METHOD FOR MANUFACTURING CUSTOM ORDER SHOES

Abstract

A method of manufacturing a custom order shoe includes steps of a last making step for producing a last based on the customer's foot data, a shoe upper knitting and shaping step for sewing an upper fabric by three-dimensional shaped knitting and keeping the shape of an upper part in a state where the last is inserted, and a shoe completing step for selectively attaching an insole and an outsole to the upper part.

Claims

1. A method for manufacturing a custom order shoe in a shoe manufacturing system comprising: a means for measuring a customer's foot-type in a store; a means for producing a last in a last factory; a means for producing an upper part 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 last making step for producing a last 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 holding the upper part in a state where the last is inserted, and a shoe completing step for attaching an insole and an outsole to the upper part selectably, wherein the shoe upper knitting and shaping step includes knitting the upper fabric into a three-dimensional shape by a circular knitting machine using a polyester processed yarn on the surface and a fused yarn on the back, the upper part being made of the outer fabric and the inner fabric continuous therewith, after sewing and closing the toe part of the inner fabric and the outer fabric, inserting the inner fabric into the inner side of the outer fabric, then fitting a frame to the opening to fix the outer fabric and the inner fabric, lastly, shape keeping the upper part by cooling and fixing after heating and fusing the fused yarn knitted into the upper fabric in a state where the last is inserted in the upper part, and the shoe completing step includes processing the outsole in a state where the last is inserted in the upper part.

2. The method according to claim 1, wherein in the shoe upper knitting and shaping step, a yarn selected from an antifouling treatment yarn made of a polyester processed yarn or a nylon processed yarn, and a short fiber spun yarn, a high strength yarn, or a combination thereof is used on the surface of the upper fabric, a fused yarn is used on the back and knitted into a three-dimensional shape by the circular knitting machine.

3. The method according to claim 1, wherein the last making step includes a step of making standard lasts corresponding to pattern orders, and the standard lasts includes 91 types for men, 79 types for women, that is 170 types in total, and 340 pieces for the left and right with two elements of foot length and foot circumference as indexes.

4. The method according to claim 2, wherein the last making step includes a step of making standard lasts corresponding to pattern orders, and the standard lasts includes 91 types for men, 79 types for women, that is 170 types in total, and 340 pieces for the left and right with two elements of foot length and foot circumference as indexes.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0025] FIG. 1 is an explanatory diagram showing an outline of the manufacturing and sales business of the custom order shoes.

[0026] FIG. 2 is a flow chart showing an example of the shoe manufacturing process according to the present invention.

[0027] FIG. 3 shows an example of a left foot last produced by the wooden-last making step according to the present invention, where (a) is a perspective view, (b) is a left-side view, (c) is a right-side view, and (d) is a bottom view.

[0028] FIG. 4 shows an example of an upper part knitted in the shoe upper knitting and molding step according to the present invention, where (a) is a front view, and (b) is a side view.

[0029] FIG. 5 is an explanatory view showing an example of the sewing procedure of the upper part shown in FIG. 4.

[0030] FIG. 6 shows an example of a state where a left foot last shown in FIG. 3 is inserted in the upper part shown in FIG. 4, where (a) is a perspective view, (b) is a left-side view, (c) is a right-side view, and (d) is a bottom view.

[0031] FIG. 7 is an explanatory view showing an example of a shoe completing step according to the present invention.

DETAILED DESCRIPTION OF EMBODIMENT

[0032] An 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.

[0033] FIG. 1 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 a customer 10 in a store 20, a means of producing last based on the foot-type data A in a wooden-last making factory 30, a means of producing an upper part in a sock factory 40, and a means of producing sole part in a shoe factory 50.

[0034] Further, FIG. 2 is a flow chart illustrating an example of the shoe manufacturing process according to the present invention. As shown in FIG. 2, 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.

[0035] (S10: Foot-Type Measuring and Data-Conversing Step)

[0036] To enable custom-made, individual foot-type measurement is performed using a 3D foot-type measurement device (FIG. 2: 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. 2: S102).

[0037] 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 ±2.5 mm and a foot circumference of ±3 mm. In the case of a man, the foot length is extended from 235 mm to 280 mm, and the foot width is extended from C to 4E, and in the case of a woman, the foot length is extended from 210 mm to 250 mm, and the foot width is extended from B to 3E, then the foot of 60 types for men, 54 types for women, and 114 types of wooden lasts can cover 90% 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.

[0038] (S20: Wooden Last Making Step)

[0039] 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. 3). On the other hand, in the step (FIG. 2: 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, 91 types for men and 79 types for women, totaling 170 types (covering 90% or more of both men and women), and 340 standard lasts for the left and right are manufactured and managed using two elements of foot length and foot circumference as indexes.

[0040] (S30: Shoe Upper Knitting and Shaping Step)

[0041] First, the upper fabric is knitted into a three-dimensional shape by a circular knitting machine using fused yarn. Specifically, the knitted fabric is simultaneously knitted with a polyester-processed yarn on the front and a fused yarn on the back (FIG. 2: S301). As shown in FIG. 4, an upper part 1 comprises an outer fabric 11 and an inner fabric 14 continuous therewith and has openings 12 and 15 at both ends of each fabric. In addition, the figure design is expressed by the outer fabric 11, and the inner fabric 14 is basically made plain. Thus, sewing can be minimized by applying the three-dimensional shaped knitting to the upper part 1. In addition, by knitting the fused 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.

[0042] Next, as shown in FIG. 5 at (1) and (2), a toe part 16 of the inner fabric 14 and a toe part 13 of the outer fabric 11 are sewn and closed. As shown in FIG. 5 at (3) and (4), the inner fabric 14 is inserted into the inside of the outer fabric 11 (FIG. 2: S302). In addition, the outer fabric 11 and the inner fabric 14 are fastened by fitting a frame to an open footwear 17 shown in FIG. 5 (4). At this time, embroidery can be applied to the footwear 17, as shown in FIG. 2: S303.

[0043] Finally, in a state of inserting the last 2 in the upper part 1 (see, FIG. 6) to hold the upper part by cooling and fixing after heating and melting the fused yarn knitted into the upper fabric (FIG. 2: S304). As described above, by employing the step of keeping the shape by heating and cooling in the state where the last 2 is inserted into the three-dimensionally shaped upper part 1 (see FIG. 6), the ultimate fit feeling that matches the foot of an individual, which not present in a conventional shoe can be obtained.

[0044] 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 fused 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.

[0045] (S40: Shoe Completing Step)

[0046] As shown in FIG. 7 at (1), (2), and (3), an outsole 3 suitable for the customer is stuck with an adhesive in a state where the last 2 is inserted into the upper part 1. Further, as shown in FIG. 7 (4), an insole 4 that matches the wearing feeling of the customer is inserted and the shoe is completed (FIG. 2: S401). Thus, by providing choices for the insole and outsole, it is possible to customize shoes that match the intended use.

INDUSTRIAL APPLICABILITY

[0047] Practical application to medical applications such as rehabilitation applications prescribed in treatment hospitals, etc., and specific applications such as professional athletes of sports competitions are considered.

LIST OF REFERENCE CHARACTERS

[0048] 1 Upper part [0049] 11 Outer fabric [0050] 12 Opening [0051] 13 Toe part [0052] 14 Inner fabric [0053] 15 Opening [0054] 16 Toe part [0055] 17 Opening for wearing [0056] 2 Last [0057] 3 Outsole [0058] 4 Insole