Patent Description:
Conventionally, insoles, which are sock linings placed on the inner soles of hard shoes, have been developed for the purpose of size adjustment and wearing comfort, and are used in a wide range of shoes from sport shoes to daily life shoes.

As a technology relating to the present invention, for example, <CIT> discloses a shoe insole characterized by being obtained as follows: a mat board having a thickness of about <NUM> is laid on the bottom of a mold frame, a silicone resin is applied to the mat board to a thickness of about <NUM>, a user of the shoe insole stands on one bare foot on an insole material formed by covering the surface of the silicone resin with a wrap film, and applies force thereto to take a footprint, and after the silicone resin for the insole material hardens, the insole material with the footprint formed thereon is cut with scissors to fit the shape of the shoe.

<CIT> discloses a method for manufacturing a sole mold in which first a foot in the current state is normalized and thereafter a mold for the normalized foot is made, differently from conventional methods of manufacturing a sole mold which emphasize only the fabrication of a precise mold of a current foot.

<CIT> discloses molded insoles for use inside shoes, the molded insole having a cork layer with portability and elasticity on the side that the sole is contacted when in use, and a resin layer with thermoplasticity and fluidity when heated on the side that contacts the sole of the shoe when in use. When the insole is placed inside a boot and pressure is applied by the foot, the cork layer deforms according to the shape of the sole and the resin layer deforms fluidly.

<CIT> discloses a shoe insole that is constituted of a first layer member serving as an insole bottom of a shoe sole form, a second layer member installed in conformity to the top of the first layer member and molded of a user's foot type, and a third layer member installed in conformity to the top of the second layer member. The second layer member is provided with deformation properties by heating, and comprises shape maintaining properties for holding its deformation state when cooled off after heating. When the first layer member and the third layer member are laminated, an outer circumference of the first layer member and the third layer member are laminated in a first area to the front of the toes in order to provide the second layer member.

Although various insoles have been developed in recent years, these insoles have a shape accommodating an average foot shape, and therefore they do not necessarily have a shape fitting purchasers. Further, although sock linings precisely fitting a foot shape and the like have also been developed as seen in.

<CIT> and <CIT>, the following problems remain: they are burdensome, time consuming, and costly.

The objective of the present invention is to provide an insole more easily fitting a purchaser's foot.

A method for manufacturing an insole according to the present invention is defined in claim <NUM>. Dependent claims <NUM>-<NUM> define particular embodiments of the method according to the claimed invention.

Further, in the method for manufacturing the insole according to the present invention, the thermoplastic resin preferably comprises a polycaprolactone resin which melts at <NUM> to <NUM>, and the film preferably comprises a polyethylene film.

Further, in the method for manufacturing the insole according to the present invention, the predetermined thickness is preferably set to <NUM> to <NUM>.

Further, in the method for manufacturing the insole according to the present invention, the nylon polyethylene bag preferably comprises at least two layers of nylon and polyethylene.

The present invention can provide an insole fitting a purchaser's foot.

Hereinafter, an embodiment according to the present invention is explained in detail with reference to the accompanying drawings. In the following, like elements are assigned the same reference numerals in all the figures in the drawings, and a repeated description is omitted. In addition, in the description in the text, the reference numerals mentioned previously are used if necessary.

<FIG> shows insoles <NUM> and <NUM> manufactured by a method for manufacturing an insole according to an embodiment of the present invention.

<FIG> shows how to form the insole <NUM> fitting a foot <NUM> of a user using the insole <NUM>.

<FIG> is a flow chart showing a procedure for manufacturing the insole <NUM> in the method for manufacturing the insole according to the embodiment of the present invention. <FIG> is a flow chart showing a procedure for forming the insole <NUM> in the method for manufacturing the insole according to the embodiment of the present invention.

The insole <NUM> is a sock lining which can be fitted to the shape of the foot <NUM> of the user. The insole <NUM> comprises a footprint resin portion <NUM>, a film portion <NUM>, and a vacuum-packed portion <NUM>.

The footprint resin portion <NUM> is a member having a footprint shape having a predetermined thickness and formed using a thermoplastic resin which melts at a predetermined temperature. Although the thermoplastic resin used is preferably a polycaprolactone resin which melts at <NUM> to <NUM>, it is needless to say that other thermoplastic resins may be used.

Although the footprint resin portion <NUM> suitably comprises the polycaprolactone resin as described above, for example, 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(R)-(polytetrafluoroethylene, PTFE), ABS resin (acrylonitrile-butadiene-styrene resin), AS resin, acrylic resin (PMMA), and the like can be also used.

The thickness of the footprint resin portion <NUM> is suitably set to <NUM> to <NUM>, and it is more preferably set to <NUM>. The footprint resin portion <NUM> is formed by injection molding.

The film portion <NUM> is formed by performing shrink processing such that the footprint resin portion <NUM> is covered with a film. The film portion <NUM> is formed of a polyethylene (PE) film, covers the whole surface of the footprint resin portion <NUM>, and is shrunk while air is removed to seal the footprint resin portion <NUM>.

Although the polyethylene (PE) film is suitably used for covering the footprint resin portion <NUM> as described above, other film materials may be used, and PET (polyethylene terephthalate), PP (polypropylene), and PVC (polyvinyl chloride) can also be used, for example.

The vacuum-packed portion <NUM> is formed by vacuum-packing in a nylon polyethylene bag. The nylon polyethylene bag is preferably made of a material which does not shrink when heated in a water bath. Here, the nylon polyethylene bag formed of two layers where nylon (NY) forms an outer layer and polyethylene (PE) forms an inner layer is explained. However, the nylon polyethylene bag may be formed of three or more layers. For example, in addition to the two layers described above, a layer of linear low density polyethylene may be disposed. The vacuum-packed portion <NUM> preferably has a cutout so that it is easy to be opened after the water bath. Covering the footprint resin portion <NUM> with the vacuum-packed portion <NUM> can give protection from dust and the like, which is convenient for storage. Although in the above description, polyethylene (PE) is disposed as the inner layer of the two-layered nylon polyethylene bag, the inner layer may be of polypropylene (PP).

Next, a procedure for manufacturing the insole <NUM> using the method for manufacturing an insole according to the embodiment of the present invention is explained. Firstly, the footprint resin portion <NUM> is formed (S1). Specifically, after the polycaprolactone resin is mixed with other materials and the like, the footprint resin portion <NUM> having a footprint shape having a thickness of <NUM> is molded by injection molding.

Next, after shrink processing is performed such that the footprint resin portion <NUM> is sealed by the film, the footprint resin portion covered with the film is vacuum-packed in the nylon polyethylene bag (S2). Specifically, the shrink processing is performed such that the whole surface of the footprint resin portion <NUM> is covered with a polyethylene film. The polyethylene film used can seal the footprint resin portion <NUM> without sticking to it. Further, after Step S2 is performed, the footprint resin portion <NUM> covered with the film is coated with the vacuum-packed portion <NUM> formed of the nylon polyethylene bag as shown in <FIG>.

Through Step S1 and Step S2, the insole <NUM> formed of the footprint resin portion <NUM> and the film portion <NUM> is completed as shown in <FIG>.

Next, after this insole <NUM> is handed to a user and the like, the user forms the insole <NUM> using the method for manufacturing the insole according to the embodiment of the present invention. In the following, a procedure for forming the insole <NUM> is described.

Firstly, the insole <NUM> is heated (S3). Specifically, the insole <NUM> is placed in a vessel and the like containing hot water warmed to a temperature of <NUM> to <NUM> or higher at which the footprint resin portion <NUM> melts, and the insole <NUM> is melt in the water bath. The insole <NUM> warmed as just described is laid on an inner sole in a shoe <NUM> of the user as shown in <FIG>. Here, although the footprint resin portion <NUM> of the insole <NUM> is melt and liquefied, since the film portion <NUM> is formed in the footprint shape, deformation hardly occurs, allowing the footprint resin portion <NUM> to maintain the footprint shape. After the insole <NUM> is heated in Step S3, the footprint resin portion <NUM> covered with the film is taken out using the cutout in the vacuum-packed portion <NUM> and the like. The vacuum-packed portion <NUM> is formed of the nylon polyethylene bag, has excellent heat resistance, does not shrink, and can maintain the shape of the footprint resin portion <NUM> covered with the film.

Next, the footprint resin portion <NUM> is hardened (S4). Specifically, after the insole <NUM> comprising the footprint resin portion <NUM> melt is placed on the inner sole in the shoe <NUM> of the user, the shoe <NUM> is put on by the foot <NUM> of the user as shown in <FIG>.

As shown in <FIG>, pressure is added to the insole <NUM> by the user putting on the shoe <NUM> and standing up to apply the user's weight. Here, since the footprint resin portion <NUM> is liquefied, the face side of the footprint resin portion <NUM> is deformed along the shape of the foot <NUM> of the user, and the reverse side of the footprint resin portion <NUM> is deformed along the shape of the inner sole of the shoe <NUM>. Further, although the film portion <NUM> is formed in the footprint shape, its shape changes corresponding to deformation of the footprint resin portion <NUM>.

By leaving it stand for <NUM> to <NUM> minutes in such a state, the footprint resin portion <NUM> is hardened, and the insole <NUM> fitting the foot <NUM> of the user is completed. It is noted that although in the above description, the shape of the footprint resin portion <NUM> is formed by the user standing up thereon, pressure may be applied depending on the posture while the shoe <NUM> is used. In the case where the shoe <NUM> is a loose-fit shoe and the like (for example, a leather shoe) instead of a tight-fit shoe, a sponge material or the like for forming the shape of the bottom surface side of the insole <NUM> liquefied may be placed, and thereafter the insole <NUM> may be laid to shape the face side to fit the shape of the foot <NUM> by the foot <NUM> of the user putting on the shoe <NUM>.

Subsequently, after the insole <NUM> is taken out as shown in <FIG>, a sponge sheet <NUM> as a flexible sheet portion is bonded thereto (S5). Specifically, the film portion <NUM> of the insole <NUM> taken out from the shoe <NUM> is peeled.

Then, the sponge sheet <NUM> is bonded to the side of the footprint resin portion <NUM> to be in contact with the sole of the foot <NUM> of the user, and an unnecessary part is cut off to obtain a desired shape. This completes the insole <NUM> fitting the foot <NUM> of the user as shown in <FIG>.

Subsequently, the insole <NUM> having the sponge sheet <NUM> bonded thereto is placed again on the inner sole of the shoe <NUM>, and the user puts on the shoe <NUM>. This results in the insole <NUM> completely fitting the foot <NUM> of the user. Accordingly, there is an advantage in that when having exercise, for example, such as running, the user can run while keeping good grip, and therefore the user can make even better time.

According to the method for manufacturing the insole according to the embodiment of the present invention, the face side of the insole <NUM> is molded along the shape of the foot <NUM> of the user, and the reverse side of the insole <NUM> is molded along the shape of the shoe <NUM>. In other words, since the insole <NUM> is molded on both the sides, the insole <NUM> having a shape optimal to both of the foot <NUM> and the shoe <NUM> of the user can be molded, which is a remarkable effect.

The insole <NUM> manufactured by the method for manufacturing the insole according to the embodiment of the present invention comprises the footprint resin portion <NUM> which melts at <NUM> to <NUM>, and therefore can be liquefied easily in general households and the like using a water bath for a few minutes (for example, <NUM> to <NUM> minutes).

In addition, in the insole <NUM>, the footprint resin portion <NUM> solidified in a footprint shape is covered with the film portion <NUM> which is laminated on the footprint resin portion <NUM> to seal it as described above, and therefore even when the footprint resin portion <NUM> is liquefied, the footprint shape is maintained.

Although it is necessary that the insole <NUM> comprising the footprint resin portion <NUM> liquefied by the water bath is placed on the inner sole of the shoe <NUM> of the user, and then the user puts on the shoe <NUM> as described above, since the footprint resin portion <NUM> can be melt at <NUM> to <NUM>, there is an advantage in that the insole <NUM> fitting the user can be formed while the user does not suffer a burn even though putting on the shoe <NUM> with a bare foot.

By the user putting on the shoe <NUM> to apply pressure, the face side of the footprint resin portion <NUM> can be formed into a shape completely fitting the foot <NUM> of the user while the reverse side of the footprint resin portion <NUM> can completely fit the shape of the inner sole of the shoe <NUM>. In other words, there is an advantage in that the best condition can be provided when the user wears a pair of the shoe <NUM> and has exercise and the like.

Conventional insoles have been formed such that a recess and a protrusion for shank and heel parts are formed in general shapes. According to the method for manufacturing the insole according to the embodiment of the present invention, instead of forming such general shapes, a shape can be molded such that not only the user's shank and heel parts can be completely fitted, but also five fingers of the foot are enveloped. This enables formation of the insole <NUM> having a more optimal shape.

In the insole <NUM>, since the film portion <NUM> which seals the footprint resin portion <NUM> is a polyethylene film, the polyethylene film can seal the footprint resin portion <NUM> without sticking to it heavily. For this reason, there is an advantage in that the film portion <NUM> of the insole <NUM> molded and hardened in the shape of the foot <NUM> of the user can be easily peeled.

Further, the method for manufacturing the insole according to the embodiment of the present invention has an effect of providing a comfort fit because after the user's footprint is fitted, the sponge sheet <NUM> having flexibility can be bonded to a part to be in contact with the sole of the foot <NUM>.

Claim 1:
A method for manufacturing an insole (<NUM>, <NUM>), comprising:
a first step of forming a footprint resin portion having a footprint shape having a predetermined thickness using a thermoplastic resin which melts at a predetermined temperature;
a second step of performing shrink processing such that the footprint resin portion (<NUM>) is covered with a film, and thereafter vacuum packing the footprint resin portion (<NUM>) covered with the film in a nylon polyethylene bag. wherein the film covers the whole surface of the footprint resin portion (<NUM>), and is shrunk while air is removed to seal the footprint resin portion (<NUM>);
a third step of heating the insole (<NUM>, <NUM>) manufactured through the first step and the second step at a predetermined temperature; and
a fourth step of attaching the insole (<NUM>, <NUM>) having the footprint resin portion (<NUM>) melt by the third step to the inside of a shoe (<NUM>) of a user, and hardening the footprint resin portion (<NUM>) by leaving it stand for a predetermined time period while the user is wearing the shoe (<NUM>),
wherein the method further comprises:
a fifth step of peeling the film after the third step and the fourth step, and thereafter attaching a flexible sheet portion (<NUM>) to a side of the footprint resin portion (<NUM>) to be in contact with the user's sole.