Last with retractable pins

A last assembly includes a plurality of retractable pins and a plurality of vacuum holes, both acting to hold footwear segments to the last assembly to facilitate manufacturing of, or modification to, an article of footwear. A method of making or modifying an article of footwear includes placing footwear segments on the last assembly by associating an extension portion of at least one footwear segment with the retractable pins, modifying the footwear segments and then removing the extension portion.

BACKGROUND

The present embodiments relate generally to footwear and in particular to a method for making footwear and an associated system.

Lasts, such as footwear lasts, may be used to make footwear. A last may generally have the shape of a foot, including a forefoot portion, a midfoot portion and a heel portion. The last may help provide contouring for the assembled article and helps to create a desired fit.

SUMMARY

In one aspect, the embodiments provide a method of creating an upper for an article of footwear including associating a footwear segment with a last member, where the last member includes a plurality of retractable pins and where the footwear segment includes an extension portion. The method also includes inserting the plurality of retractable pins through holes in the extension portion. The method also includes modifying the footwear segment while the footwear segment is on the last member and removing the extension portion.

In another aspect, the embodiments provide a last member including a plurality of retractable pins extending from an outer surface and a plurality of vacuum holes disposed on the outer surface. The plurality of retractable pins and the vacuum holes are both configured to temporarily hold one or more footwear segments in place on the last member.

In another aspect the embodiments provide a last assembly configured for use with an article of footwear. The last assembly includes a last member having the approximate shape of an article of footwear and a base member associated with a bottom portion of the last member. The base member includes a plurality of vacuum holes.

DETAILED DESCRIPTION

FIGS. 1 through 3illustrate schematic isometric views of an embodiment of last assembly100. Last assembly100may be configured for use with various kinds of footwear including, but not limited to: hiking boots, soccer shoes, football shoes, sneakers, rugby shoes, basketball shoes, baseball shoes as well as other kinds of shoes. Moreover, in some embodiments last assembly100may be configured for use with various kinds of non-sports related footwear, including, but not limited to: slippers, sandals, high heeled footwear, loafers as well as any other kinds of footwear or apparel.

Referring toFIGS. 1 through 3, last assembly100may comprise various components or members. In some embodiments, last assembly100can include last member102and base member104. Last member102may have the approximate geometry of a footwear last, and may generally be configured to receive materials associated with the upper of an article of footwear. Base member104may extend from a lower portion of last member102and may generally provide support for last assembly100.

Referring toFIGS. 1 and 2, for purposes of reference, last member102may be divided into forefoot portion10, midfoot portion12and heel portion14. Forefoot portion10may be generally associated with the toes and joints connecting the metatarsals with the phalanges. Midfoot portion12may be generally associated with the arch of a foot. Likewise, heel portion14may be generally associated with the heel of a foot, including the calcaneus bone. In addition, last member102may include lateral side16and medial side18. In particular, lateral side16and medial side18may be opposing sides of last member102. Furthermore, both lateral side16and medial side18may extend through forefoot portion10, midfoot portion12and heel portion14.

It will be understood that forefoot portion10, midfoot portion12and heel portion14are only intended for purposes of description and are not intended to demarcate precise regions of last assembly102. Likewise, lateral side16and medial side18are intended to represent generally two sides of a component, rather than precisely demarcating last member102into two halves.

For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. The term “longitudinal” as used throughout this detailed description and in the claims refers to a direction extending a length of a component. In some cases, the longitudinal direction may extend from a forefoot portion to a heel portion of the last member. Also, the term “lateral” as used throughout this detailed description and in the claims refers to a direction extending a width of a last member. In other words, the lateral direction may extend between a medial side and a lateral side of a last member. Furthermore, the term “vertical” as used throughout this detailed description and in the claims refers to a direction that is perpendicular to both the longitudinal and lateral directions. It will be understood that each of these directional adjectives may be also be applied to base member104as well.

In different embodiments, the geometry of base member104may vary. In some embodiments, base member104has a flange-like geometry that is narrower at lower portion120of last member102and widens to outer peripheral edge130of base member104. For example, in the current embodiment, the length L1of base member104at outer peripheral edge130is substantially greater than the length L2of last member102at lower portion120(seeFIG. 3). Likewise, the width W1of base member104at outer peripheral edge130is substantially greater than the width W2of last member102at lower portion120(seeFIG. 3). Thus, base member104provides a wider base for last assembly100, which may improve stability.

Referring again toFIGS. 1 and 2, in some embodiments, base member104may be generally tapered from the region adjacent to lower portion120of last member102to outer peripheral edge130. In other words, the outer surface132of base member104may be sloped towards outer peripheral edge130. In some cases, outer surface132could have a convex geometry. In other cases, outer surface132could have a concave geometry. In still other cases, outer surface132may be an inclined surface that is approximately flat. Moreover, in still other cases, the curvature of outer surface132could vary over different regions. The geometry and more specifically the curvature of outer surface132can be varied according to considerations including, for example, desired stability or to enhance engagement with external components, such as the flexible membrane described in detail below.

In some embodiments, last member102and base member104could be permanently joined. In such embodiments, last member102and base member104could be integrally formed, for example, during a molding process. In other embodiments, last member102and base member104could be permanently joined using an adhesive or other permanent means of fastening last member102and base member104. In other embodiments, last member and base member104may be removably attached or otherwise fastened. For example, one embodiment could incorporate screws or similar kinds of fasteners for temporarily securing base member104to last member102in order to enhance versatility for last assembly100.

Last assembly100may include provisions for temporarily holding portions of an article of footwear in place on last member102. In some embodiments, last assembly100may provide a single system for temporarily holding portions of an article in place on last member102. In other embodiments, last assembly100may provide two or more systems for temporarily holding portions of an article in place on last member102. In one embodiment, for example, last assembly100may incorporate two types of provisions that work cooperatively to retain portions of an article on last member102. This may help in retaining various portions of footwear on last member102over a wide range of different operating conditions or stages in a manufacturing process.

Last assembly100may include provisions for supplying vacuum pressure along one or more portions. In some embodiments, last assembly100may be provided with plurality of vacuum holes150. In particular, in some cases, plurality of vacuum holes150may be incorporated into outer surface140of last assembly100. Each vacuum hole of plurality of vacuum holes150may be in fluid communication with a vacuum pump or other source of a vacuum (not shown). Moreover, it should be understood that various means of providing fluid communication between vacuum holes150and a vacuum pump or other source could be provided in various embodiments. For example, some embodiments could incorporate internal channels, fluid lines or other means for connecting one or more vacuum holes150with a vacuum pump. In some embodiments, some or all of plurality of vacuum holes150may be in fluid communication with one or more common vacuum supply channels. In one embodiment, it is contemplated that a single vacuum supply line is introduced at a portion of last assembly100. This single supply line is then attached in a matter that places it in fluid communication with plurality of vacuum holes150. However, in some other embodiments a vacuum may not be supplied at a single location, but may be provided at one or more regions of last member100. In another embodiment, for example, vacuum holes150may be in fluid communication with holes on a lower surface of last assembly100. Thus, regions of low air pressure provided beneath or along the bottom of last assembly100may facilitate the pulling of air through vacuum holes150and out the through the lower surface of last assembly100.

In different embodiments, the locations of plurality of vacuum holes150could vary. In some embodiments, vacuum holes could be incorporated into last member102. In other embodiments, vacuum holes could be incorporated into base member104. In one embodiment, vacuum holes could be incorporated into both last member102and base member104. In some embodiments, plurality of vacuum holes150may include first set of vacuum holes152, second set of vacuum holes154and third set of vacuum holes156.

In the embodiment shown inFIGS. 1-3, first set of vacuum holes152and second set of vacuum holes154may comprise vacuum holes located along lateral side16and medial side18, respectively, of last member102. Moreover, in some embodiments, first set of vacuum holes152and second set of vacuum holes154may extend through heel portion14as well as midfoot portion12, but may not extend into forefoot portion10. Additionally, third set of vacuum holes156may extend through a substantial entirety of base member104. As described in further detail below, this arrangement may help provide a force necessary to temporarily hold the side portions of an upper in place as well as securing a flexible membrane around the entirety of base member104.

It will be understood that other embodiments could include vacuum holes in any other portions of last member102or base member104and could likewise exclude vacuum holes in any portions of last member102and/or base member104. Furthermore, while the current embodiment illustrates a substantially uniform arrangement and spacing for vacuum holes within first set of vacuum holes152, second set of vacuum holes154and third set of vacuum holes156, other embodiments could incorporate any other arrangements of vacuum holes. For example, in other embodiments the number, size and pattern of vacuum holes could vary. The locations and arrangements could be selected according to various considerations including, but not limited to: required magnitude of forces, curvature of components, intended use for last assembly100as well as possibly other considerations.

Last assembly100may further include additional provisions for holding one or more portions of an article (or materials used to construct an article) in place. In some embodiments, last assembly100may be configured with provisions for engaging features of one or more portions of an article. In one embodiment, last member102may include plurality of retractable pins180. The term “retractable pin” as used throughout this detailed description and in the claims refers to a member or element that projects outwardly from a surface of last member102. In one embodiment, each retractable pin comprises a pin-like projection that is configured to retract into and extend out of a cavity of last member102, as discussed in further detail below.

The term retractable pin is not intended to be limiting and may refer to components of varying sizes, geometries and constructions. For example, while the current embodiments illustrate retractable pins180as generally cylindrical in shape with rounded tips, other embodiments of retractable pins180could have any other geometries. As one example, other embodiments may utilize one or more curved projections or pins, including, in some cases, a rounded hook-like end for catching onto a material.

In different embodiments, the locations of one or more retractable pins could vary. In some embodiments, plurality of retractable pins180could be grouped into two or more sets of retractable pins that are disposed on different portions of last member102. For example,FIGS. 1-3illustrate an embodiment comprising first set of retractable pins182and second set of retractable pins184that are disposed on a first portion190and a second portion192, respectively, of last member102. In some cases, first portion190may be an upper instep portion, which extends through the top of midfoot portion12and some of forefoot portion10. In some cases, first portion190may be a top portion of last member102that is disposed forwards of ankle portion160. In particular, in some cases, first portion190may be associated with the lacing region or lacing area of an article, which generally includes an opening for a tongue and is bordered by eyelets for receiving a shoe lace. In some cases, second portion192may be a rearwardly facing portion of heel portion14. However, other embodiments could utilize sets of retractable pins in any other portions of last member102. As described in further detail below, the locations of each set of retractable pins may be selected to most effectively hold one or more portions of an article on last member102.

The arrangement of retractable pins may vary. In some embodiments, for example, retractable pins could be evenly spaced apart in one or more directions along a surface of last member102. In other embodiments, retractable pins could be grouped in linear arrangements. For example, in the embodiment shown inFIGS. 1-3first set of retractable pins182may be generally arranged as a single row of pins that extends in an approximately longitudinal direction of last member102. Likewise, in some cases, second set of retractable pins184may be generally arranged as a single row of pins that extends in an approximately vertical direction of last member102. Moreover, in some embodiments, first set of retractable pins182and second set of retractable pins184may be generally aligned along planar surface199(seeFIGS. 1 and 2), which intersects last member102in an approximately longitudinal direction. In some cases, planar surface199may very approximately be seen as bisecting last member102. In other cases, however, planar surface199need not be a bisecting plane and could have any other location or relative orientation.

FIG. 4is a schematic cross sectional view of first set of retractable pins182and an adjacent portion of last member102, according to an embodiment. Referring toFIG. 4, first set of retractable pins182may comprise six retractable pins, including first retractable pin401, second retractable pin402, third retractable pin403, fourth retractable pin404, fifth retractable pin405and sixth retractable pin406. Although the current embodiment includes six retractable pins for first set of retractable pins182, other embodiments can incorporate any other number retractable pins.

In some embodiments, plurality of retractable pins180may be partially housed within interior cavities410of last member102. Each of interior cavities410may include cavity walls and a retaining ring for preventing the retractable pins from falling out of the cavity. For example, first retractable pin401may be housed within first interior cavity420, which includes first cavity walls422and first retaining ring424. In particular, first retaining ring424may be configured with an aperture426that is sized to retain flange portion430of first retractable pin401. Thus, in this case, first retractable pin401may be inserted into, and partially extended from, first interior cavity420, but first retractable pin401is prevented from completely being pulled out of first interior cavity. It will be understood that the various dimensions, geometries and other properties of interior cavities410can vary in different embodiments according to, for example, the sizes, shapes and other properties of first set of retractable pins182.

In some embodiments, plurality of retractable pins180, including first set of retractable pins182, may be biased so as to be normally in an extended position. In some embodiments, plurality of retractable pins180may be spring biased. For example, as seen inFIG. 4, each retractable pin of first set of retractable pins182is associated with a corresponding spring of first set of springs440, which act to bias first set of retractable pins182in the extended position. In other embodiments, however, other provisions for biasing first set of retractable pins could be used, and the type of biasing used could be selected according to the desired biasing force, dimensions of the corresponding interior cavities as well as other considerations. Moreover, the biasing force provided by a spring or other biasing means can be varied in any manner known in the art.

It will be understood that second set of retractable pins184may be associated with similar provisions as first set of retractable pins182. For example, second set of retractable pins184may be associated with a corresponding set of interior cavities that allow for the retraction and partial extension of second set of retractable pins184. Likewise, second set of retractable pins184may be associated with a corresponding set of springs for biasing second set of retractable pins184.

As described above, plurality of retractable pins180can be used to help retain one or more portions of an article, or materials used in constructing an article, on last member102. Additionally, in some cases, plurality of retractable pins180may help to ensure proper alignment of one or more portions of an article on last member102.

FIGS. 5 through 15illustrate schematic views of a process for constructing an upper using last assembly100. In particular,FIGS. 5 through 15illustrate steps of permanently bonding or otherwise joining two or more segments of material together as the material is disposed on last assembly100. It should be understood, however, that the following method is intended to be exemplary and the uses for last assembly100are not limited to such footwear construction methods. Generally, last assembly100may be used with any system and/or method for creating articles that makes use of a last of some kind. In another embodiment, for example, last assembly100could be used with a system and method of creating graphics on an upper or portion of an article. An example of such a method is disclosed in Hull, U.S. Pat. No. 8,162,022, filed Oct. 3, 2008, and titled “Method of Customizing an Article and Apparatus”, the entirety of which is hereby incorporated by reference.

FIG. 5illustrates a schematic view of components of a footwear pressing system500, which may be used in conjunction with last assembly100, according to an embodiment. Referring toFIG. 5, footwear pressing system500includes provisions for applying pressure over one or more regions of an article of footwear or portion of an article of footwear disposed on last assembly100. In some embodiments, footwear pressing system500may be configured to provide pressure over last assembly100.

In some embodiments, footwear pressing system500may include a base platform502and a pressing assembly504. In some cases, base platform502may comprise a substantially flat rectangular surface. In other cases, base platform502could have any other geometry and could include provisions for receiving a last assembly, such as one or more recessed portions into which a portion of a last may be fit. Pressing assembly504may be configured to fit over base platform502. In some embodiments, pressing assembly504comprises an outer frame member510and a flexible membrane512that is mounted within the outer frame member510. As shown inFIG. 5, in some embodiments outer frame member510may include handles514that facilitate ease of handling.

In different embodiments, the materials used for flexible membrane512could vary. Examples of flexible materials that may be used include, but are not limited to: flexible textiles, natural rubber, synthetic rubber, silicone, elastomers, other elastomers such as silicone rubber, as well as other materials known in the art.

For purposes of clarity, only some provisions of footwear pressing system500are shown in the Figures. However, in other embodiments, additional provisions could be provided. Examples of additional provisions include, but are not limited to, provisions for supplying a vacuum between pressing assembly504and base platform502, provisions for applying heat to objects in contact with flexible membrane512, provisions for supplying power to components of footwear pressing system500, control buttons, fasteners for clamping pressing assembly504and base platform502together as well as any other provisions. Examples of such provisions are discussed and illustrated in various embodiments in the Method of Customizing an Article and Apparatus application.

FIG. 6illustrates a schematic isometric view of an embodiment various footwear segments that may be used with last assembly100and footwear pressing system500. The term “footwear segment” as used throughout this detailed description and in the claims refers to any segment of material that may be used in making, or otherwise modifying, an article of footwear. In some embodiments, a footwear segment may comprise a textile segment that is used for constructing a portion of an article, such as an upper. The term segment may include portions of material used in creating the base layer or portion of an upper as well as trim pieces which could be decorative and/or functional.

Referring first toFIG. 6, plurality of footwear segments600may comprise several distinct segments that are intended to be assembled together to form an upper for an article of footwear. Plurality of footwear segments600may include body segment602, which is configured to form the body or base layer of an upper. In some cases, body segment602is formed as a two-dimensional layer that may be later formed into a three-dimensional upper.

Plurality of footwear segments600may also include several trim segments, including toe segment610, heel segment612and eyestay segment614. In one embodiment, eyestay segment614may comprise eyelets616corresponding to the lateral and medial edges of the lacing region of the upper.

In some embodiments, one or more segments can include provisions for engaging portions of a last member. In one embodiment, body segment602is configured with extension portion620. In some cases, extension portion620may be integrally formed with body segment602. In one embodiment, for example, extension portion620may comprise a portion of body segment602that is associated with the lacing region of an upper as well as the area where a tongue may be placed. In other cases, however, extension portion620could be a distinct portion from body segment602.

Extension portion620may include holes for engaging one or more retractable pins of last member102. In some embodiments, extension portion620includes first set of holes622that are configured to first set of retractable pins182of last member102(seeFIG. 3). In some embodiments, body segment602further includes provisions for engaging with second set of retractable pins184. In some embodiments, body segment602includes second set of holes630that are configured to engage second set of retractable pins184of last member102.

Footwear segments can comprise different materials. Examples of materials that may be used include, but are not limited to: various textile materials, natural leathers, synthetic leathers, woven materials, non-woven materials, plastic materials as well as any other kinds of materials.

FIGS. 7 through 15illustrate a method of forming a footwear upper from plurality of footwear segments600, using last assembly100and footwear pressing system500. Referring first toFIG. 7, various trim segments may be associated with body segment602prior to placing plurality of footwear segments600onto last assembly100. In some cases, the trim segments may simply be placed or laid at various locations of body segment602. In other cases, the trim segments can be temporarily bonded to body segment602using, for example, a bonding agent or any other means known in the art for temporarily fixing two or more textile materials together. In other embodiments, body segment602may be placed on last assembly100prior to associating the trim segments with body segment602.

Referring next toFIGS. 8 and 9, body segment602may be placed onto last member102so that first set of retractable pins182are inserted through first set of holes622of extension portion620. Likewise, second set of holes630may be aligned with, and receive, second set of retractable pins184. As seen inFIG. 9, as body segment602wraps around heel portion14of last member102, first retractable pin802and second retractable pin804(not shown inFIG. 9) of second set of retractable pins184may be depressed into last member102. Moreover, as seen inFIG. 9, due to the presence of heel segment612, second set of retractable pins184may be partially contracted and may not extend outwardly from second set of holes630.

Next, as seen inFIG. 10, last assembly100, along with plurality of footwear segments600, may be placed on base platform502. In addition, pressing assembly504may be aligned with base platform502. As seen inFIG. 11, as pressing assembly504is placed over base platform502, flexible membrane512may flex around last member102and plurality of footwear segments600. In this case, flexible membrane512may apply a force to first set of retractable pins182. This force may be enough to partially or even fully retract first set of retractable pins182.

Referring now toFIG. 12, a vacuum may be applied between flexible membrane512and base platform502. As the pressure between flexible membrane512and base platform502decreases, the environment may apply a force that presses flexible membrane512against plurality of footwear segments600. This has the effect of compressing plurality of footwear segments600between flexible membrane512and last member102, which may help fuse adjacent footwear segments together. In some cases, further fusing can be facilitated by applying heat, which may be applied by flexible membrane512or a separate heat source.

The configuration described here may help to minimize local stresses applied by retractable pins at regions of flexible membrane512. In particular, the spring biased retractable pins180are able to fully retract within last member102as flexible membrane512tightens against plurality of footwear segments600and last assembly100. This arrangement can help reduce the tendency of flexible membrane512, which could be substantially fragile in some cases, to tear or rupture.

As seen inFIG. 13, plurality of vacuum holes150may help ensure that plurality of footwear segments600stay in place on last assembly100, which may be especially important once plurality of retractable pins180have been fully retracted (as shown inFIG. 12). For purposes of clarity,FIG. 13illustrates enlarged cross sections of two regions where plurality of vacuum holes150are disposed on last member102. However, it will be understood that this discussion may equally apply for other regions of last assembly100including vacuum holes.

In some embodiments, plurality of vacuum holes150may provide areas where flexible membrane512presents an increased inward force to hold plurality of footwear segments600in place on last assembly100. For example, first set of vacuum holes152extend inwardly and provide a path for air trapped between the various layers to flow to a region of lower air pressure. This causes flexible membrane512(which is under the force of the ambient air) to push inwardly, compressing plurality of footwear segments600against last member102in the vicinity of first set of vacuum holes152. A similar effect may occur in the vicinity of second set of vacuum holes154. This configuration creates regions on either side of last member102where the pressure of flexible membrane512is strong enough to hold plurality of footwear segments600in place. This helps to ensure that plurality of footwear segments600stays in place on last member102while the pressure (and possibly heat) applied by pressing assembly504facilitates fusing between various footwear segments (such as heel segment612and body segment602).

In some embodiments, third set of vacuum holes156may provide a path for air trapped between flexible membrane512and base member104to travel to a region of lower air pressure. This causes flexible membrane512(which is under the force of the ambient air) to wrap tightly over base member104. Moreover, the geometry of base member104helps facilitate a smooth transition for flexible membrane512between last assembly100and base platform502. In particular, the contoured shape of base member104allows flexible membrane512to gently curve down from lower peripheral edge1302of last member102, over base member104and onto base platform504. This arrangement may help avoid abrupt folds, sharp bends or edges in flexible membrane512that may impede the strength of the applied vacuum in the vicinity of last assembly100or which may possibly damage flexible membrane512.

FIGS. 14 and 15illustrate schematic views in a process for making an upper according to the current embodiments. Referring toFIGS. 14 and 15, after pressing (and possibly heating) plurality of footwear segments600on last assembly100, a formed upper1400may be removed from last assembly100. At this point, in order to prepare formed upper1400for assembly with a tongue, extension portion620may be removed. In particular, as seen inFIG. 14, extension portion620may be separated from body segment602of formed upper1400(for example, using a razor or other cutting device) and then discarded (as seen inFIG. 15).

The embodiments shown here illustrate how last assembly100provides means for holding footwear segments in place on last member102during two different stages of a manufacturing process. In particular, during a first stage in which footwear segments are placed onto last member102, plurality of retractable pins180function to hold the footwear segments on last member102. Next, during a second stage in which a flexible membrane acts to depress the plurality of retractable pins180, plurality of vacuum holes150function to hold the footwear segments on last member102. This arrangement helps to maintain the placement and alignment of footwear segments on last member102throughout the manufacturing process, which enhances accuracy and efficiency of the process.

FIGS. 16 and 17illustrate schematic views of another embodiment of extension portions that can be used for temporarily securing footwear segments onto a last assembly. Referring toFIGS. 16 and 17, plurality of footwear segments1600may be similar in many respects to plurality of footwear segments600described above. However, in contrast to body segment602of the previous embodiment, the embodiment ofFIGS. 16 and 17is open in the region bordered by eyestay segment1604. In order to wrap plurality of footwear segments1600onto a last assembly, the current embodiment makes use of detachable extension portions, which can be added and removed to plurality of footwear segments1600as discussed below.

Referring first toFIG. 16, the current system can include a plurality of extension portions1620. For purposes of clarity, six extension portions are shown here, including first extension portion1621, second extension portion1622, third extension portion1623, fourth extension portion1624, fifth extension portion1625and sixth extension portion1626. Other embodiments can include any other number of extension portions. In some cases, the number of extension portions may generally be equal to the number of pairs of eyelets of eyestay segment1604.

The details of the extension portions are described with respect to first extension portion1621, however it may be understood that other extension portions of plurality of extension portions1620may include substantially similar provisions in some embodiments. First extension portion1621may comprise a first end portion1630and a second end portion1632. First end portion1630may comprise a pin-like projecting portion1634. In some cases, projecting portion1634may be configured to fit within eyelet1640of eyestay segment1604. Second end portion1630may include ring1636. In some cases, ring1636may be configured to receive a retractable pin of last assembly100.

As seen inFIG. 17, to temporarily hold plurality of footwear segments1600on last member102, plurality of extended portions1620may be attached to plurality of eyelets1650at their first end portions and attached to corresponding retractable pins of first set of retractable pins182at their second end portions. Thus, plurality of extension portions1620provide a means of temporarily associating plurality of eyelets1650with first set of retractable pins182, which are otherwise not aligned with one another due to the generally central placement of first set of retractable pins182.

The embodiments described here and shown inFIGS. 16 and 17provide extension portions that can be reused. This arrangement may allow the same set of extension portions to be used with multiple different sets of footwear segments to decrease manufacturing costs. Moreover, while the current embodiment illustrates the use of extension portions with a single pin for engaging eyelets on one side of a footwear segment, other embodiments could use two pins to engage a pair of eyelets simultaneously. For example, in one embodiment, an extension portion comprises pins at either end for inserting into corresponding eyelets, and a central ring for engaging a retractable pin. In still another embodiment, two separate extension portions can be used for fastening opposing eyelets to the same central retractable pin.

A last assembly can include provisions for improving the ease with which materials can be associated with a last member. In some embodiments, a last member could be separable from a base member, which allows upper materials to be easily associated a lower periphery of the last member. In embodiments where the last member and base member are separable, the last assembly can include provisions for quickly and easily associating the last member and the base member.

FIGS. 18 and 19illustrate an exploded isometric view and an assembled isometric view, respectively, of an embodiment of a last assembly1800. In some embodiments, last assembly1800may comprise last member1802as well as a separable base member1804. As in the previous embodiments, last member1802and base member1804may both include a plurality of vacuum holes, including first set of vacuum holes1810and second set of vacuum holes1812, respectively. These two sets of vacuum holes may function in a similar manner to the vacuum holes described above in other embodiments.

In order to facilitate easy attachment and separation of last member1802with base member1804, last assembly1800may be configured with corresponding fitting and/or alignment features. In one embodiment, base member1804may include a central slot1820. Additionally, last member1802may include an extended portion1822that extends outwardly from a lower surface1830of last member1802. As seen in the enlarged cross-sectional view ofFIG. 19, extended portion1822may insert into central slot1820in order facilitate alignment of last member1802with base member1804as well as to provide a stable connection between last member1802and base member1804.

In different embodiments, the geometry of central slot1820could vary. In some embodiments, central slot1820extends through the entire thickness of base portion1804. In other embodiments, central slot1820may only extend partially through the thickness of base portion1804. In such embodiments, central slot1820may be characterized as groove-like or recessed.

In different embodiments, the geometry of extended portion1822could vary. In some embodiments, extended portion1822has a ridge-like geometry that forms the boundary of a central opening1852on lower surface1830. Extended portion1822may extend far enough from lower surface1830to insert into central slot1820to a desired depth. Therefore, the height of extended portion1822as measured from lower surface1830can be selected according to various factors including the desired type and degree of connection between last member1802and base member1804.

Although both central slot1820on base member1804and extended portion1822on last member1802are seen as extending through a majority of the length of last assembly1800, in other embodiments the lengths of extended portion1822and central slot1820could vary in any other manner. Furthermore, other embodiments could include multiple slots in base member1804that correspond with multiple extended portions in last member1802.

The type of connection between last member1802and base member1804can vary. In some cases, for example, extended portion1822may be tightly fit within central slot1820, so that extended portion1822and central slot1820provide a frictional fit between last member1802and base member1804. However, in other embodiments, extended portion1822may be loosely fit into central slot1820so that last member1802rests on, but is not substantially connected to, base member1804. Furthermore, in some cases, the vacuum used to draw material against the outer surfaces of last member1802and base member1804may act to temporarily keep last member1802attached to base member1804.

The arrangement described above may facilitate improved manufacturing by allowing for a separable last member1802and base member1804that can be easily separated and reattached. This may provide for arrangements, for example, where base member1804is fixedly or temporarily attached to a vacuum table or other component, with the removable last member1802being easily accessible to a user. This can also facilitate situations where material from the upper must be associated with a lower surface or periphery of last member1802before the vacuum is applied.