Patent Description:
When producing an article of footwear, a last (or a footwear model) for being covered with a cloth configuring a footwear upper is used in order to form the footwear upper into a predetermined shape.

<CIT> discloses manufacturing an article of footwear in a portable housing. <CIT> discloses a last preform reformable with a shape memory polymer. <CIT> discloses forming a last by 3D printing. <CIT> describes a last for boots, shoes and the like.

When making a made-to-order article of footwear fitting a user's feet, a dedicated last reflecting the shape of the feet of each individual is produced. Manufacturing a user-dedicated last in a conventional manner employs dedicated large-size equipment and requires time and cost.

The present disclosure proposes a user-dedicated last that can be easily manufactured without using large-scale equipment, a method for manufacturing the last, and a method for manufacturing a footwear upper using the last.

A method for manufacturing a last for forming a footwear upper configuring an article of footwear is described. The method for manufacturing a last comprises the following steps. A first step is a step of preparing a foot length forming member that defines a shape of the last at least in the lengthwise direction of the article of footwear, and a plurality of foot width forming members that define a shape of the last at least in the widthwise direction of the article of footwear. A second step is a step of assembling the foot width forming member to the foot length forming member.

A method for manufacturing a footwear upper is described. The present method for manufacturing a footwear upper comprises the following steps. A first step is a step of covering the above-mentioned last with an unformed upper made of a fiber sheet including a heat-shrinkable yarn. A second step is a step of applying heat to form the unformed upper along the shape of the last to be a formed upper.

In the following description, identical components are identically denoted. Their names and functions are also identical. Accordingly, such components will not be described repeatedly.

A last (or a footwear model) of an embodiment described below is mainly a last for a made-to-order article of footwear made to fit a user's foot. It should be noted, however, that the last of the embodiment is also applicable to a last for articles of footwear in mass production.

<FIG> is a diagram showing a user having his/her foot F imaged to obtain a foot model FM. As shown in <FIG>, a portable terminal capable of capturing an image, such as a smartphone P or a digital camera, is used to image the user's foot F to obtain image data of foot F. Image data of foot F can be obtained at a store visited by the user. The store may be a stationary store or a movable store using an automobile, a trailer, or the like. Alternatively, image data of foot F can be obtained at the user's home. The user per se may send his/her captured image data of foot F to a server of a footwear manufacturer.

<FIG> is a perspective view of foot model FM. Foot model FM shown in <FIG> is a three-dimensional foot model generated from measured data of each part of foot F of the user obtained from image data of foot F. For example, when smartphone P is used to image the user's foot F, software previously installed in smartphone P can be used to generate foot model FM based on the image data. Alternatively, foot model FM can be generated by performing an operation on both the captured image data and data in a server used by a footwear manufacturer.

Foot model FM may be formed in the same shape as the user's foot F. Alternatively, for some reason in design or functionality, foot model FM may have a specific portion corrected from the shape of the user's foot F by a desired dimension.

<FIG> is a perspective view of a last model <NUM>. Last model <NUM> shown in <FIG> is a model of a last created based on foot model FM shown in <FIG>, and customized in accordance with the shape of the user's foot F. Forming a footwear upper using a last created in accordance with last model <NUM> allows a made-to-order article of footwear dedicated to the user to be manufactured.

<FIG> is a perspective view of a cross-sectional last model <NUM>. <FIG> is a plan view of cross-sectional last model <NUM>. As shown in <FIG> and <FIG>, cross-sectional last model <NUM> is formed by a foot length forming model <NUM> and a foot width forming model <NUM>. Foot length forming model <NUM> corresponds to a cross section of the <FIG> last model <NUM> along a lengthwise direction thereof. Foot width forming model <NUM> corresponds to a cross section of the <FIG> last model <NUM> along a widthwise direction thereof.

Note that in the present specification, a lengthwise direction refers to a direction along a straight line connecting a foremost end on a toe side and a rearmost end on a heel side when an article of footwear or a last is seen in plan view. A widthwise direction refers to a direction orthogonal to the lengthwise direction in plan view. A heightwise direction refers to a direction orthogonal to a plane defined by the lengthwise direction and the widthwise direction.

Cross-sectional last model <NUM> is formed as a combination of a plurality of foot length forming models <NUM> extending in the lengthwise direction and a plurality of foot width forming models <NUM> extending in the widthwise direction. <FIG> is a perspective view showing only foot length forming model <NUM> of cross-sectional last model <NUM>. <FIG> is a perspective view showing only foot width forming model <NUM> of cross-sectional last model <NUM>. In the embodiment shown in <FIG>, the plurality of foot length forming models <NUM> are equally spaced and thus disposed in parallel. The plurality of foot width forming models <NUM> are equally spaced and thus disposed in parallel.

<FIG> is a schematic diagram showing a pattern in which cross-sectional last model <NUM> is disposed on a base member <NUM>. Base member <NUM> is in the form of a flat plate and is made for example of paper. Base member <NUM> may be significantly recyclable cardboard. Alternatively, base member <NUM> is for example a flat plate made of resin. Base member <NUM> may be of thermoplastic resin or may be a butcher-block material such as cork or felt.

As shown in <FIG>, cross-sectional last model <NUM>, more specifically, a plurality of foot length forming models <NUM> and a plurality of foot width forming models <NUM> are disposed on base member <NUM>. Densely disposing the plurality of foot length forming models <NUM> and the plurality of foot width forming models <NUM> on base member <NUM> to reduce a gap between foot length forming model <NUM> and foot width forming model <NUM> can reduce an amount of base member <NUM> wasted when parts of the last are cut out of base member <NUM>. A nesting technique may be utilized to adjust positioning of foot length forming model <NUM> and foot width forming model <NUM> on base member <NUM>. Nesting may be performed automatically by using dedicated software.

By processing base member <NUM> along foot length forming model <NUM> and foot width forming model <NUM> disposed on base member <NUM>, parts of the last, more specifically, foot length forming member <NUM> and foot width forming member <NUM> described below, are formed. For example, foot length forming member <NUM> and foot width forming member <NUM> may be formed by cutting them out of base member <NUM> with a laser cutter or the like. Foot length forming member <NUM> and foot width forming member <NUM> formed from a single base member <NUM> are each in the form of a plate and equal in thickness.

<FIG> is a schematic diagram showing an example in which base member <NUM> configures a part of a packing material. When base member <NUM> is made of cardboard, base member <NUM> may configure a packing material for packing an article of footwear, more specifically, a box <NUM> for the article of footwear. In this case, foot length forming member <NUM> and foot width forming member <NUM> cut out of base member <NUM> will configure a part (e.g., an inner box) of box <NUM> for the article of footwear.

<FIG> is a side view of foot length forming member <NUM>. <FIG> is an enlarged view of a region XI shown in <FIG>. <FIG> is an enlarged view in a vicinity of a bottom <NUM> of an engagement groove <NUM> formed in foot length forming member <NUM>. With reference to <FIG>, a specific one of a plurality of foot length forming members <NUM> formed as they are cut out of base member <NUM> in accordance with a plurality of foot length forming models <NUM> will be described as an example.

Base member <NUM> is in the form of a flat plate and foot length forming member <NUM> is formed as it is cut out of base member <NUM>, and accordingly, foot length forming member <NUM> is also in the form of a plate. Foot length forming member <NUM> extends in the lengthwise direction of the last. Foot length forming member <NUM> defines a shape of the last at least in the lengthwise direction. Foot length forming member <NUM> defines a shape of the last in the lengthwise direction and the heightwise direction.

Foot length forming member <NUM> has a plurality of engagement grooves <NUM> formed therein. Engagement grooves <NUM> are aligned at equal intervals in the lengthwise direction. Each engagement groove <NUM> is in the form of a slit extending in the heightwise direction. Engagement groove <NUM> extends downward from an upper edge of foot length forming member <NUM>. Engagement groove <NUM> has an opening <NUM> that opens at the upper edge of foot length forming member <NUM>, and has a bottom <NUM> at an intermediate position that does not reach a lower edge of foot length forming member <NUM>. As shown in <FIG>, engagement groove <NUM> may have a length that is half a length from the upper edge to the lower edge of foot length forming member <NUM> at a position where engagement groove <NUM> is formed. As shown in <FIG>, engagement groove <NUM> may have a tapered portion <NUM> that decreases the groove in width as it approaches bottom <NUM>.

<FIG> is a front view of foot width forming member <NUM>. <FIG> is an enlarged view in a vicinity of a bottom <NUM> of an engagement groove <NUM> formed in foot width forming member <NUM>. With reference to <FIG>, a specific one of a plurality of foot width forming members <NUM> cut out of base member <NUM> in accordance with a plurality of foot width forming models <NUM> will be described as an example.

Base member <NUM> is in the form of a flat plate and foot width forming member <NUM> is formed as it is cut out of base member <NUM>, and accordingly, foot width forming member <NUM> is also in the form of a plate. Foot width forming member <NUM> extends in the widthwise direction of the last. Foot width forming member <NUM> defines a shape of the last at least in the widthwise direction. Foot width forming member <NUM> defines a shape of the last in the widthwise direction and the heightwise direction. Foot width forming member <NUM> shown in <FIG> is generally in the form has a sector.

Foot width forming member <NUM> has a plurality of engagement grooves <NUM> formed therein. Engagement grooves <NUM> are aligned at equal intervals in the widthwise direction. Each engagement groove <NUM> is in the form of a slit extending in the heightwise direction. Engagement groove <NUM> extends upward from a lower edge of foot width forming member <NUM>. Engagement groove <NUM> has an opening <NUM> that opens at the lower edge of foot width forming member <NUM>, and has a bottom <NUM> at an intermediate position that does not reach an upper edge of foot width forming member <NUM>. Engagement groove <NUM> may have a length that is half a length from the upper edge to the lower edge of foot width forming member <NUM> at a position where engagement groove <NUM> is formed. As shown in <FIG>, engagement groove <NUM> may have a tapered portion <NUM> that decreases the groove in width as it approaches bottom <NUM>.

<FIG> is a perspective view of a last <NUM>. Foot width forming member <NUM> is assembled to engagement groove <NUM> formed in foot length forming member <NUM>, foot length forming member <NUM> is assembled to engagement groove <NUM> formed in foot width forming member <NUM>, and a plurality of foot length forming members <NUM> and a plurality of foot width forming members <NUM> are thus alternately assembled to form last <NUM>. The plurality of foot length forming members <NUM> are aligned in the widthwise direction of last <NUM>. The plurality of foot width forming members <NUM> are aligned in the lengthwise direction of last <NUM>.

Since foot length forming member <NUM> has engagement grooves <NUM> formed at equal intervals in the lengthwise direction, the plurality of foot width forming members <NUM> are equally spaced in the lengthwise direction. Since foot width forming member <NUM> has engagement grooves <NUM> formed at equal intervals in the widthwise direction, the plurality of foot length forming members <NUM> are equally spaced in the widthwise direction.

<FIG> is a schematic diagram showing a first example of a position identifier <NUM>. Foot length forming member <NUM> and foot width forming member <NUM> may each have position identifier <NUM> indicating a position of foot length forming member <NUM> and that of foot width forming member <NUM> in last <NUM>. The example shown in <FIG>, and those shown in <FIG> described hereinafter show position identifier <NUM> provided on foot width forming member <NUM>. In <FIG>, for simplicity, engagement groove <NUM> formed in foot width forming member <NUM> is not shown.

Position identifier <NUM> has character information "L" indicating that foot width forming member <NUM> is a part of last <NUM> for a left foot, character information "H" indicating that foot width forming member <NUM> is foot width forming member <NUM>, and character information "<NUM>" indicating that foot width forming member <NUM> is a sixth part as counted from a toe. Position identifier <NUM> has a mark. By matching the mark in direction, foot width forming member <NUM> can face in a correct direction, position identifier <NUM> is observable, and each piece of character information can be recognized correctly.

Position identifier <NUM> shown in <FIG> can be formed by laser printing. In this case, when foot length forming member <NUM> and foot width forming member <NUM> are cut out of base member <NUM>, position identifier <NUM> can simultaneously be engraved on each of foot length forming member <NUM> and foot width forming member <NUM>. Position identifier <NUM> may be printed on foot length forming member <NUM> and foot width forming member <NUM> using ink. Position identifier <NUM> may be provided by attaching a seal to foot length forming member <NUM> and foot width forming member <NUM>.

<FIG> is a schematic diagram showing a second example of position identifier <NUM>. Position identifier <NUM> may be implemented by coded information as shown in <FIG>. While position identifier <NUM> shown in <FIG> is a matrix-type two-dimensional code representing information in a mosaic of vertically and horizontally disposed, black and white cells, position identifier <NUM> may be a different type of two-dimensional code or a one-dimensional code such as a bar code.

<FIG> is a schematic diagram showing a third example of position identifier <NUM>. As shown in <FIG>, position identifier <NUM> may be implemented by an integrated circuit (IC) chip. Position identifier <NUM> implemented by the coded information shown in <FIG> or the IC chip shown in <FIG> is previously provided to base member <NUM>, and foot length forming member <NUM> and foot width forming member <NUM> may each be cut out of base member <NUM> so as to include position identifier <NUM>. Alternatively, position identifier <NUM> may be attached to foot length forming member <NUM> and foot width forming member <NUM> after they are cut out.

Position identifier <NUM> is not limited to the above-described examples. For example, coloring engagement groove <NUM> of foot length forming member <NUM> and foot width forming member <NUM> to be assembled to engagement groove <NUM>, and combining the same colors, allow an appropriate foot width forming member <NUM> to be assembled in an appropriate engagement groove <NUM>.

While foot length forming member <NUM> and foot width forming member <NUM> may be assembled manually, they may be assembled automatically by a robot. The robot reads the positional information of foot length forming member <NUM> and foot width forming member <NUM> recorded in position identifier <NUM> and recognizes a position of position identifier <NUM> in foot length forming member <NUM> and foot width forming member <NUM>, and thus ensures that foot length forming member <NUM> and foot width forming member <NUM> are each assembled in an appropriate position and an appropriate orientation.

Hereinafter, although there will be a description partially overlapping with the above description, a characteristic configuration as well as function and effect of the present embodiment will be listed below.

As shown in <FIG>, last <NUM> of the embodiment includes foot length forming member <NUM> and foot width forming member <NUM>. Foot length forming member <NUM> defines a shape of last <NUM> at least in the lengthwise direction. Foot width forming member <NUM> defines a shape of last <NUM> at least in the widthwise direction, and is assembled to foot length forming member <NUM>.

Based on foot model FM of a target user, foot length forming member <NUM> and foot width forming member <NUM> are prepared by cutting them out of sheet-shaped base member <NUM>. Foot width forming member <NUM> is assembled to foot length forming member <NUM> to form last <NUM>. No large-scale equipment is required to prepare foot length forming member <NUM> and foot width forming member <NUM> and assemble foot width forming member <NUM> to foot length forming member <NUM>. Thus, last <NUM> dedicated to the target user can be easily manufactured.

As shown in <FIG>, at least one of foot length forming member <NUM> and foot width forming member <NUM> may have position identifier <NUM> indicating a position of foot length forming member <NUM> and foot width forming member <NUM> in last <NUM>. By referring to position identifier <NUM>, a position at which foot length forming members <NUM> and foot width forming members <NUM> are each assembled can be easily recognized, and last <NUM> can be assembled faster. This allows last <NUM> to be manufactured through a more efficient operation.

As shown in <FIG> and <FIG>, foot length forming member <NUM> may be in the form of a plate. As shown in <FIG> and <FIG>, foot width forming member <NUM> may be in the form of a plate. All of the parts configuring last <NUM>, that is, foot length forming member <NUM> and foot width forming member <NUM>, can both be formed by cutting them out of sheet-shaped base member <NUM>. This allows members configuring last <NUM> to be accommodated in a small space. Base member <NUM> or foot length forming member <NUM> and foot width forming member <NUM> having been cut out can be delivered in the form of a plate, that is, a small type of packing, and hence with a reduced cost.

As shown in <FIG>, foot length forming member <NUM> may have engagement groove <NUM> formed therein, and as shown in <FIG>, foot width forming member <NUM> may be assembled in engagement groove <NUM> of foot length forming member <NUM>. Inserting foot width forming member <NUM> into engagement groove <NUM> and assembling foot length forming member <NUM> and foot width forming member <NUM> together allow last <NUM> having a three-dimensional shape to be easily produced. Furthermore, doing so can also suppress disengagement of foot length forming member <NUM> and foot width forming member <NUM> when last <NUM> is moved after the members are assembled together. Appropriately adjusting engagement groove <NUM> in depth can determine a shape in the heightwise direction of last <NUM> assembled by inserting foot width forming member <NUM> into engagement groove <NUM> of foot length forming member <NUM>.

As shown in <FIG>, engagement groove <NUM> of foot length forming member <NUM> may have tapered portion <NUM> that decreases the groove in width as it approaches bottom <NUM>. As shown in <FIG>, engagement groove <NUM> of foot width forming member <NUM> may have tapered portion <NUM> that decreases the groove in width as it approaches bottom <NUM>. Inserting foot width forming member <NUM> into engagement groove <NUM> and inserting foot length forming member <NUM> into engagement groove <NUM> to form last <NUM> can suppress disengagement of foot length forming member <NUM> and foot width forming member <NUM> when last <NUM> is moved after the members are assembled together. Forming tapered portions <NUM> and <NUM> in engagement grooves <NUM> and <NUM> to increase the grooves in width facilitates assembling foot length forming member <NUM> and foot width forming member <NUM> together. The grooves having bottoms <NUM>, <NUM> reduced in width allow foot length forming member <NUM> and foot width forming member <NUM> to be properly positioned and properly assembled.

Instead of tapered portions <NUM> and <NUM>, engagement grooves <NUM> and <NUM> may be provided with a different engagement means such as a protrusion. Engagement grooves <NUM> and <NUM> having their respective, internal protrusions engaged with each other can suppress disengagement of foot length forming member <NUM> and foot width forming member <NUM> and also allow foot length forming member <NUM> and foot width forming member <NUM> to be correctly assembled together.

As shown in <FIG> and <FIG>, foot length forming member <NUM> and foot width forming member <NUM> may be made of paper. Last <NUM> composed of parts made of paper can be light in weight. After last <NUM> is used to manufacture an article of footwear, last <NUM> can be recovered and recycled to reduce environmental burden. When foot length forming member <NUM> and foot width forming member <NUM> are made of cardboard, they will be in the form of fiber through water alone, and thus also recycled through a process with reduced environmental burden. Foot length forming member <NUM> and foot width forming member <NUM> may be made of thermoplastic resin, and in this case, after use, last <NUM> can be heated and thus molten for recycling, and thus reduce environmental burden.

As shown in <FIG>, foot length forming member <NUM> and foot width forming member <NUM> may configure a part of a packing material for packing an article of footwear (i.e., box <NUM> for the article of footwear). Producing last <NUM> using a part of a material that has conventionally been used as a packing material, e.g., cardboard, eliminates the necessity of introducing an additional material for producing last <NUM>, and also eliminates loss of material. Reduction in cost and environmental burden can thus be achieved.

Incorporating foot length forming member <NUM> and foot width forming member <NUM> into a packing material allows a user to bring foot length forming member <NUM> and foot width forming member <NUM> back to home. The user can assemble last <NUM> at home, and can use it when ordering the same article of footwear next time, use last <NUM> that is assembled as a shoe tree, store it as a child's growth record, etc..

As shown in <FIG>, foot model FM is generated from data of a captured image of a user's foot F, and last model <NUM> is generated based on foot model FM. As shown in <FIG>, foot width forming model <NUM> for forming foot width forming member <NUM> is generated by obtaining a shape of last model <NUM> in cross section in the widthwise direction. As shown in <FIG> and <FIG>, foot width forming member <NUM> is formed by processing base member <NUM> based on foot width forming model <NUM>. Foot length forming member <NUM> can also be formed in a similar method. This ensures that last <NUM> is formed to have a shape corresponding to that of foot F of the user.

In the above description of the embodiment, an example has been described in which foot length forming member <NUM> and foot width forming member <NUM> are formed by cutting them out of base member <NUM>. Foot length forming member <NUM> and foot width forming member <NUM> are not limited to being cut out of base member <NUM> in the form of a plate, and may be formed in other methods such as using a 3D printer.

Last <NUM> shown in <FIG> is formed by assembling plate-shaped foot length forming member <NUM> extending in the lengthwise direction and plate-shaped foot width forming member <NUM> extending in the widthwise direction to each other so as to be orthogonal to each other. Foot length forming member <NUM> may not necessarily be in the form of a flat plate extending in the lengthwise direction, and foot width forming member <NUM> may not necessarily be in the form of a flat plate extending in the widthwise direction. For example, foot length forming member <NUM> may have a shape curved so as to gradually increase a spacing toward the toe side of the foot, and foot width forming member <NUM> may have a shape curved so as to be orthogonal to each curved foot length forming member <NUM>. Foot length forming model <NUM> and foot width forming model <NUM> may have their cross sections in a direction determined based on the curvature of the foot.

<FIG> is a perspective view showing only foot width forming member <NUM> of last <NUM> according to a second embodiment. As shown in <FIG>, last <NUM> has defined a front foot portion and a middle foot portion. For example, the front foot portion may be defined by a region corresponding to a region from the toes to MTP joint of a wearer of an article of footwear in the lengthwise direction of the article of footwear, and the middle foot portion may be defined by a region corresponding to a region from the MTP joint to cuneiform bone of the wearer in the same direction. Further, for example, when a foremost end of last <NUM> on the side of the toes is a position of <NUM>% and a rearmost end of last <NUM> on the side of the heel is a position of <NUM>%, the front foot portion may be defined by a range of last <NUM> from <NUM>% to <NUM>-<NUM>% in the lengthwise direction, and the middle foot portion may be defined by a range behind the front foot portion to <NUM>-<NUM>%.

Last <NUM> of the second embodiment has adjacent foot width forming members <NUM> spaced narrower in the middle foot portion than in the front foot portion. The front foot portion has a small variation in foot shape for each user, and the middle foot portion has a relatively large variation in foot shape for each user. Reducing a spacing between adjacent foot width forming members <NUM> in the middle foot portion that tends to have a difference in foot shape for each user allows last <NUM> to have a middle foot portion having a shape with improved accuracy.

Thus increasing/decreasing a spacing between foot width forming members <NUM> in the lengthwise direction allows last <NUM> to be produced to reflect the user's foot shape with high accuracy. Since a spacing between foot width forming members <NUM> in the front and rear foot portions that are less likely to have a difference in foot shape for each user is not excessively reduced, the number of parts is suppressed, and last <NUM> can be manufactured faster.

<FIG> is a side view showing only foot width forming member <NUM> of last <NUM> according to a third embodiment. Last in <FIG>, as well as that in <FIG>, has defined a front foot portion and a middle foot portion. Last <NUM> of the third embodiment has adjacent foot width forming members <NUM> spaced narrower in the middle foot portion than in the front foot portion. In addition, last <NUM> has foot width forming member <NUM> with a thickness smaller in the middle foot portion than in the front foot portion.

When the middle foot portion has foot width forming member <NUM> small in thickness, the middle foot portion can have adjacent foot width forming members <NUM> easily spaced narrower. This can further improve accuracy in shape of the middle foot portion of last <NUM>, and last <NUM> can be produced to reflect the shape of the foot of the user with higher accuracy.

As shown in <FIG>, adjacent foot width forming members <NUM> may also be spaced narrower at the heel portion of last <NUM>. The heel portion also has a large difference in foot shape for each user, and accuracy in shape of last <NUM> can be further improved by also reducing a spacing between adjacent foot width forming members <NUM> in the heel portion.

<FIG> is a disassembled perspective view of last <NUM> according to a fourth embodiment. <FIG> is a perspective view of last <NUM> according to the fourth embodiment. <FIG> is a side view of last <NUM> according to the fourth embodiment. While in the first embodiment an example has been described in which foot length forming member <NUM> is in the form of a plate, foot length forming member <NUM> is not limited in shape to a plate. As shown in <FIG>, foot length forming member <NUM> may be in the form of a rod extending in the lengthwise direction of an article of footwear or last <NUM>. Foot width forming member <NUM> may have a throughhole <NUM> formed therethrough to allow rod-shaped foot length forming member <NUM> to pass therethrough.

By forming foot length forming member <NUM> in the form of a rod, forming throughhole <NUM> through plate-shaped foot width forming member <NUM>, and passing rod-shaped foot length forming member <NUM> through throughhole <NUM>, foot width forming member <NUM> can be assembled to foot length forming member <NUM>. Thus, foot length forming member <NUM> and foot width forming member <NUM> can be assembled more easily and faster than in the first embodiment.

Last <NUM> can be easily disassembled by pulling foot length forming member <NUM> out of foot width forming member <NUM> through throughhole <NUM>. This facilitates recycling foot width forming member <NUM>. Foot length forming member <NUM> may be made of paper or resin and recycled in the same manner as foot width forming member <NUM>, or foot length forming member <NUM> may be reused as it is.

<FIG> is a disassembled perspective view of foot length forming member <NUM> according to a fifth embodiment. <FIG> is a side view of foot length forming member <NUM> according to the fifth embodiment. <FIG> is an enlarged view of a portion XXVI indicated in <FIG>. <FIG> is a side view of last <NUM> according to the fifth embodiment. As well as the last in the fourth embodiment, last <NUM> in the fifth embodiment includes rod-shaped foot length forming member <NUM> and plate-shaped foot width forming member <NUM>. A plurality of foot width forming members <NUM> are aligned in the lengthwise direction of an article of footwear or last <NUM>. Last <NUM> further comprises a spacer <NUM> disposed between adjacent foot width forming members <NUM>. Spacer <NUM> has an annular shape. Spacer <NUM> defines a spacing between adjacent foot width forming members <NUM>.

When rod-shaped foot length forming member <NUM> is passed through throughhole <NUM> of foot width forming member <NUM>, managing a dimension of a gap between adjacent foot width forming members <NUM> is required. By disposing spacer <NUM> between adjacent foot width forming members <NUM> separately from foot length forming member <NUM>, a position where foot width forming member <NUM> is assembled with respect to foot length forming member <NUM> can be controlled. Foot width forming members <NUM> can thus be spaced as specified. For example, forming all spacers <NUM> identically in shape allows foot width forming members <NUM> to be equally spaced, and applying short spacer <NUM> to the middle foot portion can reduce a spacing between foot width forming members <NUM>.

Last <NUM> shown in <FIG> can be formed by fitting foot width forming member <NUM> into a space in the form of a groove between adjacent spacers <NUM> in an assembly previously formed by assembling spacers <NUM> to foot length forming member <NUM>, as shown in <FIG> and <FIG>. Alternatively, foot width forming member <NUM> and spacer <NUM> may be alternately attached to foot length forming member <NUM> to form last <NUM> shown in <FIG>.

When throughhole <NUM> is formed in plate-shaped foot width forming member <NUM>, throughhole <NUM> can be burred to circumferentially have a cylindrical wall to form a structure in which foot width forming member <NUM> and spacer <NUM> are integrated together. In this case, last <NUM> shown in <FIG> can be formed by sequentially attaching foot width forming member <NUM> to foot length forming member <NUM>, and spacer <NUM> need not be assembled to foot width forming member <NUM> separately. This allows last <NUM> to be formed through a simplified operation and thus manufactured faster.

<FIG> is a disassembled perspective view of last <NUM> according to a sixth embodiment. <FIG> is a perspective view of last <NUM> according to the sixth embodiment. Foot length forming member <NUM> may have a three-dimensional shape in addition to the plate shape and rod shape as described above. Foot length forming member <NUM> shown in <FIG> has a base portion <NUM> and a core portion <NUM>. Core portion <NUM> may be hollow or solid. Core portion <NUM> has a surface with engagement groove <NUM> formed therein. As shown in <FIG>, last <NUM> is formed by assembling foot width forming member <NUM> into engagement groove <NUM>. Foot width forming member <NUM> shown in <FIG> and <FIG> is in the form of a partially notched annulus.

Base portion <NUM> has a shape corresponding to that of an upper surface of a footwear sole to which a footwear upper is bonded. Core portion <NUM> has a three-dimensional shape obtained by reducing last model <NUM> (see <FIG>). Base portion <NUM> and core portion <NUM> are not changed in shape for each user; rather, they are previously prepared as a common member. Rather than cutting out all cross sections of last model <NUM> to provide foot width forming model <NUM>, as described in the first embodiment, last <NUM> is previously determined to some extent in shape by base portion <NUM> and core portion <NUM>. Plate-shaped foot width forming member <NUM> is inserted into engagement groove <NUM> that is provided in core portion <NUM> to form last <NUM> having a final shape corresponding to foot model FM of the user.

Last <NUM> is thus formed by fitting foot width forming member <NUM> into core portion <NUM> having a three-dimensional shape. Foot width forming member <NUM> can thus be easily assembled to foot length forming member <NUM>. An area of foot width forming member <NUM> formed in accordance with the user's foot shape is reduced, and accordingly, an area of base member <NUM> used to cut out foot width forming member <NUM> can be reduced, and a user-dedicated last can be efficiently manufactured with a small amount of material. Engagement groove <NUM> formed in core portion <NUM> extends along a surface of core portion <NUM> having a three-dimensional shape and thus has the same curvature as the surface of core portion <NUM>, and last <NUM> can achieve high reproducibility for a shape of a foot of a user.

<FIG> is a perspective view of last <NUM> according to a seventh embodiment. While in the descriptions of the above-described embodiments, foot width forming member <NUM> is assembled to foot length forming member <NUM> along the entire length of last <NUM> in the lengthwise direction to form last <NUM> corresponding to a shape of a foot of a user, foot width forming member <NUM> may not necessarily be assembled along the entire length of last <NUM>.

Last <NUM> shown in <FIG> comprises a common portion <NUM> invariable in shape and position at a toe portion and a portion extending from the middle foot portion to the heel portion corresponding a portion extending from the ankle of a foot to the arch of the foot. Last <NUM> also comprises a movable portion <NUM> that is invariable in shape and positionally variable at a portion of a foot corresponding to the tip of the first toe of the foot and that of the fifth toe of the foot. Therefore, last <NUM> has a structure in which foot length forming member <NUM> and foot width forming member <NUM> are assembled to each other only in a portion of the middle foot portion that corresponds to the instep of the foot.

That is, foot length forming member <NUM> does not necessarily define the shape of last <NUM> along the entire length of last <NUM> in the lengthwise direction. Foot length forming member <NUM> may be any such member that defines a shape of at least a portion of last <NUM> at least in the lengthwise direction. Similarly, foot width forming member <NUM> does not necessarily define the shape of last <NUM> along the entire width of last <NUM> in the widthwise direction. Foot width forming member <NUM> may be any such member that defines a shape of at least a portion of last <NUM> at least in the widthwise direction.

<FIG> is a perspective view of movable portion <NUM>. As shown in <FIG>, a position adjustment mechanism <NUM> couples a pair of right and left movable portions <NUM>. Position adjustment mechanism <NUM> changes a position of movable portion <NUM> with respect to common portion <NUM>. After position adjustment mechanism <NUM> has changed the position of movable portion <NUM> via a fitting structure, a screwing structure or the like, position adjustment mechanism <NUM> can fix movable portion <NUM> in a predetermined position. For example, position adjustment mechanism <NUM> may include a tube of a larger diameter, a tube of a smaller diameter accommodated in the tube of the larger diameter and capable of reciprocating with respect to the tube of the larger diameter, and a locking portion for locking the tube of the smaller diameter with respect to the tube of the large diameter. The locking portion may be implemented as a snap lock, a pin lock, a lock nut, or the like.

<FIG> is a perspective view of last <NUM> with movable portion <NUM> positionally changed. <FIG> is a plan view of last <NUM> with movable portion <NUM> positionally changed. As shown in <FIG> and <FIG>, movable portion <NUM> can change a widthwise dimension of last <NUM> in the middle foot portion. When position adjustment mechanism <NUM> changes a position of movable portion <NUM> to increase a distance between the paired, right and left movable portions <NUM>, last <NUM> has a middle foot portion having an increased widthwise dimension. When position adjustment mechanism <NUM> changes a position of movable portion <NUM> to decrease a distance between the paired, right and left movable portions <NUM>, last <NUM> has a middle foot portion having a decreased widthwise dimension.

Thus, last <NUM> using common portion <NUM> at a portion which is less likely to provide a difference in foot shape for each user and does not need to change last <NUM> in shape and position can have a reduced number of parts to be assembled and can hence be assembled in a reduced period of time. Forming a portion that provides a large difference in foot shape for each user and thus significantly affects an article of footwear in fitness by a combination of foot length forming member <NUM> and foot width forming member <NUM> exclusively for the user allows the user's foot shape to be better reproduced.

Using movable portion <NUM> at a portion where users are less likely to have a difference in shape while having a positional difference allows last <NUM> to be assembled in a reduced period of time. Simply positionally modifying an existing part allows last <NUM> to be adjusted in shape to match a shape of a foot of a user.

With reference to <FIG> is described an example of last <NUM> in which a portion extending from a middle foot portion to a heel portion is formed as common portion <NUM>. Instead of this example, last <NUM> may also comprise a movable portion in the heel portion. The movable portion for the heel portion may include a movable portion that is provided at a rearmost portion of the heel and can reciprocate in the lengthwise direction of last <NUM> and thus change a lengthwise dimension of last <NUM>. The movable portion for the heel portion may include a movable portion that is provided to last <NUM> at a portion of a rear foot portion located on a side/sides corresponding to the lateral ankle and/or the medial ankle and is movable in the widthwise direction of last <NUM> to allow last <NUM> to have the rear foot portion with a variable widthwise dimension.

The movable portion for the heel portion may also be movable in the heightwise direction in addition to the lengthwise and widthwise directions. The movable portion for the heel portion may be angularly variable with respect to common portion <NUM>. In this case, a cavity may be formed above and/or below the movable portion for the heel portion for allowing movement of the movable portion. After the movable portion is positionally adjusted, the cavity may be filled with any filler. The filler may be shaped to match the shape of the user's foot F.

<FIG> is a perspective view of last <NUM> according to an eighth embodiment. Last <NUM> of the eighth embodiment has common portion <NUM> to configure a bottom surface of last <NUM>. Common portion <NUM> has a shape corresponding to that of an upper surface of a footwear sole to which a footwear upper formed by last <NUM> is bonded. A groove is formed in common portion <NUM>, and plate-shaped foot width forming member <NUM> is assembled into the groove. Common portion <NUM> shown in <FIG> also functions as foot length forming member <NUM>.

When a footwear sole is formed in a mold, the footwear sole has a fixed shape regardless of a shape of a foot of a user. A bottom surface of a footwear upper that is bonded to the footwear sole has a fixed shape regardless of a shape of a foot of a user. As the footwear upper has the bottom surface fixed in shape, last <NUM> for forming the footwear upper also has a bottom surface fixed in shape. Accordingly, last <NUM> having a bottom surface portion in a shape that is common portion <NUM> can be stabilized in shape.

<FIG> is a side view of last <NUM> covered with a cover <NUM>. Last <NUM> of the eighth embodiment shown in <FIG> or lasts <NUM> of the first to seventh embodiments described above may have at least a portion thereof externally covered with cover <NUM>. As shown in <FIG>, last <NUM> may entirely, externally be covered with cover <NUM>. For last <NUM> having foot width forming member <NUM> only in a portion in the lengthwise direction, as shown in <FIG>, cover <NUM> may have a shape that covers only a part of last <NUM> that at least covers an assembly of foot length forming member <NUM> and foot width forming member <NUM>. Cover <NUM> may be in the form of a sheet, as shown in <FIG>, or in the form of a plate.

When last <NUM> is covered with cover <NUM>, last <NUM> of the embodiment can be used to form a footwear upper while suppressing an effect that a gap formed between foot length forming member <NUM> and foot width forming member <NUM> has on a shape that the footwear upper has after it is formed. This further ensures that the footwear upper is formed to have a predetermined shape.

Cover <NUM> may be a film that shrinks when it is heated, such as polystyrene film. In this case, last <NUM> can be covered with the film, which can in turn be heated and thus deformed to form cover <NUM> to cover a surface of last <NUM>. In thermally deforming cover <NUM>, (warm) air may be sent from the inside of cover <NUM>. This can suppress excessive inward shrinkage of cover <NUM> between adjacent foot length forming members <NUM> and adjacent foot width forming members <NUM> and can further increase accuracy in forming a footwear upper.

Cover <NUM> may be metal foil represented by aluminum foil, and in this case, covering a surface of last <NUM> with metal enhances thermal conductivity, which is advantageous in heating and thus forming a footwear upper, as will be described hereinafter. Alternatively, cover <NUM> may be a sock.

<FIG> is a perspective view of last <NUM> according to a ninth embodiment. <FIG> is a partial cross section of last <NUM> taken along a line XXXVII-XXXVII indicated in <FIG>. Instead of cover <NUM> described with reference to <FIG>, last <NUM> of the ninth embodiment has a cap <NUM> inserted into a space defined by foot length forming member <NUM> and foot width forming member <NUM>. While <FIG> shows cap <NUM> only in some of spaces defined by foot length forming member <NUM> and foot width forming member <NUM> for simplicity, it is desirable that cap <NUM> be provided at least in an outermost peripheral portion of last <NUM>, and it is more desirable that cap <NUM> be provided throughout last <NUM>.

As shown in <FIG>, cap <NUM> has a curved cross section. Cap <NUM> may have a shape of a portion of a spherical surface. Cap <NUM> protrudes from upper edges of foot length forming member <NUM> and foot width forming member <NUM>.

Cap <NUM> allows last <NUM> to have a smoothly curved external surface. When last <NUM> is used to form a footwear upper, cap <NUM> can prevent an end surface of foot length forming member <NUM> and/or foot width forming member <NUM> from being transferred to the footwear upper and prevent a gap between foot length forming member <NUM> and foot width forming member <NUM> from affecting the shape of the footwear upper. This further ensures that the footwear upper is formed to have a predetermined shape.

<FIG> is a partial cross section of last <NUM> comprising cap <NUM> in the form of a sphere. Instead of cap <NUM> having a curved shape shown in <FIG>, cap <NUM> may be spherical as shown in <FIG>. Although <FIG> illustrates cap <NUM> that is a hollow sphere, cap <NUM> may be a solid sphere.

<FIG> is a perspective view of last <NUM> according to a tenth embodiment. <FIG> is a side view of last <NUM> according to the tenth embodiment. As well as the lasts in the first to third embodiments, last <NUM> in the tenth embodiment has plate-shaped foot length forming member <NUM> and plate-shaped foot width forming member <NUM>. In the front foot portion and the middle foot portion, last <NUM> of the tenth embodiment, as well as the first to third embodiments, has foot width forming members <NUM> aligned in the lengthwise direction of last <NUM>.

Last <NUM> of the tenth embodiment is characterized by a configuration of foot width forming member <NUM> at a portion corresponding to a heel portion of a foot. Specifically, at the portion corresponding to the heel portion of the foot, foot width forming members <NUM> are aligned in the heightwise direction of last <NUM>. In the heel portion of last <NUM>, foot length forming member <NUM> has formed therein a plurality of engagement grooves <NUM> aligned at equal intervals in the heightwise direction. In the heel portion of last <NUM>, a plurality of foot width forming members <NUM> are assembled in engagement grooves <NUM> and thus aligned at equal intervals in the heightwise direction. It should be noted that the pitch of the plurality of foot width forming members <NUM> may be fixed or changed to be smaller for a portion which requires accuracy, in particular, than other portions.

A radial engagement groove <NUM> is formed in each of foot width forming members <NUM> in the heel portion. A plate-shaped engagement member <NUM> extending in the heightwise direction is assembled in radial engagement groove <NUM>. Combining a plurality of foot width forming members <NUM> and a plurality of engagement members <NUM> in the form of a grid enhances the heel portion of last <NUM> in strength.

The heel portion has a relatively large variation in foot shape for each user. In addition, when the heel portion is compared with other portions, the former has a surface of a foot having protrusion and depression with significant variation in shape. A plurality of foot width forming members <NUM> aligned in the heightwise direction can reproduce a shape of a foot better than using foot width forming member <NUM> that extends in the heightwise direction to form a heel portion of last <NUM>. This can further improve accuracy in shape of last <NUM>, and last <NUM> can be produced to reflect the shape of the foot of the user with higher accuracy.

In an eleventh embodiment will be described one example of a method for manufacturing a footwear upper using last <NUM> described in the above embodiments. <FIG> is a perspective view showing last <NUM> covered with an unformed upper <NUM>. For example, a material made of a fiber sheet including a heat-shrinkable yarn (i.e., unformed upper <NUM>) is prepared for a footwear upper. Last <NUM> is covered with unformed upper <NUM> larger than the external shape of last <NUM> to obtain the configuration shown in <FIG>.

<FIG> is a schematic diagram of a process of heating unformed upper <NUM> covering last <NUM>. As shown in <FIG>, last <NUM> covered with unformed upper <NUM> is accommodated in a heating box <NUM>. In this state, hot steam <NUM> is discharged from an internal surface of heating box <NUM>. Thus, unformed upper <NUM> is heated with steam. By this heating with steam, unformed upper <NUM> is entirely, uniformly heated. The heating can cause the heat-shrinkable yarn to shrink to allow unformed upper <NUM> to be a formed upper along the shape of last <NUM>.

Through such a manufacturing process, a footwear upper matching a user's foot F in shape and thus dedicated to the user can be manufactured without using large-scale equipment.

Heating box <NUM> may be a steam oven. While unformed upper <NUM> is heated with steam, unformed upper <NUM> may be heated with hot air, warm water or the like. Unformed upper <NUM> may be heated partially rather than entirely. The thus formed upper is attached to a separately formed footwear sole through adhesion, thermal fusion bonding, or the like.

While each step is performed or after the whole process is completed, a footwear tongue is formed, a footwear opening is processed, eyelets are attached for passing a footwear lace therethrough, an ornament and a tag are attached, a logo is printed, an insole is attached and the like to manufacture an article of footwear.

The method for manufacturing the footwear upper is not limited to thermal shrinkage of a fiber sheet including a heat-shrinkable yarn, as described above, and a variety of methods may be employed, for example, knitting a material around last <NUM> directly, additive manufacturing with a 3D printer, or the like. It is also possible to use last <NUM> of the embodiments in a conventionally known process of forming a footwear upper in a factory.

The characteristic configurations disclosed in the above-described embodiments and modifications thereof will be summarized as follows.

A last according to an embodiment of the present disclosure is directed to forming a footwear upper configuring an article of footwear. The last comprises a foot length forming member that defines a shape of the last at least in a lengthwise direction of the article of footwear, and a plurality of foot width forming members that define a shape of the last at least in a widthwise direction of the article of footwear and are assembled to the foot length forming member.

In a last according to an embodiment of the present disclosure, at least one of the foot length forming member and the foot width forming member may have a position identifier that indicates a position of the foot length forming member and the foot width forming member in the last.

In a last according to an embodiment of the present disclosure, a plurality of foot width forming members may be aligned in the lengthwise direction, and adjacent foot width forming members may be spaced narrower in a middle foot portion of the last than in a front foot portion of the last.

In a last according to an embodiment of the present disclosure, the foot width forming member may be in the form of a plate, a plurality of foot width forming members may be aligned in the lengthwise direction, and the foot width forming member may be smaller in thickness in the middle foot portion of the last than in the front foot portion of the last.

The last has a heel portion with a plurality of foot width forming members aligned in the heightwise direction.

In a last according to an embodiment of the present disclosure, the foot length forming member may be in the form of a rod extending in the lengthwise direction and the foot width forming member may have a throughhole formed therein to pass the foot length forming member therethrough.

A last according to an embodiment of the present disclosure may have a plurality of foot width forming members aligned in the lengthwise direction and may further comprise a spacer disposed between adjacent foot width forming members to define a spacing between the adjacent foot width forming members.

In a last according to an embodiment of the present disclosure, the foot length forming member may be in the form of a plate.

In a last according to an embodiment of the present disclosure, the foot length forming member may have a hollow or solid three-dimensional shape.

The foot length forming member has an engagement groove, and the foot width forming member is assembled to the engagement groove.

In a last according to an embodiment of the present disclosure, the foot width forming member may have a second engagement groove, the foot length forming member may be assembled to the second engagement groove, and the engagement groove and the second engagement groove may each have a tapered portion allowing the groove to have a width reduced as it approaches the bottom of the groove.

In a last according to an embodiment of the present disclosure, the foot length forming member and the foot width forming member may be formed of paper.

In a last according to an embodiment of the present disclosure, the foot length forming member and the foot width forming member may configure a part of a packing material for packing an article of footwear.

A last according to an embodiment of the present disclosure may further comprise a common portion invariable in shape and position.

In a last according to an embodiment of the present disclosure, the common portion may configure a bottom surface of the last and have a shape corresponding to that of an upper surface of a footwear sole to which a footwear upper is bonded.

A last according to an embodiment of the present disclosure may further comprise a movable portion invariable in shape and positionally variable.

A last according to an embodiment of the present disclosure may further comprise a cover in the form of a sheet or a plate and externally covering at least a portion of the last.

A method for manufacturing a last according to an embodiment of the present disclosure is a method for manufacturing a last for forming a footwear upper configuring an article of footwear. The method for manufacturing a last comprises the following steps. A first step is a step of preparing a foot length forming member that defines a shape of the last at least in the lengthwise direction of the article of footwear, and a plurality of foot width forming members that define a shape of the last at least in the widthwise direction of the article of footwear. A second step is a step of assembling the foot width forming member to the foot length forming member.

In a method for manufacturing a last according to an embodiment of the present disclosure, the step of preparing the foot length forming member and the foot width forming member may include the steps of: generating a foot model for a user; generating a foot width forming model from the foot model for forming the foot width forming member; and processing a base member based on the foot width forming model to form the foot width forming member.

A method for manufacturing a footwear upper according to an embodiment of the present disclosure comprises the following steps. A first step is a step of covering the last of any one of the above aspects with an unformed upper made of a fiber sheet including a heat-shrinkable yarn. A second step is a step of applying heat to form the unformed upper along the shape of the last to be a formed upper.

Claim 1:
A last (<NUM>) for forming a footwear upper configuring an article of footwear, comprising a heel portion, a front foot portion and a middle foot portion, wherein the last further comprises:
a foot length forming member (<NUM>) that defines a shape of the last (<NUM>) at least in a lengthwise direction of the article of footwear;
a plurality of foot width forming members (<NUM>) that define a shape of the last (<NUM>) at least in a widthwise direction of the article of footwear and are assembled to the foot length forming member (<NUM>); wherein
the plurality of the foot width forming members (<NUM>) are aligned in a heightwise direction in the heel portion of the last (<NUM>) and aligned in the lengthwise direction in the front foot portion and the middle foot portion of the last (<NUM>), wherein
in the heel portion of the last (<NUM>) the foot length forming member (<NUM>) has formed therein a plurality of engagement grooves (<NUM>) aligned at equal intervals in the heightwise direction, wherein the plurality of foot width forming members (<NUM>) are assembled in engagement grooves (<NUM>) and thus aligned at equal intervals in the heightwise direction.