, and one type of multivariate analysis is multiple regression analysis. It is a statistical method that allows for the quantification of how much each of several related factors (explanatory variables) influences a given outcome (dependent variable) in the form of a function, expressing the relationship between the two and making predictions based on that.

[0271] In this method of calculating foot size for areas without landmarks using statistics, the most important length for manufacturing is the length from the heel to the posterior edge of the ball of the big toe (hereinafter referred to as the posterior edge distance). The posterior edge of the ball of the big toe, as the name suggests, is the end of the ball-shaped first metatarsophalangeal joint that is behind (towards the heel). Even if the foot length (length from heel to toe) is the same, the posterior edge distance is not necessarily the same. In the method disclosed herein, as described above, foot size data is used as an independent variable, and the above posterior edge distance is calculated by multivariate analysis.

[0272] On the other hand, the posterior edge distance may be calculated as follows. Specifically, instead of the length from the heel to the posterior edge of the ball of the big toe, the length from the heel to the most prominent part of the ball of the big toe (hereinafter referred to as the HB length) is calculated by calculation according to a certain rule (a rule based on statistical data). Furthermore, the posterior edge of the ball of the big toe is set at a point that is moved (descended) by a predetermined length (a length determined by the above-mentioned certain rule) toward the heel from the point corresponding to the HB length. The length from the heel to the point set as the posterior edge of the ball of the big toe is then taken as the posterior edge distance. The posterior edge distance may be calculated in this way.

[0273] In conventional face-to-face fittings, it was crucial to palpate the posterior edge of the ball of the foot, which varies from person to person, and to manufacture insoles to fit that area. In other words, whether or not an insole fits the individual differences in the posterior edge of the ball of the foot is one of the clear differences that distinguishes a custom-made insole from a mass-produced, universally compatible insole manufactured in a factory. In this disclosure, the fit is improved by calculating (estimating) the aforementioned posterior edge distance, which varies from person to person, from foot size data.

[0274] After calculating the trailing edge distance using the method described above, the ergonomically designed arch shape size is determined. Once the trailing edge distance is determined, the shape of the human foot can be adapted to the ergonomically designed arch shape, regardless of race. This ergonomically designed arch shape is intermediate (neutral) and imperfect, and cannot properly guide the trajectory of the COP, which differs from person to person, but it serves as a basic shape for guiding the COP.

[0275] By making millimeter-level partial shape changes from this basic shape, the insole shape is transformed to appropriately guide the trajectory of the COP and body movements, which differ from person to person. By making shape changes that result in thousands to hundreds of billions of possible patterns, the shape pattern is transformed to best suit the individual's movements, enabling the creation of custom-made insoles. The data required for this shape is the motion data and medical interview data described below in (B), (b-1) to (b-5) and (C).

[0276] (B) Comprehensive motion data is motion data acquired electronically as comprehensive data of daily living activities and sports performance. In this context, "comprehensive" refers to motion data as electronic data that includes a mixture of multiple actions and is continuous, and does not limit itself to performing specific actions.

[0277] For example, this could include continuous motion data from everyday life, such as standing up from a chair, starting to walk, changing direction, and reaching a destination, or from sports, such as throwing a ball, running, changing direction, and stopping. It is preferable to record these comprehensive motions as continuous movements lasting about one minute, and it is also preferable that they include various elements of movement as described above.

[0278] Furthermore, it is even better if the data is acquired simultaneously from two directions. While it is preferable to capture the data using a camera fixed on a tripod, the measurement terminal may be moved to follow the subject as needed. To improve data accuracy, it is preferable to acquire the data while closer to the subject.

[0279] (B) If comprehensive motion data is difficult to obtain, five types of modified motion data may be used as electronic data as an alternative. The five types of modified motion data are: (b-1) balance motion data for standing on one leg (hereinafter referred to as single-leg balance data), (b-2) stepping motion data in place (hereinafter referred to as stepping data), (b-3) walking motion data (hereinafter referred to as walking data), (b-4) motion data for repeating lateral jumps or similar movements that involve rapidly changing direction from side to side (hereinafter referred to as side step data), and (b-5) motion data specific to sports (for example, golf swing motion in the case of golf, or batting swing motion or pitching motion in the case of baseball (hereinafter referred to as specific motion data)). One or more of these five types of modified motion data may be used.

[0280] The electronic data mentioned above refers to all data that can be transmitted and received via the Internet, including, for example, video data, still image data, sensor data, audio data, text data, CSV data, XML data, etc.

[0281] Furthermore, sensor data refers to data measured by various motion-sensing sensors installed in smartphones, tablet devices, and other electronic devices. For example, there is acceleration data acquired by an accelerometer. By repeatedly applying differential calculus to the obtained data, it is possible to obtain data related to velocity and position, thus making it possible to represent movement in data form. In addition, there is real-world data, which is exemplified by recent sensing technologies. This is sensor data known as augmented reality (AR) technology, which involves irradiating the surrounding real environment with laser light and measuring scattered and reflected light to recognize the surrounding situation, including human movement. As described above, it has become possible in recent years to convert human movement into data using various sensors.

[0282] (b-1) One of the modifications of (B), single-leg balance data, can be a modification of comprehensive movement data because single-leg standing is an evaluation method that embodies the state of whole-body balance in all movements. The movement data is based on evaluating the whole body, and in some cases, it evaluates the way of movement (how to maintain balance) of parts. Data is basically acquired from the front, but from other directions as needed. Hold the single-leg stance for several seconds, then switch sides. In addition, advanced movements may be added as needed. Focus on the differences in how to maintain balance when standing on one leg with both feet and the whole body.

[0283] (b-2) One of the modifications of (B), the stepping data, is an evaluation method that embodies the balance and walking motion while standing on one leg, and can be a modification of comprehensive motion data. The height, speed, and number of times the foot is lifted are changed as needed, and the movement of each part of the body during these actions is observed and evaluated.

[0284] (b-3) Walking data, one of the modifications of (B), can be used as a modification of comprehensive movement data because walking is one of the most frequently performed movements in daily life, and problems throughout the body and decreased athletic performance very often result from imbalances in walking. Data is acquired from the front and rear, and from the side as needed, for the distance that can be walked. Conditions such as walking speed are changed as needed. It is preferable to perform walking in several trials to grasp the trends of the movement.

[0285] (b-4) Side step data, one of the modifications of (B), can be a modification of comprehensive motion data because left-right changes of direction are frequently used in sports, and the ability to change direction on the left and right directly affects sports performance. Data of the side step movement is acquired from the front and, if necessary, from various directions. The evaluation is performed on how the feet and body parts are used when changing direction on the left and right.

[0286] (b-5) Specific motion data, one of the modifications of (B), involves different specific movements for each sport. In the case of sports, it goes without saying that it is important to evaluate the required sports movements in order to change the shape according to the performance to be achieved. For example, in the case of golf, golf swing movements, in the case of baseball, batting movements, etc., motion data for each sport is acquired from the necessary angles.

[0287] The comprehensive motion data described above, and the five modified motion data used as needed, are acquired by the user or assistant as electronic data via the internet and other electronic data exchange methods. The COP trajectory is estimated from this motion data, and a few millimeters of shape modification are pattern-based to optimize it. The method of shape modification is determined from the motion data using a proprietary algorithm. For example, the relationship between the degree of shoulder sway during movement and the position of the pelvis, and the direction in which the leg is kicked are used as evaluation points, and the decision on shape modification is made by at least one of a human and a computer. This may be done collaboratively by a human and a computer, by a human alone, or by a computer alone. In practice, it is preferable to perform it automatically by a computer alone.

[0288] (C) The medical interview data primarily obtains information on (I) the location of calluses on the feet, (II) the type of problems the patient is experiencing, and (III) body pain. These (I) to (III) data are used to improve the accuracy of the shape changes determined from (B), (b-1) to (b-5) and (C), and to determine whether the shape changes will be burdensome to the body. In other words, the final confirmation of the shape changes determined from the motion data can be performed using this data. In addition, if necessary, the medical interview data may be evaluated first before the shape changes based on the motion data, and the motion data may be referenced based on that evaluation.

[0289] (I) The location of calluses on the soles of the feet indicates that the area is repeatedly subjected to load due to the thickening of the skin. In other words, the COP (Coefficient of Performance) often follows a trajectory that passes over the area of ​​the callus during movement, and the validity of judgments made from evaluating movement can be confirmed by the location of calluses on the soles of the feet. Furthermore, evaluating the location of calluses on the soles of the feet first and then evaluating movement based on that information allows for more accurate movement analysis.

[0290] (II) The type of problem a person is experiencing will result in a characteristic trajectory of the COP. In cases of knee pain or hip pain, there is a strong tendency to swing the shoulders widely from side to side when walking, and the movement of the COP associated with this is characteristic. These, like (I) the location of calluses on the feet, contribute to confirming the validity of judgments evaluated from movement and to more accurate movement analysis.

[0291] (III) Regarding physical pain, the body skillfully uses avoidance and compensatory movements to reduce pain by trying to avoid the burden as much as possible. However, these unusual movements can cause the following problems. Thus, by investigating which parts of the body have what type and degree of pain through interviews, it becomes possible to confirm the validity of judgments about shape changes obtained from movement evaluations and to perform more accurate movement analysis.

[0292] Furthermore, additional questionnaire items and content may be added as needed, and it is preferable to utilize free-response fields and other features to obtain a wide range of information regarding users' concerns.

[0293] By acquiring electronic data using the internet through the scheme described above, it becomes possible to manufacture custom-made insoles of the same quality as those produced in person, but without face-to-face interaction.

[0294] According to the insole manufacturing system of the embodiment of this disclosure, the shape of the protrusions on the insole is determined based on the user's movement data as electronic data. Therefore, based on various data transmitted via a communication line such as the internet, it is possible to manufacture custom-made insoles that match the dynamic foot and physical condition without requiring face-to-face interaction with a technician.

[0295] Furthermore, based on foot skeletal data obtained from the skeletal information of the user's foot, the foot size is measured from the shape of the bony protrusions of the foot, and the foot size data is used as an independent variable. Using a proprietary statistical model derived from multivariate analysis, the foot size of the parts of the foot without bony protrusions is calculated. This makes it possible to calculate the foot size of the parts of the foot without bony protrusions (parts without landmarks), which previously had to be measured face-to-face, without performing face-to-face measurements. Therefore, by simply obtaining foot skeletal data, which is skeletal information of the foot, it is possible to manufacture custom-made insoles that fit the user.

[0296] In particular, by calculating the length from the heel to the posterior edge of the ball of the foot, which is the area with the greatest individual variation, this dimension, which previously could only be measured face-to-face, can now be calculated without face-to-face measurement. Therefore, by simply sending and receiving foot skeletal data via the internet, it is possible to create custom-made insoles tailored to the user.

[0297] In recent years, methods for manufacturing insoles that primarily use foot shape data obtained from sensing technologies such as 3D scanners have emerged. However, it has been kinematically and anatomically proven that foot shape data acquired by 3D scanners and the like is merely a static representation of the user's foot shape (foot shape in static standing, lying down, and sitting positions), and is completely different from the foot shape during movement. Rather, the foot is constantly deforming during movement to match the position of the load and the shape of the floor surface, and this deforming function of the foot is the basis of the human walking ability, which is so excellent. Therefore, it is difficult to produce an optimal insole that matches the dynamic state of the foot and body during walking, sports, etc., with insoles that are primarily manufactured using this static foot shape data. This disclosure is superior to conventional manufacturing systems that primarily use static foot shape data obtained from 3D scanners and the like, in that it is a more logically valid and rational method that makes it possible to determine the shape of the protrusions to be placed on custom-made insoles based on dynamic movement data.

[0298] Furthermore, the system includes a process for partially modifying the shape of the insole based on the comprehensive motion data acquired as electronic data, which comprehensively captures daily activities and sports performance. This allows for partial, millimeter-level shape changes or fine adjustments to the protrusions on the insole based on this data. As a result, it is possible to produce custom-made insoles that can correct the movement trajectory of the COP (Corpus Controlled) to the optimal position, which varies from person to person.

[0299] Furthermore, as a variation of comprehensive motion data, it is also possible to fine-tune the shape of the protrusions based on one or more combinations of the five types of modified motion data as electronic data: single-leg balance data, stepping data, walking data, side-step data, and specific motion data.

[0300] Furthermore, by making partial shape changes to the insole based on the medical interview data, which includes information about the location of calluses on the feet, the types of problems the user is experiencing, and the areas of body pain, it is possible to improve accuracy through shape changes determined from (B), (b-1) to (b-5) and (C), and to determine whether the shape changes will be burdensome to the body. As a result, it is possible to produce custom-made insoles that are more suitable for the user.

[0301] Furthermore, by acquiring foot skeletal data, movement data, or medical interview data as electronic data from the user's foot skeletal information via the internet, various data necessary for creating custom-made insoles can be easily sent and received over the internet without requiring face-to-face meetings with technicians. This solves the problems of regional service disparities and soaring sales prices that have been challenges in custom-made products. In addition, by creating custom-made insoles that match the dynamic foot and physical condition, it becomes possible to produce superior custom-made insoles that are of higher quality and have greater medical and logical validity than conventional ones.

[0302] Here, regarding the sensation of the soles of the feet and the foot movements (actions) based on that sensation, it has been found that humans have a characteristic of consciously or unconsciously stepping on hard objects or parts of the foot that feel hard.

[0303] More precisely, a situation where one consciously or unconsciously steps on a particular part occurs when its hardness, height, etc., fall within a certain range. On the other hand, if the hardness, height, etc., exceed a certain limit, a person or the sole of their foot will feel discomfort and consciously try to avoid stepping on that part. Thus, depending on the degree of hardness and height, situations can arise where one consciously or unconsciously steps on a surface, or conversely, where one consciously tries to avoid stepping on it.

[0304] Further details will be explained below.

[0305] [Physical Effects (Edge Effect)] The movement of the COP (Core Point) can be likened to the trajectory of skiing. When skiing on a slope of a snowy mountain, a phenomenon occurs where the ski is pulled downwards down the slope. Similarly, by creating a slightly curved edge (unevenness) on the sole side of the foot, the COP can be guided in the opposite direction to that edge. This phenomenon and effect is also referred to as the edge effect.

[0306] By utilizing this edge effect, it is possible to intentionally create the movement (trajectory) of the center of gravity (COP) to match the movement characteristics of various sports, including walking. For example, by creating an edge on the outside (little toe side) of the sole of the foot inside the shoe, the COP can move more easily inward, resulting in easier generation of the force to quickly change direction inward. In this case, the explosiveness of changes of direction can be improved in sports with many changes of direction, such as soccer. In golf, the edge effect can appropriately guide the movement of the foot, enabling a stable swing centered on rotational movement (in other words, a swing that suppresses "sway": the movement of the body's axis from side to side during the swing).

[0307] [Effect of Activating Foot Function] It is known that in modern times, a very large percentage of people do not have their little toe touching the ground. In contrast, by applying pressure to the area below the little toe on the sole of the foot, the activity of the flexor digiti minimi brevis and / or abductor digiti minimi brevis can be improved. In this case, the little toe will be activated from the perspective of muscle activity. As a result, the functionality of the lateral part of the foot may be improved. This can suppress excessive lateral displacement of the COP during exercise such as walking, and lead to more efficient movement.

[0308] Furthermore, the peroneus longus muscle pulls through the lateral midfoot of the sole, and in this respect, the lateral midfoot of the sole is an important area responsible for changing the direction of movement. By compressing the lateral midfoot of the sole, it is possible to increase the activity of the peroneus longus muscle, in addition to the flexor digiti minimi brevis and abductor digiti minimi muscles mentioned above.

[0309] The peroneus longus muscle is known to be active when the ball of the big toe makes contact with the ground and pushes off, and is an extremely important muscle in walking and various sports. Furthermore, among the muscle groups originating in the lower leg, the peroneus longus is the only muscle that can move the center of gravity (COP) to the medial side (towards the big toe) of the foot, and for this reason, it can be said to be an indispensable muscle for COP control and body center of gravity control.

[0310] Therefore, activating the peroneus longus muscle improves the push-off motion on the medial side of the foot (big toe side), thereby suppressing excessive lateral shift of the center of gravity (COP). As a result, it becomes possible to induce more efficient movement during exercise such as walking, by suppressing excessive lateral shift of the body's center of gravity.

[0311] By utilizing these characteristics, the design concept and manufacturing system described herein allow for the adjustment of the height and hardness of the parts while positioning them according to the trajectory so that the COP traces a desired path.

[0312] In other words, by controlling the arrangement of parts, as well as their height and hardness, it is possible to guide the trajectory of the COP (Coefficient of Motion) by causing a person to consciously or unconsciously step into a predetermined area due to those parts.

[0313] According to this disclosure, in addition to the (A) foot skeletal data, (B) comprehensive movement data, and (C) medical history data already explained, by comprehensively and comprehensively considering various factors such as the characteristics of human foot movement as described above, it will be possible to design and manufacture any insole that can guide the trajectory of the COP to a desired position.

[0314] Here, the design (creation of design drawings) may be performed using artificial intelligence (AI). In this disclosure, as mentioned above, several thousand patterns or more, preferably several hundred thousand patterns or more, and even more preferably several hundred billion patterns or more are assumed for the design patterns. Machine learning is performed on such a vast number of design patterns, linked to the measured foot shape data. Machine learning, as used here, means that the input patterns are learned in a defined form. In this disclosure, the insole is classified into areas 1 to 9, and parts are selected for each area. For example, "parts are selected for each area" is one of the input patterns. Here, machine learning refers to the learning of design patterns in a defined form using such input patterns.

[0315] On the other hand, learning can also be performed in a form where the input pattern is not predetermined. Here, such learning is called deep learning. In deep learning, for example, design patterns (part arrangement patterns) are taken in as images and learned as a whole. In this type of deep learning, information such as whether the insole is classified into areas 1 to 9, or whether parts are selected for each area, is not attached to the learning process. In this case, it becomes possible to perform learning that has a broader and deeper range of applications.

[0316] Furthermore, there are various methods of so-called deep learning, and other forms and variations of deep learning may also be included. For example, while we mentioned above that "parts are selected for each area," in the case of selecting parts for each area, it is also conceivable that the AI ​​would be trained to perform deep learning in a way that mimics human selection.

[0317] Alternatively, training could involve building a Large-Scale Language Model (LLM). In this case, pattern codes describing the insole specifications would be incorporated as text information for training. In other words, thousands of patterns, preferably hundreds of thousands, and even more preferably hundreds of billions of patterns, would be linked to the measured foot shape data for training.

[0318] In AI-powered design, based on a learning model trained using the methods described above, when input (in this case, foot shape data and design specifications) is provided, an output (in this case, an insole design drawing) that is suitable for the input is returned.

[0319] Here, the learned values ​​may further include various aspects related to use, such as the specific effects of using the insoles, actual effects, sensory effects, user evaluations, and impressions. In addition to elements related to use, marketing elements such as sales status, sales region, sales performance, and attributes of purchasers may also be included.

[0320] According to this disclosure, the manufacturing process can proceed without the user and manufacturer having to meet in person, and users can request and have insoles manufactured regardless of the region or area in which they live.

[0321] Furthermore, from the manufacturer's perspective, even without advanced skills or knowledge, insoles can be easily and reliably produced as long as the minimum necessary equipment is in place. Specifically, they can be manufactured by assembling the insole parts according to a projected image. Therefore, production can be carried out without any restrictions on location.

[0322] This advantage has become even more significant in light of recent global events and trends. For example, in recent years, global emergencies such as the COVID-19 pandemic and wars have occurred, affecting the production and distribution of goods, resulting in chronic shortages and price increases. These problems were particularly severe when production and distribution bases were concentrated or limited to specific locations or regions. When production and distribution bases are concentrated or limited to specific locations or regions, the impact is enormous if those bases cease to function.

[0323] In this regard, the insole manufacturing system and method disclosed herein eliminate the need to concentrate manufacturing in a specific location or region, nor are there any restrictions on its location. Therefore, manufacturing locations and regions can be dispersed, and can even be said to naturally become dispersed. This is because, as mentioned above, various data necessary for manufacturing insoles can be sent and received via the internet, and insoles can be manufactured based on this data. Needless to say, a supply chain can also be established so that insole parts can be obtained from a wide distribution network.

[0324] Furthermore, when production bases, logistics bases, supply chains, etc., are dispersed, and globalization leads to dispersed trade both domestically and internationally, exchange rate risk can also arise. In addition to emergencies such as the global spread of viruses like COVID-19 and wars mentioned above, exchange rates often fluctuate significantly due to various factors such as political events and speculative actions. In such cases, fluctuations in the prices of goods and services (for example, price increases) occur, and the stable supply of goods and services (supply at a fixed price) can also be threatened.

[0325] According to the insole manufacturing system and manufacturing method disclosed herein, for example, it is easy to establish a manufacturing base in Japan to avoid exchange rate risk, and the issue of exchange rate risk can also be resolved.

[0326] Furthermore, there are no restrictions on the location of the production base; it can be built in any place, including private homes, public facilities, and welfare facilities. For example, public facilities and welfare facilities are usually equipped with earthquake-resistant and seismic isolation measures, so by locating the production base in such facilities, it is possible to operate even during natural disasters such as earthquakes.

[0327] Furthermore, establishing production bases in public facilities, welfare facilities, etc., can effectively create jobs. This effective job creation can lead to stable production.

[0328] Thus, the insole manufacturing system and manufacturing method disclosed herein allow for the arbitrary and simple construction of an effective manufacturing and supply system, such as distributing manufacturing bases or establishing manufacturing bases in desired locations, in order to address the challenges mentioned above. For example, it is possible to achieve a supply system equivalent to or better than that of a large-scale factory, while minimizing risks, without having to establish a large-scale factory. Furthermore, it is possible to enjoy benefits that cannot be obtained with a system that produces in a large-scale factory.

[0329] The insole manufacturing system and manufacturing method disclosed herein can achieve a higher level of stable supply of goods and services, and can also effectively correct the problem of regional disparities in services.

[0330] Furthermore, the insole manufacturing system and method disclosed herein do not require high skill levels and can be manufactured anywhere. In this case, it is also realistically possible for the user themselves to manufacture the insoles.

[0331] These effects and benefits can be obtained not only in Japan but in any country; in other words, the insole manufacturing system and method disclosed herein can be implemented in any country. The insole manufacturing system and method disclosed herein will bring advantages on a global scale and contribute to the economy.

[0332] The above describes the insole manufacturing system according to the embodiments of this disclosure. However, this disclosure is not limited to the embodiments described above, and various modifications and changes are possible based on the technical concept of this disclosure.

[0333] For example, in this embodiment, foot skeletal data, movement data, or medical interview data obtained from the user's foot skeletal information are acquired via an internet connection, but the invention is not limited to this. For example, these various types of data can be stored on a recording medium such as a DVD, and this recording medium can be sent by mail or other means to produce custom-made insoles without requiring face-to-face interaction with a technician.

[0334] Furthermore, although this embodiment describes an insole that is fitted as a shoe insert, it can also be applied to footwear in which a protrusion is formed as a midsole. In other words, it can also be used as a manufacturing system for footwear equipped with a custom-made midsole.

[0335] [Other Embodiments] Another embodiment of the present disclosure is a method for manufacturing an insole used as a shoe insert and which is custom-made to suit the condition of the user's foot, characterized in that the shape of a protrusion provided on the insole is determined based on motion data as electronic data representing the user's movements.

[0336] Motion data may be comprehensive motion data consisting of a mixture of multiple movements in a continuous sequence. Motion data may be one or more combinations of single-leg balance data, stepping data, walking data, side-stepping data, or specific motion data.

[0337] The motion data and comprehensive motion data may be 2D and / or 3D videos used to estimate the position and movement trajectory of the COP and determine a method for changing the shape of the protrusion using a predetermined algorithm.

[0338] Based on foot skeletal data obtained from the skeletal information of the user's foot, the foot size may be measured from the shape of the bony protrusions and joints of the user's foot, and the foot size data may be used as an independent variable, and the foot size of the area of ​​the foot without bony protrusions may be calculated using a proprietary statistical model derived from multivariate analysis.

[0339] Foot size may be calculated by measuring the length from the heel to the posterior edge of the ball of the foot. The partial shape of the insole may be modified based on questionnaire data, which includes information about the location of calluses on the feet, the types of problems the patient is experiencing, and the location of body pain. Movement data, foot skeletal data, or questionnaire data may be obtained via an internet connection.

[0340] According to this, it is possible to provide a method for manufacturing custom-made insoles without requiring face-to-face meetings with engineers.

[0341] Currently, in some regions, people cannot obtain insoles, or are unaware of their existence and therefore cannot benefit from them, creating a disparity. The root of this disparity lies in face-to-face manufacturing. This disclosure will establish a non-face-to-face manufacturing method (business model), enabling the provision of technology not only in Japan but also to people around the world who suffer from physical problems or difficulties with sports performance, thereby correcting the service disparity.

[0342] Static foot shape data acquired using 3D scanners, which have become widely used in recent years, represents only the static shape of the user's foot (foot shape in static standing, lying down, and sitting positions), and it has been kinematically and anatomically proven that this shape is completely different from the foot shape during movement. Rather, the foot is constantly deforming during movement in accordance with the position of the load and the shape of the floor surface, and this deforming function of the foot is the basis of the human walking ability, which is so excellent. Therefore, it is difficult to produce an optimal insole that matches the dynamic state of the foot and body during walking, sports, etc., using insoles that are mainly manufactured based on this static foot shape data. In this disclosure, by making it possible to determine the shape of the protrusions on a custom-made insole based on electronically exchangeable dynamic motion data, it becomes possible to provide insoles that match the dynamic state of the foot and body, which was difficult with conventional manufacturing methods, to people all over the world.

[0343] Due to the face-to-face nature of insoles, their price has skyrocketed, limiting their purchase to a select few wealthy individuals or production covered by Japan's medical insurance system. Lowering prices is essential for more people to benefit from custom-made insoles. Furthermore, due to the nature of medical insurance, which only applies after a diagnosis has been made, it is institutionally difficult to produce insoles from a preventative medicine perspective. Pain resulting from poor body movement, characteristic poor movements that cause sports injuries, and other issues that occur before a diagnosis is made at a medical institution make preventative medical tools that do not rely on medical insurance extremely important. This disclosure reveals a technological philosophy that can accelerate the promotion of foot health and make a significant contribution to society.

[0344] In one example, the insole may be constructed by dividing the upper surface of the insole into three regions: the forefoot, the midfoot, and the rearfoot, and having a protrusion with a height of 0.2 mm to 15 mm projecting upward from the upper surface or downward from the lower surface of the insole from the outer side of one of the forefoot, the midfoot, and the rearfoot, or two of the three regions, or all three regions.

[0345] The height of the protrusion may be between 0.2 mm and 11 mm. Alternatively, the height of the protrusion may be between 0.2 mm and 7 mm.

[0346] The lateral forefoot convexity formed in the forefoot may push upward the metatarsals and phalanges on the lateral side of the sole of the human foot, the lateral metatarsal convexity formed in the midfoot may push upward directly below the cuboid bone, or slightly distal to the cuboid bone, to a height higher than the arch height of the medial border of the navicular bone, and the lateral hindfoot may push upward on the lateral side of the calcaneus to a height higher than the medial side of the calcaneus.

[0347] The protrusions of the forefoot, midfoot, and hindfoot may be formed integrally and continuously. A second protrusion may be provided on the inner edge of the forefoot.

[0348] According to the insole of this disclosure, the outer part of the user's sole is pushed upward, which makes it difficult for the COP to shift outward and guides the COP inward (towards the big toe). The movement trajectory of the COP has the characteristic of reflecting the movement trajectory of the body's center of gravity (located near the pelvis when a person is standing), and by guiding the movement trajectory of the COP, the movement trajectory of the body's center of gravity is corrected, which can lead to more efficient movement with excessive outward shift of the body's center of gravity suppressed.

[0349] In one example, the insole of the present disclosure may be provided with an insole whose upper surface is divided into three regions: a forefoot, a midfoot, and a rearfoot, and which has a group of medial forefoot protrusions that project upward from the upper surface or downward from the lower surface of the insole, and which are arranged to wrap around the outer circumference of the big toe in a plan view.

[0350] The medial forefoot convex group may consist of one or more of the following: a first convex portion located near the proximal phalanx between the big toe and the second toe; a second convex portion extending from the first convex portion toward the toes; a third convex portion extending from the first convex portion toward the big toe, traversing the proximal phalanx of the big toe; a fourth convex portion located along the vicinity of the posterior edge of the ball of the big toe; and a fifth convex portion located from the vicinity of the posterior edge of the ball of the big toe along the curvature of the medial edge of the insole.

[0351] This disclosure may also include footwear in which the medial forefoot convex group is provided as a midsole.

[0352] According to the insole described herein, the provision of a group of medial forefoot protrusions can encourage pushing off with a specific area near the big toe or improve the force of pushing off.

[0353] Hereinafter, this disclosure may include the inventive concept of the following manufacturing method.

[0354] [Item 1] A method for manufacturing an insole, comprising an insole composed of multiple parts, wherein a desired insole is manufactured from several thousand patterns, preferably several hundred thousand patterns, and more preferably several hundred billion patterns, by combining the multiple parts, wherein the insole is designed using a design unit configured on a computer, which selects the multiple parts from a predetermined parts list according to the input design specifications, and designs the insole by arranging the selected multiple parts.

[0355] [Item 2] The manufacturing method according to Item 1, further comprising using an output unit that outputs to the outside information of the actual size form or the relative form of each of the plurality of parts selected and arranged by the design unit in the arranged state.

[0356] [Item 3] The manufacturing method according to Item 1, further comprising using a display unit that superimposes the individual parts of the plurality of parts selected and arranged by the design unit in a recognizable manner.

[0357] [Item 4] The manufacturing method according to Item 1, comprising using: a comparison unit that compares the arrangement state of the plurality of parts arranged by the design unit (hereinafter referred to as the model arrangement) with the arrangement state of the plurality of parts as actual objects placed in predetermined positions (hereinafter referred to as the actual arrangement); and a determination unit that determines whether the model arrangement and the actual arrangement match based on the results of the comparison by the comparison unit.

[0358] [Item 5] The manufacturing method according to Item 1, wherein the insole includes at least one of a base part and an additional part, and for the base part and the additional part, for each area arbitrarily divided in the approximate shape of a human foot, a part is selected from a plurality of parts prepared according to that area, and further, for the additional part, a part is arbitrarily selected from a plurality of types of parts in which at least one element selected from the group of elements such as shape, size, thickness, and hardness is different.

[0359] [Item 6] The manufacturing method according to Item 1, wherein the insole comprises at least a base sole layer, a parts layer placed on the base sole layer, and an intermediate layer placed adjacent to at least one of the two surfaces of the parts layer.

[0360] [Item 7] The manufacturing method according to Item 1, wherein the parts list includes a list of parts groups that are pre-composed by combining any multiple parts, and the design unit is configured to be able to select one or more parts groups from the list of parts groups as parts to be selected.

[0361] Furthermore, this disclosure may include the inventive concept of the insole itself, which is produced by the manufacturing system and manufacturing method described above.

Claims

1. An insole manufacturing system for an insole composed of multiple parts, wherein a desired insole is manufactured from several thousand patterns, preferably several hundred thousand patterns, and more preferably several hundred billion patterns, by combining the multiple parts, the manufacturing system comprising a computer-based design unit that selects the multiple parts from a predetermined parts list according to input design specifications, and designs the insole by arranging the selected multiple parts.

2. The manufacturing system according to claim 1, further comprising an output unit that outputs to the outside information of the actual-size form or the relative form of each of the plurality of parts selected and arranged by the design unit in the arranged state.

3. The manufacturing system according to claim 1, further comprising a display unit that superimposes and displays the individual parts of the plurality of parts selected and arranged by the design unit in a recognizable manner.

4. A manufacturing system according to claim 1, comprising: a comparison unit that compares the arrangement of the plurality of parts arranged by the design unit (hereinafter referred to as the model arrangement) with the arrangement of the plurality of parts as actual objects placed in predetermined positions (hereinafter referred to as the actual object arrangement); and a determination unit that determines whether the model arrangement and the actual object arrangement match based on the results of the comparison by the comparison unit.

5. The manufacturing system according to claim 1, wherein the insole includes at least one of a base part and an additional part, the base part and the additional part are selected from a plurality of parts prepared according to each area arbitrarily divided in the approximate shape of a human foot, and the additional part is arbitrarily selected from a plurality of types of parts in which at least one element selected from the group of elements of shape, size, thickness, and hardness is different.

6. The manufacturing system according to claim 1, wherein the insole comprises at least a base sole layer, a part layer placed on the base sole layer, and an intermediate layer placed adjacent to at least one of the two surfaces of the part layer.

7. The manufacturing system according to claim 1, wherein the parts list includes a list of parts groups that are pre-composed by combining any multiple parts, and the design unit is configured to select one or more parts groups from the list of parts groups as parts to be selected.

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