WO2025238784A1 - Method for manufacturing shoe fitting foot of user - Google Patents

Abstract

[Problem] To provide a shoe which fits the foot of a user. [Solution] A manufacturing a shoe that fits the foot of a user is characterized by comprising: a first step for installing an outsole part 12 having a shoe sole capable of contacting the ground; a second step for laminating a flexible sheet part 14 having flexibility onto the outsole part 12; a third step for laminating, onto the flexible sheet part 14, a foot-shaped resin part 16 having the shape of a foot and composed of a thermoplastic resin that melts at a prescribed temperature; a fourth step for laminating, on the foot-shaped resin part 16, a fabric part 18 composed of a fabric in contact with the foot of the user; a fifth step for heating the shoe manufactured through the first step, the second step, the third step, and the fourth step at a prescribed temperature; and a sixth step for curing the foot-shaped resin part 16 by allowing a prescribed period of time to elapse in a state where the foot of the user is placed on the foot-shaped resin part 16 melted in the fifth step, and body weight is applied thereto.

Description

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

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

Traditionally, shoes have an insole layered on top of an outsole that is placed on the ground and has a contact surface that comes into contact with the user's foot. Insoles are made of a variety of materials, taking into consideration comfort and other factors. As a technology related to the present invention, for example, Patent Document 1 discloses a shoe insole that is characterized by the following: a backing approximately 0.5 mm thick is placed on the bottom of a mold, silicone resin is applied to a thickness of approximately 7 mm on the backing, the surface of the silicone resin is covered with plastic wrap, the user of the shoe insole stands barefoot on the insole material, and applies pressure to take an impression of the sole of the foot; after the silicone resin in the insole material has hardened, the insole material that has been formed with the sole impression is cut out with scissors to fit the shape of the shoe, thereby completing the shoe insole.

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

Japanese Patent Application Laid-Open No. 2005-198921 Japanese Patent Application Laid-Open No. 2013-212335

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

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

The object of the present invention is to provide shoes that fit the user's feet.

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

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

Furthermore, in the method for manufacturing shoes that fit a user's feet according to the present invention, it is preferable that the thermoplastic resin contains polycaprolactone resin that melts at 60 to 70°C.

The present invention makes it possible to provide shoes that fit the purchaser's feet.

1 is a diagram showing a shoe manufactured by a shoe manufacturing method according to an embodiment of the present invention; 1A and 1B are diagrams showing a shoe manufactured by a shoe manufacturing method according to an embodiment of the present invention, viewed from the top and bottom sides. 1 is a flowchart showing a procedure for manufacturing shoes in a shoe manufacturing method according to an embodiment of the present invention. 10A and 10B are diagrams showing another shoe manufactured by a shoe manufacturing method according to an embodiment of the present invention.

Below, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Below, similar elements in all drawings will be given the same reference numerals, and duplicate explanations will be omitted. Furthermore, in the explanations in the main text, previously mentioned reference numerals will be used as necessary.

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

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

Figure 3 is a flowchart showing the steps for manufacturing shoes 10 in a shoe manufacturing method according to an embodiment of the present invention.

Shoe 10 is footwear that can be adjusted to fit the shape of the user's foot 3. Shoe 10 originally functions as a sandal, but the detachable instep band is removed to facilitate vacuum packing, although the instep band can also be attached in advance.

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

The outsole portion 12 is the part on the bottom of the shoe that comes into direct contact with the ground. Materials that can be used to construct the outsole portion 12 include, for example, rubber, PVC (polyvinyl chloride), PU (polyurethane), EVA (ethylene vinyl acetate), and cowhide.

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

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

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

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

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

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

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

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

The foot-shaped resin portion 16 is a foot-shaped component with a specified thickness, made of a thermoplastic resin that melts at a specified temperature. The thermoplastic resin used is preferably polycaprolactone resin, which melts at 60-70°C, but other thermoplastic resins may also be used. The foot-shaped resin portion 16 is adhered so that it is layered on top of the flexible sheet portion 14.

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

The foot-shaped resin portion 16 is preferably set to a thickness of 1 mm to 3 mm, and more preferably set to 1.5 mm. The foot-shaped resin portion 12 is formed by injection molding.

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

The shoe 10, which is composed of an outsole portion 12, a flexible sheet portion 14, a foot-shaped resin portion 16, and a fabric portion 18, is preferably covered with a vacuum pack portion 20.

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

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

Next, the procedure for manufacturing shoe 10 using the shoe manufacturing method of an embodiment of the present invention will be described. First, the outsole portion 12 is formed and placed at the bottom (S2). Materials that can be used to construct the outsole portion 12 include, for example, rubber, PVC (polyvinyl chloride), PU (polyurethane), EVA (ethylene vinyl acetate), and cowhide.

After step S2, the flexible sheet portion 14 is formed and laminated onto the outsole portion 12 (S4). The flexible sheet portion 14 can be made from materials such as polyurethane foam and polyethylene foam.

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

After step S6, the fabric part 18 is formed and adhered so that it is layered on top of the foot-shaped resin part 16 (S8). The fabric part 18 is preferably made of a material that feels good against the skin, and can be made of suede, for example.

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

After step S8, the shoe 10 formed through steps S2 to S8 is heated (S10). Specifically, the shoe 10 is placed in a container or the like containing hot water heated to a temperature of 60-70°C or higher, which is believed to melt the foot-shaped resin portion 12, and the foot-shaped resin portion 16 of the shoe 10 is melted by the hot water.

Next, the foot-shaped resin portion 16 is hardened (S12). Specifically, the user puts on the shoe 10 containing the molten foot-shaped resin portion 16. The user puts on the shoe 10, stands upright, and applies pressure to the shoe 10 by putting on the shoe 10 and putting on the user's weight. At this point, because the foot-shaped resin portion 16 is in a liquefied state, the surface side of the foot-shaped resin portion 16 deforms to fit the shape of the user's foot.

By leaving the shoe in this state for 3 to 7 minutes, the foot-shaped resin portion 16 hardens, and the shoe 10 is completed to fit the user's foot. Attaching an instep band to the shoe 10 that fits the user's foot completes the sandal.

Next, we will explain a modified version of the shoe 10 produced using the shoe manufacturing method according to an embodiment of the present invention. As shown in Figure 4, the modified version of the shoe 10 is a sneaker 10a, which includes an outsole portion 12, a flexible sheet portion 14, a foot-shaped resin portion 16, and a fabric portion 18.

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

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

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

When the user puts on the sneakers 10a and stands upright, the user's weight is applied, causing pressure to be applied to the sneakers 10a. Because the foot-shaped resin portion 16 is liquefied, the surface of the foot-shaped resin portion 16 deforms to fit the shape of the user's foot.

By leaving it in this state for 10 to 15 minutes, the foot-shaped resin portion 16 will harden, and the sneaker 10a will be completed, fitting the user's foot.

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

2 shoes, 3 pairs, 9 plastic bag, 10 shoes, 10a sneakers, 12 outsole portion, 14 flexible sheet portion, 16 foot-shaped resin portion, 18 fabric portion, 20 vacuum-packed portion.

Claims (3)

an outsole portion having a sole capable of coming into contact with the ground;
a flexible sheet portion laminated on the outsole portion and having flexibility;
a foot-shaped resin portion laminated on the flexible sheet portion and made of a thermoplastic resin that melts at a predetermined temperature;
a fabric portion that is layered on the foot-shaped resin portion and that comes into contact with the user's foot;
A shoe that fits a user's foot, comprising: a first step of providing an outsole portion having a sole capable of contacting the ground;
a second step of laminating a flexible sheet portion having flexibility onto the outsole portion;
a third step of laminating a foot-shaped resin portion made of a thermoplastic resin that melts at a predetermined temperature on the flexible sheet portion;
a fourth step of laminating a fabric portion made of fabric that comes into contact with the user's foot on the foot-shaped resin portion;
a fifth step of heating the shoes manufactured through the first step, the second step, the third step, and the fourth step at a predetermined temperature;
a sixth step of placing the user's foot on the shoe having the foot-shaped resin portion melted in the fifth step, and allowing the shoe to stand for a predetermined period of time while the user places their weight on the shoe, thereby hardening the foot-shaped resin portion;
1. A method for manufacturing a shoe that fits a user's foot, comprising: 3. The method for manufacturing a shoe that fits a user's foot according to claim 2,
A method for manufacturing shoes that fit a user's feet, characterized in that the thermoplastic resin contains polycaprolactone resin that melts at 60 to 70°C.