U.S. patent application number 14/375763 was filed with the patent office on 2015-01-15 for shoe and manufacturing method therefor.
This patent application is currently assigned to ASICS CORPORATION. The applicant listed for this patent is Kenta Moriyasu, Norihiko Taniguchi. Invention is credited to Kenta Moriyasu, Norihiko Taniguchi.
Application Number | 20150013187 14/375763 |
Document ID | / |
Family ID | 48983735 |
Filed Date | 2015-01-15 |
United States Patent
Application |
20150013187 |
Kind Code |
A1 |
Taniguchi; Norihiko ; et
al. |
January 15, 2015 |
Shoe and Manufacturing Method Therefor
Abstract
A method for manufacturing a shoe, the method including the
steps of: attaching a sock-shaped base member 1 forming a portion
of an upper to a last portion 52 of a core 50, the core 50
including a core print 51 and the last portion 52; attaching the
core 50 to an outer mold 61, 62; supplying a molten resin 71, 72 to
be a reinforcement member 2 and/or a sole member 3, 4 into between
the outer mold 61, 62 and the base member 1; and allowing the
molten resin 71, 72 to cure, thereby forming the reinforcement
member 2 and/or the sole member 3, 4 integral with the base member
1.
Inventors: |
Taniguchi; Norihiko;
(Kobe-shi, JP) ; Moriyasu; Kenta; (Kobe-shi,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Taniguchi; Norihiko
Moriyasu; Kenta |
Kobe-shi
Kobe-shi |
|
JP
JP |
|
|
Assignee: |
ASICS CORPORATION
Kobe-shi
JP
|
Family ID: |
48983735 |
Appl. No.: |
14/375763 |
Filed: |
February 17, 2012 |
PCT Filed: |
February 17, 2012 |
PCT NO: |
PCT/JP2012/053817 |
371 Date: |
July 30, 2014 |
Current U.S.
Class: |
36/84 ;
12/142R |
Current CPC
Class: |
A43B 23/0255 20130101;
B29D 35/02 20130101; B29D 35/08 20130101; A43B 7/1495 20130101;
A43B 1/04 20130101; B29D 35/126 20130101; B29D 35/146 20130101;
B29D 35/0009 20130101; A43B 23/0235 20130101; A43B 9/18 20130101;
B29D 35/06 20130101; A43B 23/0245 20130101; A43C 1/00 20130101;
A43B 23/0265 20130101 |
Class at
Publication: |
36/84 ;
12/142.R |
International
Class: |
A43B 1/04 20060101
A43B001/04; A43B 23/02 20060101 A43B023/02 |
Claims
1. A shoe comprising an upper, the upper comprising: a sock-shaped
base member of a knit fabric, a knit-like fabric and/or a woven
fabric; and a reinforcement member with the base member the
reinforcement member being substantially without sewn to the base
member, and the reinforcement member being bonded and/or welded to
a surface of the base member.
2. A shoe according to claim 1, wherein the reinforcement member
covers at least a portion of a medial-side surface and a
lateral-side surface.
3. A shoe according to claim 2, wherein the reinforcement member
covers a portion of each of a front foot section, a middle foot
section and a rear foot section on the medial-side surface, and
covers a portion of each of the front foot section, the middle foot
section and the rear foot section on the lateral-side surface.
4. A shoe according to claim 3, wherein the reinforcement member
covers a portion of a bottom surface of a foot and continuously
extends from the bottom surface of the foot onto the opposite side
surfaces of the foot.
5. A shoe according to claim 4, wherein the reinforcement member
covers a bottom surface of the middle foot section.
6. A shoe according to claim 5, wherein in the middle foot section,
the reinforcement member continuously extends from the bottom
surface onto the opposite side surfaces.
7. A shoe according to claim 6, wherein the reinforcement member
includes a lacing loop integrally formed along an upper edge of the
reinforcement member.
8. A shoe according to claim 6, wherein the reinforcement member
includes an ornamental eyelet integrally formed along an upper edge
of the reinforcement member.
9. A shoe according to claim 6, wherein the reinforcement member
covers a circumference of a top line.
10. A shoe comprising: a sock-shaped base member of a knit fabric,
a knit-like fabric and/or a woven fabric forming a portion of an
upper; and a sole member made of a resin bonded and/or welded to a
bottom surface of the base member.
11. A shoe according to claim 10, wherein the resin is a foamed
material, and the sole member is a midsole member.
12. A shoe according to claim 11, wherein on a medial-side surface
and a lateral-side surface of a foot, the midsole member covers a
portion of each side surface of the foot.
13. A shoe according to claim 12, wherein the midsole member covers
opposite side surfaces of a middle foot section, and a lacing
aperture is formed along an upper edge of the midsole member.
14. A shoe according to claim 11, wherein a heel counter is
integrally formed with the midsole member.
15. A shoe according to claim 11, wherein the midsole member covers
a circumference of a top line.
16. A method for manufacturing a shoe, the method comprising the
steps of: attaching a sock-shaped base member forming a portion of
an upper to a last portion of a core, the core including a core
print and the last portion; loading the core onto an outer mold;
supplying a molten resin to be a reinforcement member and/or a sole
member into between the outer mold and the base member; and
allowing the molten resin to cure, thereby forming the
reinforcement member and/or the sole member integral with the base
member.
17. A manufacturing method according to claim 16, wherein in the
step of loading the core, the core print of the core his supported
by the outer mold, with the core print protruding from a top line
of the base member.
18. A manufacturing method according to claim 17, wherein the
loading step is performed with the core positioned so that the core
print is below the last portion.
19. A manufacturing method according to claim 18, wherein: the
outer mold includes a first outer mold, to which the core print is
attached, and a second outer mold meshing with the first outer
mold, the method comprising: a first supply step of supplying a
first molten resin to be the reinforcement member into between the
first outer mold and the second outer mold and the last portion; a
step of allowing the first molten resin to cure, thereby forming
the reinforcement member integral with the base member; a step of
meshing a third outer mold, which meshes with the first outer mold,
onto the first outer mold, replacing the second outer mold; a
second supply step of supplying a second molten resin to be the
sole member into between the third outer mold and the last portion;
and a step of allowing the second molten resin to cure, thereby
forming the sole member integral with the base member.
20. A manufacturing method according to claim 19, wherein in the
meshing step after the first supply step, the second outer mold is
removed, with the core print remaining attached to the first outer
mold, and the third outer mold is meshed onto the first outer mold,
replacing the second outer mold.
21. A method for manufacturing a shoe, the method comprising the
steps of: attaching a sock-shaped base member made of a knit fabric
and/or a woven fabric forming a portion of an upper to a last and
heating the sock-shaped base member, thereby forming a sock
portion; and heating a sole member made of a knit fabric and/or a
woven fabric integral with the base member during the heating of
the base member, thereby melting the sole member.
22. A shoe according to claim 1, wherein: the reinforcement member
comprises a pair of side surface portions extending in an up-down
direction along each of a medial-side surface and a lateral-side
surface of a middle foot section of a foot, a lower portion
extending in a front-rear direction in a lower portion of the side
surfaces, and an ornamental eyelet extending in the front-rear
direction along an instep of the foot and having a plurality of
lacing apertures; and a portion of the base member is enclosed,
over an entire circumference thereof, by the pair of side surface
portions, the lower portion and the ornamental eyelet.
23. A shoe according to claim 22, wherein the lacing apertures are
provided near upper ends of the side surface portions extending
from the lower portion toward the ornamental eyelet.
24. A shoe according to claim 10, wherein: the sole member
comprises a pair of side surface portions extending in an up-down
direction along each of a medial-side surface and a lateral-side
surface of a middle foot section of a foot, a roll-up lower portion
rolled up from a bottom surface and extending in a front-rear
direction in a lower portion of the side surfaces, and an upper
edge portion extending in the front-rear direction along an instep
of the foot and having a plurality of lacing apertures 304; and a
portion of the base member is enclosed, over an entire
circumference thereof, by the pair of side surface portions, the
roll-up lower portion and the upper edge portion.
25. A shoe according to claim 24, wherein the lacing apertures are
provided near upper ends of the side surface portions extending
from the lower portion toward the upper edge portion.
Description
TECHNICAL FIELD
[0001] The present invention relates to a shoe using a sock-shaped
upper member, and a manufacturing method therefor.
BACKGROUND ART
[0002] In recent years, it has been proposed to form a sock-shaped
upper member by a knitting machine or a weaving machine (the first
patent document).
CITATION LIST
Patent Literature
[0003] First Patent Document: JP2004-105323A (Abstract)
SUMMARY OF INVENTION
[0004] A sock-shaped upper member of this type typically has a
small rigidity and needs to be reinforced. However, since the upper
member is sock-shaped, it is difficult to sew a reinforcement
member thereto.
[0005] Such a problem arises also with members other than the upper
members produced by a knitting machine, or the like, as long as
they are sock-shaped upper members having a small rigidity.
[0006] It is therefore an object of the present invention to
provide a shoe using a sock-shaped upper member having a small
rigidity having such a structure that the upper member can be
easily reinforced, and a manufacturing method therefor.
[0007] A shoe according to a first aspect of the present invention
includes an upper 12, the upper 12 including:
[0008] a sock-shaped base member 1 of a knit fabric, a knit-like
fabric and/or a woven fabric; and
[0009] a reinforcement member 2 integral with the base member 1,
the reinforcement member 2 being substantially not sewn
(substantially without sewn) to the base member 1, and the
reinforcement member 2 being bonded and/or welded to a surface of
the base member 1. Herein, "substantially not sewn to
(substantially without sewn to)" means that "portions of the
reinforcement member around or near eyelets or portions thereof
around or near loops may be sewn to the base member 1". Where there
is a plurality of reinforcement members, only some of them may be
sewn.
[0010] In the present aspect, the upper 12 is reinforced by the
reinforcement member 2, with the reinforcement member 2 being
bonded or welded to, but not sewn to, the sock-shaped base member
1. Therefore, the sock-shaped base member 1 of a knit fabric, a
knit-like fabric and/or a woven fabric, which is difficult to
retain its shape, can be attached to the last, and the
reinforcement member 2 can easily be integrated with the base
member 1 via bonding or welding, thereby facilitating the
production of the upper 12.
[0011] In the present invention, a sock-shaped knit fabric or woven
fabric can be produced by a well-known knitting machine or weaving
machine.
[0012] A knit-like fabric means a fabric having a
macroscopically-reticulated fabric structure, i.e., a lattice
structure, and such a case is also encompassed by the present
invention because the base member 1 is flexible and has a small
rigidity.
[0013] Sock-shaped means a tubular shape that is open at least at
the top line (mouth), while it may be open also in portions other
than the top line, e.g., instep or toe portions, as long as it is
shaped so that it can be attached to the last.
[0014] The reinforcement member 2 is less stretchable than the
sock-shaped base member 1, and may typically be a non-stretchable
member.
[0015] A shoe according to a second aspect of the present invention
includes a sock-shaped base member 1 of a knit fabric, a knit-like
fabric and/or a woven fabric forming a portion of an upper 12, and
a sole member 3, 4 made of a resin bonded and/or welded to a bottom
surface of the base member 1.
[0016] In the second aspect, the sole member 3, 4 is bonded or
welded to the bottom surface of the sock-shaped base member 1. This
facilitates the production of the shoe.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIGS. 1A, 1B and 1C are side views showing a base member, a
reinforcement member and a sole member, respectively, according to
Example 1 of the present invention.
[0018] FIGS. 2A and 2B are a side view and a transverse
cross-sectional view, respectively, showing a shoe of Example
1.
[0019] FIGS. 3A and 3B are a side view and a plan view,
respectively, showing a shoe of Example 2.
[0020] FIGS. 4A and 4B are side views showing shoes of Examples 3
and 4, respectively.
[0021] FIGS. 5A, 5B and 5C are side views showing a base member, a
sole member and a shoe, respectively, according to Example 5 of the
present invention.
[0022] FIGS. 6A, 6B and 6C are a side view, a plan view and a
transverse cross-sectional view, respectively, showing a shoe
according to Example 6, and FIG. 6D is a transverse cross-sectional
view showing a shoe according to Example 7.
[0023] FIGS. 7A and 7B are a side view and a plan view,
respectively, showing a shoe according to Example 8.
[0024] FIGS. 8A, 8B, 8C, 8D and 8E are step diagrams showing an
example of a manufacturing method of the present invention.
[0025] FIGS. 9A, 9B, 9C, 9D and 9E are step diagrams showing
another example of a manufacturing method of the present
invention.
[0026] FIGS. 10A, 10B and 10C are step diagrams showing the other
example.
[0027] FIG. 11 is a side view useful in understanding still another
manufacturing method.
DESCRIPTION OF EMBODIMENTS
[0028] In a preferred embodiment of the first aspect, the
reinforcement member 2 covers a portion of a side surface of a
foot.
[0029] In a further preferred embodiment of the first aspect, the
reinforcement member 2 covers a portion of each of a front foot
section, a middle foot section and a rear foot section on the
opposite side surfaces.
[0030] In this case, the side surface of the base member 1 is
reinforced by the reinforcement member 2 in the front foot section,
the middle foot section and the rear foot section, thereby making
it possible to support the foot by the upper 12 even if the base
member 1 has a small rigidity.
[0031] In a further preferred embodiment of the first aspect, the
reinforcement member 2 covers a portion of the bottom surface of
the foot and continuously extends from the bottom surface onto the
opposite side surfaces.
[0032] In this case, the reinforcement member 2 continuously
extending from the bottom surface onto the side surfaces is
continuous in the foot-circumference direction, thereby stabilizing
the support of the foot.
[0033] In a further preferred embodiment of the first aspect, the
reinforcement member 2 covers the bottom surface of the middle foot
section.
[0034] In a further preferred embodiment of the first aspect, in
the middle foot section, the reinforcement member 2 continuously
extends from the bottom surface onto the opposite side
surfaces.
[0035] In this case, the reinforcement member 2, which is
continuous in the foot-circumference direction in the middle foot
section, further stabilizes the support of the foot.
[0036] In a further preferred embodiment of the first aspect, the
reinforcement member 2 includes a lacing loop 20 integrally formed
along an upper edge of the reinforcement member 2.
[0037] In this case, a shoelace is passed through a loop 20 along
the upper edge of the middle foot section, and the upper member 12
is fitted to the foot via the reinforcement member 2, which
continuously extends from the bottom surface onto the opposite side
surfaces in the middle foot section. Therefore, even if the
rigidity of the base member 1 is small, the support of the foot is
stabilized by the upper member 12.
[0038] In a further preferred embodiment of the first aspect, the
reinforcement member 2 includes an ornamental eyelet 21 integrally
formed along an upper edge of the reinforcement member 2.
[0039] In this case, a shoelace is passed through a lacing aperture
formed in the ornamental eyelet along the upper edge of the middle
foot section, and the upper member 12 is fitted to the foot via the
reinforcement member 2, which continuously extends from the bottom
surface onto the opposite side surfaces in the middle foot section.
Therefore, even if the rigidity of the base member 1 is small, the
support of the foot is stabilized by the upper member 12.
[0040] In a further preferred embodiment of the first aspect, the
reinforcement member 2 covers a circumference of a top line.
[0041] In this case, the circumference of the top line is
reinforced by the reinforcement member 2, thereby making the top
line less deformable and further stabilizing the support of the
foot.
[0042] In a further preferred embodiment of the first aspect, the
reinforcement member 2 includes a pair of side surface portions 2f
and 2f extending in an up-down direction along each of a
medial-side surface and a lateral-side surface of a middle foot
section, a lower portion 2e extending in a front-rear direction in
a lower portion of the side surfaces, and an ornamental eyelet 21
extending in the front-rear direction along an instep of the foot
and having a plurality of lacing apertures 20A; and a portion of
the base member 1 is enclosed, over an entire circumference
thereof, by the pair of side surface portions 2f and 2f, the lower
portion 2e and the ornamental eyelet 21.
[0043] In this case, a portion of the base member 1 is enclosed by
the reinforcement member 2 in the middle foot section, thereby
stabilizing the support in the middle foot section.
[0044] In this case, in a further preferred embodiment, the lacing
apertures 20A are provided near upper ends of side surface portions
2f and 2f extending from the lower portion 2e toward the ornamental
eyelet 21.
[0045] A shoelace passed through the lacing apertures 20A pulls up
the lower portion 2e via the side surface portions 2f and 2f. As
described above, since a portion of the base member 1 is enclosed
by the reinforcement member 2, the upper 12 including the base
member 1 and the reinforcement member 2 is likely to fit to the
foot in the middle foot section.
[0046] In a preferred embodiment of the second aspect, the resin is
a foamed material such as ethylene-vinyl acetate copolymer (EVA), a
urethane-based material, a styrene-based material, an olefin-based
material, etc., and the sole member is a midsole member 3.
[0047] In this case, the midsole member 3 made of EVA, or the like,
can be easily formed on the bottom surface of the upper.
[0048] In a further preferred embodiment of the second aspect, the
midsole member 3 covers a portion of each side surface of the
foot.
[0049] In this case, the midsole member 3 supports the opposite
side surfaces of the foot, thereby stabilizing the support of the
foot, and it is possible to easily produce a shoe in which the
midsole member 3 is rolled up on the side surface of the foot.
[0050] In a further preferred embodiment of the second aspect, the
midsole member covers opposite side surfaces of a middle foot
section, and a lacing aperture is formed along an upper edge of the
midsole member 3.
[0051] In this case, since the midsole member 3 typically has a
greater rigidity than the base member 1, and the lacing aperture is
formed along an upper edge of the midsole member 3 having a great
rigidity, the base member 1 can be fitted to the foot together with
the midsole member 3 by pulling up the midsole member 3 by means of
a shoelace, or the like. Therefore, even with the base member 1
having a small rigidity, the upper and the sole are likely to fit
to the foot, and the foot is supported from the opposite side
surfaces by means of the midsole member 3, thereby stabilizing the
support of the foot.
[0052] In a further preferred embodiment of the second aspect, a
heel counter 33 is integrally formed with the midsole member 3.
[0053] In this case, since the heel counter 33 is formed integrally
continuously with the sole by means of the midsole member 3, it is
possible to realize a stable support of the heel of the foot even
with the base member 1 having a small rigidity.
[0054] In a further preferred embodiment of the second aspect, the
midsole member 3 covers a circumference of a top line.
[0055] In this case, since the circumference of the top line is
covered by the midsole member 3 having a greater rigidity than the
base member 1, the shape of the top line is more likely to be
retained.
[0056] In a further preferred embodiment of the second aspect, the
sole member 3 includes a pair of side surface portions 3f and 3f
extending in an up-down direction along each of a medial-side
surface and a lateral-side surface of a middle foot section of a
foot, a roll-up lower portion 3e rolled up from a bottom surface
and extending in a front-rear direction in a lower portion of the
side surfaces, and an upper edge portion 31 extending in a
front-rear direction along an instep of the foot and having a
plurality of lacing apertures 30A; and a portion of the base member
1 is enclosed, over an entire circumference thereof, by the pair of
side surface portions 3f and 3f, the roll-up lower portion 3e and
the upper edge portion 31.
[0057] In this case, since a portion of the base member 1 is
enclosed by the sole member 3 in the middle foot section, the
support of the middle foot section is stabilized.
[0058] In this case, in a further preferred embodiment, the lacing
apertures 20A are provided near upper ends of the side surface
portions 3f and 3f extending from the lower portion 3e toward the
upper edge portion 31.
[0059] A shoelace passed through the lacing apertures 30A pulls up
the lower portion 3e via the side surface portions 3f and 3f. As
described above, since a portion of the base member 1 is enclosed
by the sole member 3, the upper 12 including the base member 1 and
the sole member 3 is likely to fit to the foot in the middle foot
section.
[0060] Each of the shoes described above is produced by the
following manufacturing method, for example.
[0061] That is, an aspect of the method of the present invention
includes the steps of:
[0062] attaching a sock-shaped base member 1 forming a portion of
an upper to a last portion 52 of a core 50, the core 50 including a
core print 51 and the last portion 52;
[0063] loading the core 50 onto an outer mold 61, 62;
[0064] supplying a molten resin 71, 72 to be a reinforcement member
2 and/or a sole member 3, 4 into between the outer mold 61, 62 and
the base member 1; and
[0065] allowing the molten resin 71, 72 to cure, thereby forming
the reinforcement member 2 and/or the sole member 3, 4 integral
with the base member 1.
[0066] In this case, it is possible to manufacture a shoe in which
the reinforcement member 2 or the midsole member 3 is integral with
the base member 1 only by performing the process of attaching the
base member 1 to the last (the core 50) having the core print 51,
and further loading the core 50 onto the outer mold 61, 62.
Therefore, the shoe manufacture can be automated, and it is
therefore possible to reduce the manufacturing cost.
[0067] Note that the base member 1 may be a sock that is
stretchable and that does not shrink by heat. That is, the base
member 1 may be any member as long as it can be attached to the
last and it fits to the last.
[0068] Note that in the present aspect, the base member 1 may be a
sock of a woven cotton that is stretchable and that does not shrink
by heat. That is, the present aspect can be used as long as the
upper member can be attached to the last and it fits to the
last.
[0069] Preferably, in the step of loading the core 50, the core
print 51 of the core 50 is supported by the outer mold 61, 62, with
the core print 51 protruding from a top line of the base member
1.
[0070] More preferably, the loading step is performed with the core
50 positioned so that the core print 51 is below the last portion
52.
[0071] In this case, the core print 51 is supported by the outer
mold 61, and the core 50 is stably supported by the outer mold
61.
[0072] More preferably, the outer mold 61, 62 includes a first
outer mold 61, to which the core print 51 is attached, and a second
outer mold 62 meshing with the first outer mold 61, the method
including:
[0073] a first supply step of supplying a first molten resin 71 to
be the reinforcement member 2 into between the first outer mold 61
and the second outer mold 62 and the last portion 52;
[0074] a step of allowing the first molten resin 71 to cure,
thereby forming the reinforcement member 2 integral with the base
member 1;
[0075] a step of meshing a third outer mold 63, which meshes with
the first outer mold 61, onto the first outer mold 61, replacing
the second outer mold 62;
[0076] a second supply step of supplying a second molten resin 72
to be the sole member 3, 4 into between the third outer mold 63 and
the last portion 52; and a step of allowing the second molten resin
72 to cure, thereby forming the sole member 3, 4 integral with the
base member 1.
[0077] In this case, the manufacture of a shoe in which the
reinforcement member 2 and the midsole member 3 are formed integral
with the base member 1 can be automated, and it is therefore
possible to significantly reduce the manufacturing cost.
[0078] More preferably, in the meshing step after the first supply
step, the second outer mold 62 is removed, with the core print 51
remaining attached to the first outer mold 61, and the third outer
mold 63 is meshed onto the first outer mold 61, replacing the
second outer mold 62.
[0079] In this case, it is possible to form the midsole member 3,
following the reinforcement member 2, integral with the base member
1, with the core print 51 remaining attached to the first outer
mold 61.
[0080] Another aspect of the present invention includes the steps
of;
[0081] attaching a sock-shaped base member 1 made of a knit fabric
and/or a woven fabric forming a portion of an upper to a last and
heating the sock-shaped base member 1, thereby forming a sock
portion; and
[0082] heating a sole member 3A made of a knit fabric and/or a
woven fabric integral with the base member 1 during the heating of
the base member 1, thereby melting the sole member 3A.
[0083] In this case, it is possible to manufacture a shoe in which
the sole is integral with the base member 1 only by attaching the
base member 1 to the last and heating the base member 1, and it is
therefore possible to further reduce the manufacturing cost.
[0084] The present invention will be understood more clearly from
the following description of preferred examples taken in
conjunction with the accompanying drawings. Note however that the
examples and the drawings are merely illustrative and should not be
taken to define the scope of the present invention. The scope of
the present invention shall be defined only by the appended claims.
In the accompanying drawings, like reference numerals denote like
components throughout the plurality of figures.
EXAMPLES
[0085] Examples of the present invention will now be described with
reference to the drawings.
[0086] FIGS. 1A to 2A show Example 1.
[0087] As shown in FIGS. 1A to 1C, the shoe includes the base
member 1, the reinforcement member 2, the midsole member 3, and an
outsole 4. Note that in the drawings to be discussed below, the
base member 1 is shown to be lattice-patterned, the reinforcement
member 2 is shown to be dotted, and the outsole 4 is shown to be in
solid black.
[0088] The base member 1 of FIG. 1A is formed in a sock shape by a
knit fabric, a knit-like fabric and/or a woven fabric.
[0089] Herein, a knit fabric or a woven fabric can be produced by a
well-known knitting machine or weaving machine, and can be formed
by a synthetic resin fiber that shrinks by heat. An example of the
base member 1 is disclosed in JP2004-105323A, the content of which
is herein incorporated by reference in its entirety.
[0090] For example, the base member 1 may be obtained by weaving a
member into a sock shape by a weaving machine, attaching the member
to the last and heating the member so as to thermally shrink the
member into a shape conforming to the last, and such a member is
used as a portion of the upper.
[0091] The knit-like fabric is a web molded into a knit-like
configuration, in which case it easily fits to the shape of the
last because it is knit-like.
[0092] The reinforcement member 2 is not substantially sewn to the
base member 1, and the reinforcement member 2 is bonded and/or
welded to the surface of the base member 1, thereby forming the
upper 12 of FIG. 2A, in which the reinforcement member 2 is
integral with the base member 1. Such a reinforcement member 2 may
be a planar member obtained by die-cut, or a member that is
three-dimensionally molded into a predetermined shape, or the base
member 1 may be insert-molded during the molding process as will be
described later.
[0093] The reinforcement member 2 may be bonded to the base member
1 with an adhesive or welded thereto, or a portion of the
reinforcement member 2 may be bonded to the base member 1 while
another portion of the reinforcement member 2 is welded to the base
member 1.
[0094] The reinforcement member 2 may be of a stretchable material
or a less stretchable material, or it may also be of a foamed
material such as EVA, which is used in the midsole. Typically, the
reinforcement member 2 uses a material that is less stretchable
than the base member 1.
[0095] That is, the reinforcement member 2 has a greater rigidity
than the base member 1, and the tensile rigidity of the
reinforcement member 2, for example, is greater than that of the
base member 1.
[0096] As shown in FIG. 2A, on the medial-side surface and on the
lateral-side surface, the reinforcement member 2 has a front foot
portion 2a, a middle foot portion 2b and a rear foot portion 2c
covering portions of the front foot section, the middle foot
section and the rear foot section, respectively. As shown in FIG.
2B, the reinforcement member 2 includes a bottom portion 2d
covering a portion of the bottom surface of the middle foot
section, and it continuously extends from the bottom surface onto
the opposite side surfaces in the middle foot section as shown in
FIG. 2B. The bottom portion 2b may be continuously extending
completely across the bottom surface of the middle foot
section.
[0097] Note that where the reinforcement member 2 is welded to the
base member 1 by molding, the reinforcement member 2 may cover the
entire surface of the base member 1.
[0098] As shown in FIGS. 2A and 2B, the reinforcement member 2
includes lacing loops 20 integrally formed along the upper edge of
the reinforcement member 2.
[0099] Note that the structure of the medial-side surface and that
of the lateral-side surface are substantially approximate to each
other, and only one of the side surfaces is shown in each side
view.
[0100] Note that as shown in FIGS. 3A and 3B, the reinforcement
member 2 may include the ornamental eyelet 21 integrally formed
along the upper edge of the reinforcement member 2. In this case,
eyelet apertures to be the lacing apertures 20A may be formed in
the ornamental eyelet 21. A portion of the reinforcement member 2
may form a moon-shaped core (heel counter), for example, covering
the rear surface of the heel.
[0101] In the example of FIGS. 3A and 3B, the reinforcement member
2 includes loop-shaped portions in the front foot section and the
middle foot section so as to enclose the entire circumferences of
enclosed portions 11 of the base member 1, thereby realizing a
stable support of the foot by means of the reinforcement member 2
even with the base member 1 having a small rigidity.
[0102] Each loop-shaped portion of the reinforcement member 2 is
formed by the ornamental eyelet 21, the lower portion 2e, and a
pair of side surface portions 2f connecting between the ornamental
eyelet 21 and the lower portion 2e, thereby enclosing the
circumference of an enclosed portion 11 of the base member 1.
[0103] As shown in FIGS. 4A and 4B, the reinforcement member 2 has
a top line portion 2g covering the side surface and the rear
surface of the top line.
[0104] As shown in FIG. 4B, the top line portion 2g and the lower
portion 2e may be connected together by the rear foot portion 2c
and the side surface portions 2f and 2f, thereby forming an
enclosed portion 11 where the base member 1 is enclosed by the
reinforcement member 2 also in the rear foot portion 2c.
[0105] In FIGS. 5A to 5C, the base member 1 is reinforced by the
midsole member 3 in this example. That is, in this example, the
shoe includes the sock-shaped base member 1 of a knit fabric, a
knit-like fabric and/or a woven fabric forming a portion of the
upper 12, and the midsole member 3 and the outsole 4 made of a
resin bonded and/or welded to the bottom surface of the base member
1. The resin of the midsole member 3 is made of a foamed material
such as ethylene-vinyl acetate copolymer EVA.
[0106] The heel counter 33 is formed integral with the midsole
member 3. The heel counter 33 covers the rear surface and the
opposite side surfaces of the foot in the rear foot section of the
foot. The midsole member 3 has a greater rigidity than the base
member 1, and the tensile rigidity of the midsole member 3, for
example, is greater than that of the base member 1.
[0107] As shown in FIGS. 6A to 6D, the midsole member 3 covers the
opposite side surfaces of the foot in the middle foot section, for
example. An upper edge portion 31 including lacing apertures 30A
formed therein may be formed integrally along the upper edge of the
midsole member 3.
[0108] In the example of FIGS. 6A and 6B, the midsole member 3
includes loop-shaped portions provided in the middle foot section,
for example, so as to enclose the entire circumferences of enclosed
portions 11 of the base member 1, thereby realizing a stable
support of the foot by the means of midsole member 3 even with the
base member 1 having a small rigidity.
[0109] Each loop-shaped portion of the midsole member 3 is formed
by the upper edge portion 31, a roll-up lower portion 3e, and a
pair of side surface portions 3f connecting between the upper edge
portion 31 and the roll-up lower portion 3e, thereby enclosing the
circumference of an enclosed portion 11 of the base member 1.
[0110] As shown in FIG. 6D, the lacing apertures 30A may match
lacing apertures 10A formed in the base member 1. In this case, the
lacing apertures 10A are formed in advance in the base member 1,
and the upper edge portion 31 is bonded or welded to the base
member 1.
[0111] On the other hand, as shown in FIG. 6C, the upper edge
portion 31 including the lacing apertures 30A may be protruding
above the base member 1, with the upper edge portion 31 being not
attached to the base member 1. In this case, eyelet members may be
attached to the lacing apertures 30A of the midsole member 3.
[0112] Note that a shoelace 8 is denoted by a two-dot chain line in
FIGS. 6C and 6D.
[0113] In the example of FIG. 6C, where the midsole member 3 is
welded to the base member 1, a release agent may be applied to an
upper portion of the base member 1 so that the upper edge portion
31 and the base member 1 will be left unwelded.
[0114] As shown in FIGS. 7A and 7B, the midsole member 3 may
include a top line portion 32 covering the side surface and the
rear surface of the top line.
[0115] Next, a method for manufacturing a shoe having such a
structure as described above will be described.
[0116] FIGS. 8A to 8E show an example of the method.
[0117] First, the sock-shaped base member 1 forming a portion of
the upper shown in FIG. 8A is provided, and the sock-shaped base
member 1 is attached to the last portion 52 of the core 50 of FIG.
8B, the core 50 including the core print 51 and the last portion
52. Upon attachment, the core print 51 of the core 50 is protruding
from the top line of the base member 1.
[0118] Note that where the base member 1 is of a material that
thermally shrinks, the base member 1 may be heated after the
attachment, thereby fitting the base member 1 to the core 50.
[0119] In this state, the core 50 of FIG. 8C is loaded onto the
outer mold 61, 62, and the core 50 is supported by the outer mold
61, 62.
[0120] Note that the core 50 is loaded onto the lower outer mold 61
with the core 50 positioned so that the core print 51 (FIG. 8B) is
below the last portion 52, after which the upper outer mold 62 is
meshed onto the outer mold 61, and the molds are clamped
together.
[0121] After the clamping, a molten resin 71 or 72 to be the
reinforcement member 2 or the midsole member 3 is supplied into
between the outer mold 61, 62 and the base member 1 as shown in
FIG. 8D. Then, the molten resin 71 or 72 is cooled and allowed to
cure, and the intermediate shoe product having the reinforcement
member 2 or the midsole member 3 integrally formed with the base
member 1 is taken out of the mold as shown in FIG. 8E.
[0122] In this case, the base member 1 may become buried in the
inner surface of the reinforcement member 2 or the midsole member
3. Therefore, if a reinforcement fiber is provided woven in
portions of the base member 1, the reinforcement member 2 or the
midsole member 3 may be reinforced by the fiber.
[0123] Note that after the molding, the lacing apertures 20A may be
formed by a machining process in the area of the ornamental eyelet
21.
[0124] Next, an example of a method for manufacturing a shoe in
which the reinforcement member 2 is welded to the base member 1,
and the midsole member 3 is further welded to the reinforcement
member 2, as shown in FIGS. 2A to 4B, will be described with
reference to FIGS. 9A to 10C.
[0125] In this case, steps similar to those shown in FIGS. 8A to 8D
are performed as shown in FIGS. 9A to 9D, but as for the molten
resin, the molten resin 71 to form the reinforcement member 2 is
supplied, thereby first reaching a state where the reinforcement
member 2 is welded to the base member 1.
[0126] That is, as shown in FIGS. 9C and 9D, a first supply step is
performed for supplying the first molten resin 71 to be the
reinforcement member 2 into between the first outer mold 61 and the
second outer mold 62, which mesh with each other, and the last
portion 52. Then, the first molten resin 71 is allowed to cure,
thereby forming the reinforcement member 2 integral with the base
member 1.
[0127] Then, as shown in FIGS. 9D and 9E, the second outer mold 62
is removed from the first outer mold 61, and the third outer mold
63, which meshes with the first outer mold 61, is meshed onto the
first outer mold 61, replacing the second outer mold 62, as shown
in FIG. 10A.
[0128] In the step of meshing the third outer mold 63 after the
first supply step, the second outer mold 62 of FIG. 9D is removed,
with the core print 51 of FIG. 9B remaining attached to the first
outer mold 61, and the third outer mold 63 of FIG. 10A is meshed
onto the first outer mold 61, replacing the second outer mold
62.
[0129] After the meshing, a second supply step of supplying the
second molten resin 72 to be the midsole member 3 or the outsole
member 4 into between the third outer mold 63 and the last portion
52 is performed as shown in FIG. 10B. Then, the second molten resin
72 cures, thereby forming the midsole member 3 integral with the
reinforcement member 2. Thus, there is obtained a shoe of FIG. 10C,
in which the base member 1, the reinforcement member 2 and the
midsole member 3 are integral together. Note that the outsole is
thereafter bonded to the bottom surface of the midsole member
3.
[0130] In the manufacturing method, in a case where the upper edge
portion 31 of the midsole member 3 is left unwelded to the base
member 1 as shown in FIG. 6C, a release agent may be applied to the
surface of the base member 1 and the last portion 52.
[0131] On the other hand, in a case where the upper edge portion 31
of the midsole member 3 is welded to the base member 1 as shown in
FIG. 6D, a thread of a material having a good affinity with the
midsole member 3 may be provided woven in the base member 1.
[0132] Next, another manufacturing method will be described with
reference to FIG. 11.
[0133] First, a sock-shaped shoe member is provided, including a
sock-shaped base member 1 made of a knit fabric and/or a woven
fabric and forming a portion of an upper, and a sole member 3A made
of a knit fabric and/or a woven fabric and integral with the base
member 1.
[0134] The sock-shaped shoe member is attached to a last and
heated, thereby forming a sock portion and heating and welding the
sole member 3A during the heating. Then, the shoe member is removed
from the last, thereby producing a shoe reinforced with a
fiber.
[0135] While preferred examples have been described above with
reference to the drawings, various obvious changes and
modifications will readily occur to those skilled in the art upon
reading the present specification.
[0136] For example, after molding and welding the midsole member 3
of FIG. 10B, the outsole member 4 made of a urethane resin, or the
like, may be molded and welded by a similar method.
[0137] The outsole member 4, instead of the midsole member 3, may
be welded, through molding, to the base member 1.
[0138] The reinforcement member 2 and the midsole member 3 may be
an FRP containing a reinforcement fiber.
[0139] For the molding method of FIGS. 8A to 10C, another molding
method, called VAR.TM. or R.TM., may be used, as well as an
injection molding method and a compression molding method using a
mold. Moreover, when the reinforcement member or the midsole member
is molded, another reinforcement member for reinforcing the arch of
the middle foot section may be provided by insert molding.
[0140] Thus, such changes and modifications are deemed to fall
within the scope of the present invention, which is defined by the
appended claims.
INDUSTRIAL APPLICABILITY
[0141] The present invention is applicable to shoes having the base
member 1 of a small rigidity.
REFERENCE SIGNS LIST
[0142] 1: Base member
[0143] 10A: Lacing aperture, 11: Enclosed portion, 12: Upper
[0144] 2: Reinforcement member, 2a: Front foot portion, 2b: Middle
foot portion, 2c: Rear foot portion, 2d: Bottom portion, 2e: Lower
portion
[0145] 2f: Side surface portion, 2g: Top line portion
[0146] 20: Loop, 20A: Lacing aperture, 21: Ornamental eyelet
[0147] 22: Top line portion
[0148] 3: Midsole member, 3e: Roll-up lower portion, 3f: Side
surface portion
[0149] 30A: Lacing aperture, 31: Upper edge portion, 32: Top line
portion, 33: Heel counter
[0150] 4: Outsole member
[0151] 50: Core, 51: Core print, 52: Last portion
[0152] 61: First outer mold, 62: Second outer mold, 63: Third outer
mold
[0153] 71: First molten resin, 72: Second molten resin
* * * * *