Patent Description:
Regarding the conventional shoe manufacturing or sales systems, prior arts are as follows.

<CIT> (Patent Document <NUM>) proposes "a shoe manufacturing system, a shoe manufacturing method, and a computer program for shoe manufacturing operation" that can efficiently cope with a complex and diverse process of each vendor, and can realize total management including order management.

Further, <CIT> (Patent Document <NUM>) discloses "an information processing apparatus, an information processing method, and a program" for providing a new method capable of matching equally and easily, even in an item of unstandardized shape.

Moreover, <CIT> (Patent Document <NUM>) discloses "an order receiving and sales business system for order shoes" as a service business model that can be easily used by establishing foot-type measuring stations nationwide.

On the other hand, the upper knitting or molding technique of the conventional shoe has been disclosed as follows.

<CIT> (Patent Document <NUM>) discloses "a method of knitting a shoe upper" providing a knitting method capable of making a heel portion into a more wrapped shape.

Further, <CIT> (Patent Document <NUM>) discloses "a shoe upper and a shoe using said shoe upper", in which a reinforcing member can be disposed at a predetermined position without limiting the appearance of the shoe, and hardly making the user feel uncomfortable.

In addition, <CIT> (Patent Document <NUM>) discloses "a method for manufacturing a shoe upper" capable of manufacturing a shoe upper having a double-layer structure with good productivity. <CIT> describes a method for manufacturing a shoe, the method comprises the steps of providing at least one stretchable portion on the shoe upper, stretching the at least one stretchable portion of the shoe upper for adapting a size of the shoe upper and permanently attaching at least one rigid element at least partly on the stretched stretchable portion so that the stretched stretchable portion is locked. <CIT> describes a shoemaking method. A cavity model having a foot shape cavity is made by using a molding material; a three-dimensional copy model of a foot shape is made by injecting a solid material into a cavity of the cavity model; the three-dimensional copy model is measured and the resulting measurement data is converted to measurement CAD data; the use of the foot shape of the CAD data on the foot shape, suitable for the above-mentioned shoe last CAD data, the use of the last CAD data And numerical control processing method to make the last; the assembly of the made last and heel, soles, upper assembly into shoes. <CIT> teaches to produce a custom shoe last. Foot contour measurements are taken by a relatively unskilled person, utilizing a measuring block carrying a plurality of parallel air-pressure operated probes that are extended simultaneously into engagement with the foot. The degree to which each probe must be extended to contact the foot produces an electrical signal that is recorded. At a processing center a computer combines the foot model data with empirically derived style model data to produce a punch-tape containing last-information signals. This punch-tape is used to control operation of an automatic milling machine which cuts the custom shoe-last from a wood blank or block.

However, the conventional shoe manufacturing or sales system merely matches a shoe closest to a human foot based on data obtained by a foot-type measurement 3D scanner, and it is only intended to align the human foot with the shoe of the mass-produced product standard. In addition, the shoe using conventional knit fabrics has a problem in that many cutting and sewing processes are used, including complicated processes that are not compatible with a custom order service.

Hence, the present invention has been developed by the inventor in view of the above problems, and it aims to provide a method for manufacturing custom order shoes capable of shortening the manufacturing time, reducing the cost, and provide a fit feeling suitable for the customer's feet.

The invention is defined by the appended independent claim <NUM>. Additional embodiments are defined in the dependent claims.

In order to solve the above-mentioned problems, the present invention includes: a customer's foot-type measuring means in a store, a last making means in a wooden last factory, an upper part making means in a sock factory, and a sole part making means in a shoe factory. It also includes: a wooden-last making step for making the last to fit the customer's foot on the basis of the customer's foot type data; a shoe upper knitting and molding step for sewing the upper fabric by three-dimensional knitting, and then holding the upper part in a state where the above-mentioned last is inserted, and a shoe completing step for selectively attaching an insole and an outsole to the upper part. By coordinating the above-mentioned steps, it is possible to make a shoe in a short period of time and provide a shoe having a fit feeling suitable to the customer's foot.

Further, the wooden-last making step of the present invention is characterized in that it includes a step of producing a standard last corresponding to a pattern order.

Further, the shoe upper knitting and molding step of the present invention is characterized in that the upper fabric is knitted into a three-dimensional shape by a circular knitting machine using a fusible yarn, and in a state where the last is inserted, the fusible yarn knitted into the upper fabric is heated and melted, and then cooled and fixed to maintain the upper part.

Further, the shoe completing step of the present invention is characterized in that the outsole is processed in a state where the last is inserted into the upper part.

As described above, in the method of manufacturing a custom order shoe according to the present invention, by employing the step of making a standard last corresponding to a pattern order, it is possible to select an optimal combination of last not only from the full custom orders but also from the customer's foot type data, and it is possible to shorten the manufacturing time and reduce the cost. It is also characterized by producing no disposal inventory and few waste materials due to the custom order. Furthermore, by devising a method of organizing the upper part and eliminating scrap materials, business activities can be carried out environmental friendly.

In addition, by adopting a shoe upper knitting and molding step in which the upper part is kept in a state where the last is inserted after sewing the upper fabric by three-dimensional molding knitting, types of shoe sizes can be reduced because it can correspond to a certain range of sizes like socks. In addition, since the upper part is kept in shape by using the last, the operation can be streamlined.

In addition, by employing the shoe completing step of selectively attaching the insole and the outsole to the upper part, it is possible to provide a custom order shoe according to the application.

Embodiment of the present invention will be described below with reference to the drawings. Note that each configuration of the method of manufacturing a custom order shoe according to the present invention is not limited to the following examples and can be appropriately modified depending on the usage condition.

<FIG> is an explanatory diagram showing an outline of the manufacturing and sales business of the custom order shoes. Instead of fitting feet to shoes, this business aims to provide the best shoes for customers at a reasonable price. As will be described later, it includes a means of measuring the foot-type of the customer <NUM> in a store <NUM>, a means of producing last based on the foot-type data A in a wooden-last making factory <NUM>, a means of producing an upper part in a sock factory <NUM>, and a means of producing sole part in a shoe factory <NUM>.

Further, <FIG> is a flow chart illustrating an example of the shoe manufacturing process according to the present invention. As shown in <FIG>, the shoe manufacturing process includes: a foot-type measuring and data conversing step (S10) for measuring the foot type of the customer and converting the information into data, a wooden-last making step (S20) for producing a last that matches the foot of the customer based on the foot type data of the customer, a shoe upper knitting and shaping step (S30) for sewing the upper fabric by three-dimensional shaped knitting and then holding the upper part in a state where the last is inserted, and a shoe completing step (S40) for selectively attaching the insole and the outsole to the upper part. The shoe manufacturing process is characterized in that, by coordinating the respective steps (S10, S20, S30, and S40), it is possible to speedily provide the shoes having a fit feeling that matches the feet of the customer.

To enable custom-made, individual foot-type measurement is performed using a 3D foot-type measurement device (<FIG>: S101). By making a shaved-out wooden last based on the obtained scanned data, it is possible to make a wooden last according to the full custom-made. On the other hand, by dividing the foot type corresponding to the shoe application, the posture habit, and the motor function of the customer into several elements (foot length, foot width, foot circumference, etc.) based on the obtained scanned data, and preparing the respective options, pattern order or Made-to-Measure becomes possible. (<FIG>: S102).

Here, as an example of the pattern order, certain types of wooden last are produced in advance based on the idea that if the allowable fitting range of one shoe is assumed to be a foot length of ±<NUM> and a foot circumference of ±<NUM>. In the case of a man, the foot length is extended from <NUM> to <NUM>, and the foot width is extended from C to 4E, and in the case of a woman, the foot length is extended from <NUM> to <NUM>, and the foot width is extended from B to 3E, then the foot of <NUM> types for men, <NUM> types for women, and <NUM> types of wooden lasts can cover <NUM>% or more of the foot of both men and women. In addition, by selecting optimal combinations for the customer's foot type from 3D foot type scanned data, the production time can be shortened and the costs of producing a wooden last without versatility can be reduced.

To enable custom-made, a wooden last tailored to the customer's foot is produced on the basis of the customer's foot type data (see <FIG>). On the other hand, in the step (<FIG>:S201) of producing a standard last corresponding to the pattern order, according to the concept of the correspondence example of the pattern order described above, <NUM> types for men and <NUM> types for women, totaling <NUM> types (covering <NUM>% or more of both men and women), and <NUM> standard lasts for the left and right are manufactured and managed using two elements of foot length and foot circumference as indexes.

First, the upper fabric is knitted into a three-dimensional shape by a circular knitting machine using fusible yarn. Specifically, the knitted fabric is simultaneously knitted with a polyester-processed yarn on the front and a fusible yarn on the back (<FIG>:S301). As shown in <FIG>, the upper part <NUM> comprises an outer fabric <NUM> and an inner fabric <NUM> continuous therewith and has openings <NUM> and <NUM> at both ends of each fabric. In addition, the figure design is expressed by the outer fabric <NUM>, and the inner fabric <NUM> is basically made plain. Thus, sewing can be minimized by applying the three-dimensional shaped knitting to the upper part <NUM>. In addition, by knitting the fusible yarn into the fabric to form a double structure, the fused yarn does not contact with the skin side, and it is also useful for maintaining the intensity of the shoe.

Next, as shown in <FIG>, the toe part <NUM> of the inner fabric <NUM> and the toe part <NUM> of the outer fabric <NUM> are sewn and closed. As shown in <FIG>, the inner fabric <NUM> is inserted into the inside of the outer fabric <NUM> (<FIG>: S302). In addition, the outer fabric <NUM> and the inner fabric <NUM> are fastened by fitting a frame to an open footwear <NUM> shown in <FIG> (<NUM>). At this time, embroidery can be applied to the footwear <NUM>, as shown in <FIG>: S303.

Finally, in a state of inserting the last <NUM> in the upper part <NUM> (see, <FIG>) to hold the upper part by cooling and fixing after heating and melting the fusible yarn knitted into the upper fabric (<FIG>: S304). As described above, by employing the step of keeping the shape by heating and cooling in the state where the last <NUM> is inserted into the three-dimensionally shaped upper part <NUM> (see <FIG>), the ultimate fit feeling that matches the foot of an individual, which not present in a conventional shoe can be obtained.

In addition, in the shoe upper knitting and shaping step, a yarn selected from a yarn obtained by subjecting the upper fabric to an antifouling treatment consisting of a polyester processed yarn or a nylon processed yarn on the surface, a short fiber spun yarn, a high strength yarn or a combination thereof may be used, and the yarn may be knitted into a three-dimensional shape by a circular knitting machine using a fusible yarn on the back. Using the antifouling yarn can make the shoe resistant to fouling. Further, using short fiber spun yarn also makes it possible to create a more casual atmosphere. Furthermore, by using a high strength yarn for the toe or heel, it is possible to produce a tough shoe with higher strength, and by using a knit shaped upper knitted by a circular knitting machine, it is possible to expect wider versatility of the upper part.

As shown in <FIG> (<FIG>) (<FIG>) and <FIG>, an outsole <NUM> suitable for the customer is stuck with an adhesive in a state where the last <NUM> is inserted into the upper part <NUM>. Further, as shown in <FIG> (<NUM>), an insole <NUM> that matches the wearing feeling of the customer is inserted and the shoe is completed (<FIG>: S401). Thus, by providing choices for the insole and outsole, it is possible to customize shoes that match the intended use.

Claim 1:
A method for manufacturing a custom order shoe comprising:
a means for measuring a customer's foot-type in a store;
a means for producing a last (<NUM>) in a wooden last factory;
a means for producing an upper part (<NUM>) in a sock factory; and
a means for producing a sole part in a shoe factory,
the method for manufacturing a custom order shoe comprising:
a wooden last (<NUM>) making step for producing a last (<NUM>) that fits the customer's foot based on the customer's foot data;
a shoe upper knitting and shaping step for three-dimension shaped knitting the upper fabric and then holding the upper part (<NUM>) in a state where the last (<NUM>) is inserted, and
a shoe completing step for attaching an insole (<NUM>) and an outsole (<NUM>) to the upper part (<NUM>) selectably,
wherein by coordinating said three steps, it is possible to speedily provide a shoe that fits the customer's foot,
the shoe upper knitting and shaping step includes:
knitting the upper fabric into a tube shape having a double-layer structure of polyester processed yarn on the surface and a fusible yarn on the back using a circular knitting machine, the upper part (<NUM>) being made of an outer fabric (<NUM>) and an inner fabric (<NUM>) continuous therewith,
after sewing and closing the toe parts (<NUM>, <NUM>) of the inner fabric (<NUM>) and the outer fabric (<NUM>), inserting the inner fabric (<NUM>) into the inner side of the outer fabric (<NUM>),
then fitting a frame to the opening (<NUM>) to fix the outer fabric (<NUM>) and the inner fabric (<NUM>),
lastly, shape keeping the upper part (<NUM>) by cooling and fixing after heating and fusing the fusible yarn knitted into the upper fabric in a state where the last (<NUM>) is inserted in the upper part (<NUM>), such that the fused yarn does not come into contact with a skin side, and
the shoe completing step includes processing the outsole (<NUM>) in a state where the last (<NUM>) is inserted in the upper part (<NUM>).