SHOE UPPER AND SHOE

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to Japanese Patent Application No. 2024-201884 filed on Nov. 19, 2024, the entire disclosure of which is incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates to an upper and a shoe.

BACKGROUND

Conventionally, methods that enable manufacturing of shoes that can cope with a wide range of foot sizes using uppers of the same dimensions have been proposed (for example, see Japanese Unexamined Patent Publication No. 2014-210179 below).

Japanese Unexamined Patent Publication No. 2014-210179 discloses an upper formed of a knitted material, including at least a first partial region including a first yarn and a second partial region including a second yarn, and configured such that the first yarn has a higher elasticity than that of the second yarn. In the upper described in Japanese Unexamined Patent Publication No. 2014-210179, the first and second partial regions are alternately disposed to extend orthogonally to a longitudinal axis of a shoe.

According to the upper described in Japanese Unexamined Patent Publication No. 2014-210179, the first partial region firmly encloses a foot, while a force applied in a lateral direction is diverted into the second partial region. Moreover, according to the upper described in Japanese Unexamined Patent Publication No. 2014-210179, the first and second partial regions are alternately arranged to extend orthogonally to the longitudinal axis, thereby enabling adjustment of shoe size in the longitudinal direction.

That is, according to the upper described in Japanese Unexamined Patent Publication No. 2014-210179, even when shoes are manufactured using uppers of same dimensions, the shoes can apply necessary pressure (give a fit feeling) to respective feet of wearers and size adjustment is possible, thus enabling coping with feet of a wide range of foot sizes.

SUMMARY OF THE INVENTION

Technical Problem

However, with the upper described above, while, when a wearer wears the shoe, the first partial region is stretched to be in a shape conforming to a shape of the foot of the wearer, when the wearer takes off the shoe (when the wearer does not wear the shoe), the first partial region is contracted to return to an original shape. That is, the shoe using the upper described above does not have a shape conforming to the shape of the foot of the wearer when is not worn. Therefore, the shoe using the upper described above can cope with both a person whose foot size is a first size and a person whose foot size is a second size, but when the person whose shoe size is the second size wears the shoe, a pressure applied to the foot is larger than that when the first person whose shoe size is the first size wears the shoe and a pressing feeling (tightening feeling) to the foot is likely to be increased too much. That is, although, by using uppers of the same dimensions, the shoes including the uppers described above can be configured such that persons that have feet in a wide range of sizes can wear the shoes, the shape of each of the shoes does not correspond to a shape of a foot of a corresponding one of the wearers when the shoe is not worn, a pressing feeling to the foot differs depending on dimensions of the foot of each of the wearers and a same fitting feeling cannot be given thereto.

In view of the foregoing, the present disclosure has been devised, it is therefore an object of the present disclosure to enable production of customized shoes of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers whose foot shapes are different and that can give similar feelings from uppers of same dimensions.

Solution to the Problem

In order to achieve the object described above, according to a first aspect of the present disclosure, provided is a shoe upper that includes an upper body that covers an instep part of a foot of a wearer and an upper bottom portion that covers a sole of the foot of the wearer and is configured such that the upper bottom portion is fixed to an upper portion of a shoe sole, the shoe upper including a first portion, and a second portion having a higher stretchability than that of the first portion, being configured such that the first portion is provided at least at the upper body, and the second portion is provided at least at the upper bottom portion.

In the shoe upper (which will be hereinafter simply referred to as the “upper”) of the first aspect, the second portion having a higher stretchability than that of the first portion is provided at the upper bottom portion that is fixed to a shoe sole (which will be hereinafter simply referred to as the “sole”). When the upper having a configuration described above is placed over a first last having a shape that corresponds to a foot of a first wearer, the second portion of the upper bottom portion is stretched to conform to the shape of the foot of the first wearer. Then, when the upper placed over the first last is fixed to the sole, the stretched second portion is fixed to the sole and does not return to an original contracted state, and therefore, a first customized shoe having a shape corresponding to the shape of the foot of the first wearer is manufactured. When an upper of the same dimensions is placed over a second last having a shape that corresponds to a foot of a second wearer whose foot shape is different from that of the first wearer, the second portion at the upper bottom portion is stretched to conform to the shape of the foot of the second wearer, and when the upper is fixed to a sole, a second customized shoe having a shape that corresponds to the shape of the foot of the second wearer is manufactured. Although the first customized shoe and the second customized shoe are manufactured from the uppers of the same dimensions, since the first customized shoe is manufactured to conform to the shape of the foot of the first wearer, regardless of whether the first customized shoe is worn or not worn, and the second customized shoe is also manufactured to conform to the shape of the foot of the second wearer, regardless of whether the second customized shoe is worn or not worn, each of the shoes can provide a similar fit feeling to the foot of a corresponding one of the wearers. Based on the foregoing, according to the first aspect, customizes shoes of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers whose foot shape are different and that at the upper bottom portion so as to be can be produced from uppers of same dimensions.

According to a second aspect, in the first aspect, the second portion is provided at the upper bottom portion so as to be stretched and contracted at least in a foot width direction.

According to the upper of the second aspect, the second portion can be fixed to the sole in a state where the second portion is stretched at least in the foot width direction at the upper bottom portion. Therefore, according to the second aspect, customized shoes of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers shapes of cross sections (cut faces each of which extends along an imaginary plane perpendicular to the foot length direction) of which are different and that can give similar fit feelings, that is, for example, a wide-width customized shoe with a larger width than that of a non-customized shoe fixed to the sole with the second portion not stretched in the foot width direction, a high-instep customized shoes with a higher instep than that of the non-customized shoe, and a wide-width and high-instep customized shoes with a larger width and a higher instep than those of the non-customized shoe, or the like, can be produced from uppers of same dimensions by causing the second portion to be stretched in the foot width direction in accordance with a shape of a foot of an individual wearer.

According to a third aspect, in the second aspect, the second portion is provided at the upper bottom portion so as to be stretched and contracted also in a foot length direction.

According to the upper of the third aspect, the second portion can be fixed to the sole in a state where the second portion is stretched not only in the foot width direction but also in the foot length direction at the upper bottom portion. Therefore, according to the third aspect, customized shoes of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers at least ones of cross-sectional shapes and sizes of which are different and that can give similar fit feelings can be produced from uppers of same dimensions by causing the second portion to be stretched at least in one of the foot width direction and the foot length direction in accordance with a shape of a foot of an individual wearer.

According to a fourth aspect, in the first aspect, the second portion includes a stretchable material.

Herein, the term “stretchable material” refers to a stretch yarn having a property of stretching when tension is applied thereto and returning to an original length before stretching when the applied tension is removed (stretch recovery property) or an elastic material, such as a natural rubber, a synthetic rubber, or the like, itself. As the stretch yarn, for example, a rubber yarn formed of a natural rubber or a synthetic rubber, and an elastic yarn formed of polyurethane, polyester, or polyolefin, or the like can be used.

According to the shoe upper of the fourth aspect, the second portion having a higher stretchability than that of the first portion can be easily formed by causing the second portion to include the stretchable material.

According to a fifth aspect, provided is a shoe that includes a sole and an upper that is fixed to an upper portion of the sole and in which the upper is the shoe upper of any one of the first to fourth aspects.

According to the shoe of the fifth aspect, since the shoe includes the shoe upper according to any one of the first to fourth aspects described above, customized shoes of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers whose foot shapes are different and that can give similar fit feelings from uppers of same dimensions can be produced.

According to a sixth aspect, in the fifth aspect, the upper is fixed to the sole in a state where the second portion provided at the upper bottom portion is stretched at least in the foot width direction.

The shoe of the sixth aspect has the upper fixed to the sole in a state where the second portion provided at the upper bottom portion is stretched at least in the foot width direction. By forming the shoe in a configuration described above, customized shoes of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers shapes of cross sections of which are different and that can give similar fit feelings can be produced from uppers of same dimensions by causing the second portion to be stretched in the foot width direction in accordance with a shape of a foot of an individual wearer.

According to a seventh aspect, in the fifth aspect, the upper is fixed to the sole in a state where the second portion provided at the upper bottom portion is stretched at least in the foot length direction.

In the shoe of the seventh aspect, the upper is fixed to the sole in a state where the second portion provided at the upper bottom portion is stretched at least in the foot length direction. By forming the shoe in a configuration described above, customized shoes of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers at least ones of cross-sectional shapes and sizes of which are different and that can give similar fit feelings can be produced from uppers of same dimensions by causing the second portion to be stretched at least in one of the foot width direction and the foot length direction in accordance with a shape of a foot of an individual wearer.

Advantages of the Invention

As described above, according to the present disclosure, it is possible to produce customized shoes of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers whose foot shapes are different and that can give similar fit feelings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a shoe including an upper of a first embodiment.

FIG. 2 is a side view illustrating the shoe of FIG. 1, as viewed from a lateral side, together with a bone structure of a foot.

FIG. 3 is a cross-sectional view taken along the line A-A of FIG. 2.

FIG. 4 is a bottom view of the upper of the first embodiment.

FIG. 5 is a cross-sectional view taken along the line A-A of FIG. 2, illustrating a manufacturing process of a customized shoe S11 in comparison with a manufacturing process of a non-customized shoe S0, illustrating how an upper in a temporary shape is placed over a last in a deforming step in a section (a), illustrating the upper after the deforming step in a section (b), illustrating how the upper is adhesively fixed to a sole in a main shape-retaining step in a section (c), illustrating shoes after a last taking-out step in a section (d).

FIG. 6 is a cross-sectional view taken along the line A-A of FIG. 2, illustrating a manufacturing process of a customized shoe S12 in comparison with the manufacturing process of the non-customized shoe S0, illustrating how an upper in a temporary shape over a last in the deforming step in a section (a), illustrating the upper after the deforming step in a section (b), illustrating how the upper is adhesively fixed to the sole in the main shape-retaining step in a section (c), illustrating shoes after the last taking-out step in a section (d).

FIG. 7 is a cross-sectional view taken along the line A-A of FIG. 2, illustrating a manufacturing process of a customized shoe S13 in comparison with the manufacturing process of the non-customized shoe S0, illustrating how an upper in a temporary shape over a last in the deforming step in a section (a), illustrating the upper after the deforming step in a section (b), illustrating how the upper is adhesively fixed to the sole in the main shape-retaining step in a section (c), illustrating shoes after the last taking-out step in a section (d).

FIG. 8 is a bottom view of an upper of a second embodiment.

FIG. 9 is an explanatory diagram illustrating a method for manufacturing customized shoes, an upper section is a cross-sectional view taken along the line B-B of FIG. 8, illustrating the upper made into a temporary shape in a temporary shape-retaining step, a middle section is a cross-sectional view taken along the line B-B of FIG. 8, illustrating the upper after the deforming step, a lower section is a cross-sectional view taken along the line B-B in FIG. 8, illustrating the upper after the main shape-retaining step, together with a side view viewed from a lateral side of the sole.

FIG. 10 is a bottom view of the upper of a third embodiment.

FIG. 11 is a bottom view of the upper of a fourth embodiment.

FIG. 12 is a cross-sectional view of a shoe including an upper of a fifth embodiment, corresponding to FIG. 3.

FIG. 13 is a cross-sectional view of a shoe including an upper of a sixth embodiment, corresponding to FIG. 3.

FIG. 14 is a cross-sectional view of a shoe including an upper of a seventh embodiment, corresponding to FIG. 3.

FIG. 15 is a cross-sectional view of a shoe including an upper of an eighth embodiment, as viewed from the lateral side.

DETAILED DESCRIPTION

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings. The following embodiments are mere examples by nature, and are not intended to limit the scope of applications or uses of the present disclosure.

First Embodiment

FIG. 1 and FIG. 2 illustrate an overall configuration of an upper 20 according to a first embodiment and a left-foot shoe of a customized shoe S1 (which will be hereinafter simply referred to as a “shoe S1”) including the upper 20. Since a right-foot shoe is configured to be symmetrical to the left-foot shoe, in the following description, the left-foot shoe illustrated in FIG. 1 and FIG. 2 will be described and description of the right-foot shoe is omitted. In the following description, the term “fore (front)” and “rear (hind)” represent a positional relationship in a foot length direction of the shoe S1 and the term “medial side” and “lateral side” represent a position relationship in a foot width direction of the shoe S1. Furthermore, “above (upper side)” and “below (lower side)” represent a positional relationship in an up-and-down direction of the shoe S1 (a positional relationship in a height direction orthogonal to a placing surface when the shoe S1 is placed on a flat surface).

-Shoe Configuration-

The shoe S1 includes a sole 10 and an upper 20 that is disposed above the sole.

<Sole>

As illustrated in FIG. 1 and FIG. 2, the sole 10 includes an outsole 11 and a midsole 12. The sole 10 is provided at a lowest portion of the shoe S1 and includes a ground contact surface 10a that contacts a road surface.

• • a foot of a person will be referred to as a forefoot F, a midfoot M, and a rearfoot H.

The outsole 11 is provided in a range extending from a fore end to a rear end of the shoe S1 so as to correspond to a range extending from a forefoot F to a rearfoot H of a foot f of a wearer. The outsole 11 is formed of a hard stretchable material having a higher hardness than that of the midsole 12. Specifically, as a material of the outsole 11, for example, a thermoplastic resin, such as ethylene-vinyl acetate copolymer (EVA) or the like, a thermosetting resin, such as polyurethane (PU) or the like, or a rubber material, such as butadiene rubber, chloroprene rubber, or the like, are suitable. A lower surface of the outsole 11 serves as the ground contact surface 10a of the sole 10 that contacts the road surface during walking or running.

The midsole 12 is provided across an entire range from the fore end to the rear end in the foot length direction (a fore-and-rear direction) of the shoe S1 and from a medial side end to a lateral side end of the sole 10 in the foot width direction. An upper surface of the midsole 12 is formed into a curved shape so as to conform to a sole surface of the foot f of the shoe wearer, serving as a sole support surface that supports the sole surface of the foot of the shoe wearer. In the first embodiment, the upper surface of the midsole 12 serves as an upper fixing surface to which the upper bottom portion 22 of the upper 20 that will be described later is fixed.

The midsole 12 is formed of a soft stretchable material having a lower hardness than that of the outsole 11. Specifically, as a material of the midsole 12, for example, a thermoplastic synthetic resin, such as ethylene vinyl acetate copolymer (EVA) or the like, a foamed body thereof, a thermosetting resin, such as polyurethane (PU) or the like, a formed body thereof, a rubber material, such as butadiene rubber, chloroprene rubber, or the like, a foamed body thereof, or the like, are suitable. The midsole 12 is stacked on an upper side of the outsole 11 by being firmly attached to the outsole 11 via an adhesive or the like.

The midsole 12 includes an upper midsole 13 and a lower midsole 14 stacked on a lower side of the upper midsole 13. A wave plate 15 is disposed between the upper and lower midsoles 13 and 14 at a location corresponding to the rearfoot H. The wave plate 15 is formed into a wave-like shape in which protrusions and depressions repeat in the fore-and-rear direction.

In the first embodiment, the sole 10 including the ground contact surface 10a that contacts the road surface is configured of the outsole 11 and the midsole 12 described above.

<Upper>

The upper 20 includes an upper body 21 covering an instep side (an upper part including a heel part, both side parts, an instep part, and a toe part) of the foot f of the wearer from a heel to a toe, and an upper bottom portion 22 covering a sole part (a foot sole part) of the foot f of the wearer from the heel to the toe. In the first embodiment, the upper body 21 and the upper bottom portion 22 are integrally formed of a knitted material and are configured into a pouch-like structure. Note that a material of the upper body 21 and the upper bottom portion 22 is not particularly limited and the upper body 21 and the upper bottom portion 22 may be formed of, for example, a woven fabric, a non-woven fabric, a mesh material, a synthetic leather, an artificial leather, a natural leather, a rubber, a resin sheet, or the like, in addition to the knitted material. Alternatively, the upper body 21 and the upper bottom portion 22 may be separately formed and joined through sewing, bonding, fusing, or the like to form a pouch-like structure.

Note that, in the first embodiment, the upper 20 includes an outer upper 20a having a pouch-like structure and an inner upper 20b similarly having a pouch-like structure and conforming to an inner surface of the outer upper 20a. The upper 20 is formed into a single pouch-like structure by joining the uppers 20a and 20b through sewing, bonding, fusing, or the like in a state where the inner upper 20b is provided inside the outer upper 20a.

As will be described in detail later, in the first embodiment, a thermally fusing yarn is partially woven into the upper 20 during knitting the upper 20 and, in a final product state illustrated in FIG. 1 to FIG. 3, the thermal fusing yarn has been melted and then solidified. The thermally fusing yarn is melted and bonded by heating and cooling the upper 20 in a state where the upper 20 is placed over a temporary shape retaining last L0 after knitting, so that a shape of the upper 20 is retained as a temporary shape conforming to the temporary shape retaining last L0. As will be described in detail later, the upper 20 is adhesively fixed to the sole 10 corresponding to a width of a foot of an individual wearer in a state where the upper 20 is placed over a corresponding one of lasts L11 to L13 each having a shape corresponding to a shape of the foot of the corresponding individual wearer after retaining the upper 20 in the temporary shape, and thus, the shoe S1 (customized shoes S11 to S13) a shape of which is customized such that the shape corresponds to the shape of the foot of the corresponding wearer is formed.

The upper body 21 is provided across a range extending from a medial side to a lateral side within the range from the fore end (toe) to the rear end (heel) of the shoe S1 in the fore-and-rear direction so as to integrally cover the instep side (the upper part) of the foot f of the wearer. A wearing opening O is formed in the upper portion of the upper body 21 so as to be opened around an ankle of the wearer. In the first embodiment, as illustrated in FIG. 1 and FIG. 2, eyelets through which a shoelace is passed are not provided in the upper body 21, but the upper body 21 may include eyelets and be configured to be tightened with the shoelace.

The upper 20 includes a first portion A1 and a second portion A2 having a higher stretchability than that of the first portion A1. The first portion A1 and the second portion A2 are configured such that the second portion A2 includes a stretchable material while the first portion A1 does not include a stretchable material, so that the second portion A2 has a higher stretchability than that of the first portion A1. In the first embodiment, a stretch yarn is woven into the second portion A2 as the stretchable material, while no stretch yarn is woven into the first portion A1. Note that, in FIG. 2 to FIG. 7, in order to emphasize the second portion A2, the second portion A2 is hatched with dots. In FIG. 3, FIG. 5, FIG. 6, and FIG. 7, in order to draw attention to the upper 20, the sole 10 is not hatched.

As used herein, the term “stretch yarn” refers to a yarn having a property (stretch recovery property) of stretching when a tensile force is applied thereto and recovering to an original length before stretching when the applied tensile force is removed. For example, a rubber yarn formed of a natural rubber or a synthetic rubber, a polyurethane-based, polyester-based, or a polyolefin-based elastic yarn, or the like can be used as the stretch yarn. In the first embodiment, a yarn having a higher stretch recovery rate than that of a main yarn (a yarn used most abundantly in the upper 20) is used as the stretch yarn.

Note that, in the first embodiment, as described above, the upper 20 is formed into a single pouch-like structure by joining the outer upper 20a having a pouch-like structure and the inner upper 20b having a pouch-like structure through sewing, bonding, fusing, or the like. In the second portion A2, the stretch yarn is woven into each of the uppers 20a and 20b as the stretchable material, so that both the uppers 20a and 20b are stretched together.

In the first embodiment, the first portion A1 is configured to be a non-stretchable portion that has almost no stretchability. In the first embodiment, the first portion A1 includes a low melting point material and is configured to have almost no stretchability (not to stretch) by, after knitting the upper 20, heating and cooling the upper 20 in a state where the upper 20 is placed over the temporary shape retaining last L0 to melt and solidify the low melting point material. In the first embodiment, the thermally fusing yarn described above is woven into the first portion A1 of the upper 20 as the low melting point material.

As used herein, the term “thermally fusing yarn” refers to a yarn having a high melt and fusion property and formed of a material having a relatively low melting point. For example, a yarn formed of nylon or the like that has a relatively low melting point can be used as the thermally fusing yarn. In the first embodiment, a yarn formed of a material having a lower melting point than those of other yarn materials used for the upper 20 is used as the thermally fusing yarn.

Note that, in the first embodiment, as described above, the upper 20 is formed into a single pouch-like structure by joining the outer upper 20a having a pouch-like structure and the inner upper 20b having a pouch-like structure through sewing, bonding, fusing, or the like. In the first portion A1 of the upper 20, the thermally fusing yarn is woven into at least the outer upper 20a as the low melting point material.

In the first embodiment, the first portion A1 and the second portion A2 are provided on the upper body 21 and the upper bottom portion 22, respectively.

As illustrated in FIG. 2, in the upper body 21, a wearing opening part 23 surrounding the wearing opening O is formed in the second portion A2, a remaining portion is formed in the first portion A1. That is, in the wearing opening part 23 of the upper body 21, each of the outer upper 20a and the inner upper 20b includes the stretchable material (the elastic yarn is woven thereinto). On the other hand, in the remaining portion of the upper body 21 other than the wearing opening part 23, neither the outer upper 20a nor the inner upper 20b includes the stretchable material (the elastic yarn is not woven thereinto) and the outer upper 20a includes the low melting point material (the thermally fusing yarn is woven thereinto).

As illustrated in FIG. 3 and FIG. 4, at the upper bottom portion 22, the second portion A2 is provided so as to be stretchable in the foot width direction and a portion other than the second portion A2 is formed to be the first portion A1.

In the first embodiment, at the upper bottom portion 22, the second portion A2 extends in the foot length direction (the fore-and-rear direction) at center in the foot width direction and is provided so as to extend from a forefoot F to a rearfoot H. By providing the second portion A2 such that the second portion A2 extends in the foot length direction in a manner described above, the upper bottom portion 22 can be easily stretched and contracted in the foot width direction. Moreover, in the first embodiment, the second portion A2 is provided over a wide range at the upper bottom portion 22, excluding an outer edge portion in the foot width direction, so as to be largely stretched in the foot width direction. That is, in the first embodiment, the second portion A2 is provided over a wide area at the upper bottom portion 22, excluding an outer peripheral portion. The portion of the upper bottom portion 22 other than the second portion A2 (that is, the outer peripheral portion) is formed into the first portion A1. That is, in the wide area at the upper bottom portion 22 excluding the outer peripheral portion, each of the outer upper 20a and the inner upper 20b includes the stretchable material (the stretch yarn is woven thereinto). On the other hand, in the outer peripheral portion of the upper bottom portion 22, neither the outer upper 20a nor the inner upper 20b includes the stretchable material (the stretch yarn is not woven thereinto) and the outer upper 20a includes the low melting point material (the thermally fusing yarn is woven thereinto).

As described above, in the first embodiment, by providing the second portion A2 over a wide range in the foot length direction from the forefoot F to the rearfoot H at the upper bottom portion 22 and further providing the second portion A2 over a wide range in the foot width direction, the upper 20 is configured to be stretchable in the foot width direction over a wide range in the foot length direction and capable of being largely stretched in the foot width direction.

-Method for Manufacturing Customized Shoe-Next-

a method for manufacturing customized shoes S11 to S13 (which will be hereinafter simply referred to as shoes S11 to S13) using the uppers 20 having same dimensions will be described with reference to FIG. 5, FIG. 6, and FIG. 7. Note that a left side of each of FIG. 5, FIG. 6, and FIG. 7 illustrates a manufacturing process of a non-customized shoe S0 obtained by fixing the upper 20 in a temporary shape to a standard sole 10s without deforming the upper 20 for comparison with manufacturing processes of the shoes S11 to S13, a right side of FIG. 5 illustrates the manufacturing process of the shoe S11, a right side of FIG. 6 illustrates the manufacturing process of the shoe S12, and a right side of FIG. 7 illustrates the manufacturing process of the shoe S13.

To make it easy to understand description, sizes of the shoes S11 to S13 are same as that of the non-customized shoe S0. Moreover, each of the shoes S11 to S13 has a larger girth than that of the non-customized shoe S0 from the forefoot to the rearfoot. Specifically, the shoe S11 illustrated in FIG. 5 is a high-instep type shoe with a not significantly different width and a higher instep from the forefoot to the rearfoot, as compared to the non-customized shoe S0, the shoe S12 illustrated in FIG. 6 is a wide-width (flat) type shoe with a larger width and a slightly lower instep from the forefoot to the rearfoot, as compared to the non-customized shoe S0, and the shoe S13 illustrated in FIG. 7 is a high-instep and wide-width type shoe with a larger width and a higher instep from the forefoot to the rearfoot, as compared to the non-customized shoe S0. Although the shoes S11 to S13 are described as examples of the customized shoe S1 herein, the customized shoe S1 that can be manufactured using the uppers 20 having the same dimensions are not limited to the shoes S11 to S13 and the customized shoes S1 each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers shapes of cross sections (cut faces each of which extends along an imaginary plane perpendicular to the foot length direction) of which are different can be produced by causing the second portion A2 to be stretched in the foot width direction in accordance with a shape of a foot of each individual wearer (changing a degree of stretching in accordance with the shape of the foot of each individual wearer).

In manufacturing any one of the shoes S11 to S13, first, a corresponding one of the uppers 20 after being knitted is placed over a corresponding one of the temporary shape retaining lasts L0 in the same shape and is heated and cooled to retain the upper 20 in a temporary shape of the upper 20 conforming to the temporary shape retaining last L0 (a temporary shape-retaining step). Thus, in manufacturing any one of the shoes S11 to S13, the upper 20 is retained in the same temporary shape conforming to the temporary shape retaining last L0 (see a left side of a section (a) of each of FIG. 5, FIG. 6, and FIG. 7).

Note that the temporary shape retaining last L0 used herein may be individually produced for each of planned dimensions (size and width and girth specification), but it is preferable that one temporary shape retaining last L0 is shared by every consecutive three to five dimensions from a viewpoint of costs or the like. For example, in terms of size, when sizes in 0.5 cm increments are planned in a range of 20 cm to 30 cm, one temporary shape retaining last L0 can be shared, for example, by every four consecutive sizes, that is, a first temporary shape retaining last L0 in the same shape is used for 20 cm, 20.5 cm, 21 cm, and 21.5 cm, a second temporary shape retaining last L0 in the same shape is used for 22 cm, 22.5 cm, 23 cm, and 23.5 cm, or the like. When specifications A, B, C, D, E, 2E, 3E, 4E, F, and G are planned for each of the width and the girth, for example, the temporary shape retaining last L0 in the same shape can be shared, for example, by every five consecutive specifications, that is, a small temporary shape retaining last L0 in the same shape is used for the specifications A to E, a large temporary shape retaining last L0 in the same shape is used for the specifications 2E to G, or the like. The temporary shape retaining last L0 is preferably formed to have a shape corresponding to a smallest one of sizes or specifications that share the same temporary shape retaining last L0.

Next, as illustrated in a right side of a section (a) of each of FIG. 5, FIG. 6, and FIG. 7, in manufacturing any one of the shoes S11 to S13, the upper 20 in the temporary shape is placed over a corresponding one of the last L11 to L13 each of which has a shape corresponding to a shape of a foot of a corresponding target wearer. Thus, as illustrated in a right side of a section (b) of each of FIG. 5, FIG. 6, and FIG. 7, each of the uppers 20 is deformed into a shape where the second portion A2 provided at the upper bottom portion 22 is stretched in the foot width direction and that conforms to an outer surface shape of a corresponding one of the lasts L11 to L13 (a shape corresponding to the shape of the foot of the corresponding target wearer) (a deforming step).

As illustrated in the sections (a) and (b) of FIG. 5, the last L11 is a high-instep type last a width w11 of which is not significantly different from a width w0 of the temporary shape retaining last L0 but an instep height h11 of which is higher than an instep height h0 of the temporary shape retaining last L0. Therefore, the upper 20 placed over the last L11 is deformed into a high instep shape where the second portion A2 provided at the upper bottom portion 22 is stretched in the foot width direction and that conforms to an outer shape of the last L11 of the high-instep type.

As illustrated in the sections (a) and (b) of FIG. 6, the last L12 is a wide-width (flat) type last a width w12 of which is significantly larger than the width w0 of the temporary shape retaining last L0 and an instep height h12 of which is slightly lower than the instep height h0 of the temporary shape retaining last L0. Therefore, the upper 20 placed over the last L12 is deformed into a wide-width shape where the second portion A2 provided at the upper bottom portion 22 is stretched in the foot width direction and that conforms to an outer surface shape of the last L12 of the wide-width (flat) type.

As illustrated in the sections (a) and (b) of FIG. 7, the last L13 is a high-instep and wide-width type last a width w13 and an instep height h13 of which are larger than the width w0 and the instep height h0 of the temporary shape retaining last L0. Therefore, the upper 20 placed over the last L13 is deformed into a high-instep and wide-width shape where the second portion A2 provided at the upper bottom portion 22 is largely stretched in the foot width direction and that conforms to an outer surface shape of the last L13 of the high-instep and wide-width type.

Next, as illustrated in a section (c) of each of FIG. 5, FIG. 6, and FIG. 7, the upper bottom portion 22 of the upper 20 which has been placed on a corresponding one of the lasts L11 to L13 and deformed is adhesively fixed to an upper surface of a corresponding one of the soles 10 that corresponds to a width of a foot of a corresponding target wearer (a corresponding one of the widths w11 to w13 of the lasts L11 to L13) while the upper 20 is kept placed over the corresponding one of the lasts L11 to L13. Thus, the upper 20 is adhesively fixed to the sole 10 in a state where the second portion A2 provided at the upper bottom portion 22 is stretched and the upper 20 is retained in a shape corresponding to the shape of the foot of the corresponding target wearer (a main shape-retaining step).

As illustrated in the section (c) of FIG. 5, the upper 20 placed over the last L11 the width w11 of which is not significantly different from the width w0 of the temporary shape retaining last L0 is adhesively fixed to the standard sole 10s (sole 10). As illustrated in sections (c) of FIG. 6 and FIG. 7, each of the uppers 20 that are placed over the lasts L12 and L13 and the widths w12 and w13 of which are significantly larger than the width w0 of the temporary shape retaining last L0 is adhesively fixed to a wide-width sole 10w (sole 10) that is wider than the standard sole 10s.

When the upper bottom portion 22 of each of the uppers 20 placed over the lasts L11 to L13 is fixed to the upper surface of the corresponding one of the soles 10, the stretched second portion A2 is fixed to the sole 10 and thus does not return to an original contracted shape. That is, the upper 20 is retained in the shape corresponding to the shape of the foot of the corresponding target wearer. The upper 20 placed over the last L11 is retained in a high-instep shape corresponding to the shape of the foot of the corresponding wearer of the high-instep type, the upper 20 placed over the last L12 is retained in a wide-width shape corresponding to the shape of the foot of the corresponding wearer of the wide-width (flat) type, and the upper 20 placed over the last L13 is retained in a high-instep and wide-width shape corresponding to the shape of the foot of the corresponding wearer of the high-instep and wide-width type.

Next, as illustrated in a section (d) of each of FIG. 5, FIG. 6, and FIG. 7, the shoes S11 to S13 are completed by taking out the lasts L11 to L13 from inside of the uppers 20 (a last taking-out step).

As described above, the upper 20 is configured as in the first embodiment, and thus, the customized shoes S1 (the shoes S11 to S13) each of which has a shape corresponding to a corresponding one of feet of individual wearers can be produced using uppers 20 having the same dimensions simply by using the lasts L11 to L13 each of which has a shape corresponding to a corresponding one of the feet of the plurality of wearers that have different shapes. In each of the shoes S11 to S13, the stretched second portion A2 is made not to return to the original contracted shape by deforming a corresponding one of the uppers 20 into a shape conforming to the outer surface shape of a corresponding one of the lasts L11 to L13 (a shape corresponding to the shape of the foot of the corresponding target wearer) by causing the second portion A2 of provided at the upper bottom portion 22 to be stretched and fixing the upper bottom portion 22 including the stretched second portion A2 to a corresponding one of the respective soles 10. That is, in each of the shoes S11 to S13, the corresponding one of the uppers 20 is produced so as to have a shape (a targeted internal volume) corresponding to the shape of the foot of the corresponding wearer even when the shoe is not worn, and therefore, even when a person of any one of the high-instep type, the wide-width (flat) type, and the high-instep and wide-width type wears a corresponding one of the customized shoes S11 to S13 that corresponds to the type of the person, a stretched and contracted state is not significantly different among the respective upper bodies 21 and an equivalent fit feeling is given to all the wearers.

-Advantageous Effects Of First Embodiment-

As described above, in the upper 20 of the first embodiment, the second portion A2 having a higher stretchability than that of the first portion A1 is provided at the upper bottom portion 22 that is fixed to the sole 10. When the upper 20 having the configuration described above is placed over the last L11 having a shape corresponding to a foot of a first wearer (for example, a wearer of the high-instep type corresponding to the shoe S11), the second portion A2 of the upper bottom portion 22 is stretched to be in a shape (high-instep shape) corresponding to the foot of the first wearer. Then, when the upper 20 placed over the last L11 is fixed to the corresponding sole 10, the stretched second portion A2 is fixed to the sole 10 and thus does not return to an original contracted state, so that a first customized shoe S1 (for example, the shoe S11) having a shape (high-instep shape) corresponding to the shape of the foot of the first wearer is produced. When the upper 20 having the same dimensions is placed over the last L12 or the last L13 that has a shape corresponding to a foot of a second wearer (for example, a wearer of a wide-width (flat) type corresponding to the shoe S12 or a wearer of a high-step and wide-width type corresponding to the shoe S13) having a foot shape different from that of the first wearer, the second portion A2 of the upper bottom portion 22 is stretched to be in a shape (a wide-width (flat) shape or a high-instep and wide-width shape) corresponding to the foot of the second wear and, when the upper 20 placed on the last L12 of the last L13 is fixed to the corresponding sole 10, a second customized shoes S1 (for example, the shoe S12 or S13) having a shape (the wide-width (flat) shape or the high-instep and wide-width shape) corresponding to the shape of the foot of the second wearer is produced. Although the first customized shoe S1 (for example, the shoe S11) and the second customized shoe S1 (for example, the shoe S12 or S13) are formed from the uppers 20 having the same dimensions, the first customized shoe S1 is produced to have a shape (the high-instep shape) corresponding to the shape of the foot of the first wearer, regardless of whether the first customized shoe S1 is worn or not worn, and the second customized shoe S1 is produced to have a shape (the wide-width (flat) shape or the high-instep and wide-width shape) corresponding to the shape of the foot of the second wearer, regardless of whether the second customized shoe S1 is worn or not worn, and therefore, each of the shoes S1 (the shoes S11 to S13) can give a similar fit feeling to the foot of the corresponding wearer. Thus, according to the first embodiment, the customized shoes S1 (the shoes S11 to S13) of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers shapes of which are different and that can give similar fit feelings can be produced from the uppers of same dimensions.

Note that, in the first embodiment, as examples of the customized shoes S1 of a plurality of types that can be produced from the uppers 20 having the same dimensions, the shoe S11 of the high-instep type with a not significantly different width and a higher instep from the forefoot to the rearfoot, the shoe S12 of the wide-width (flat) type with a larger width and a slightly lower instep from the forefoot to the rearfoot, and the shoe S13 of the high-instep and wide-width type with a larger width and a higher instep, as compared to the non-customized shoe S0, have been descried. As described above, customized shoes that can be produced using the uppers 20 having the same dimensions are not limited to the shoes S11 to S13 described above. According to the upper 20 configured as in first embodiment, the customized shoes S1 in various shapes in accordance with foot shapes of individual wearers (shapes of cross sections, each extending from a forefoot to a rearfoot), including a customized shoe S1 in which, in the forefoot, an instep is not significantly different but a width is larger, in a midfoot, the width and the instep are larger, and in the rearfoot, the width is not significantly different, or the like, as compared to the non-customized shoe S0, can be produced.

Moreover, according to the first embodiment, the second portion A2 is provided to be stretched and contracted in the foot width direction at the upper bottom portion 22, and therefore, the upper 20 can be fixed to the sole 10 such that the second portion A2 is stretched at least in the foot width direction at the upper bottom portion 22. Therefore, according to the first embodiment, the customized shoes S11 to S13 of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers shapes of cross sections of which are different and that can give similar fit feelings, g that is, the high-instep customized shoe S11 the instep of which is higher than that of the non-customized shoe S0 that is fixed to the sole 10 without the second portion A2 stretched in the foot width direction, the wide-width customized shoe S12 the width of which is larger than that of the non-customized shoe S0, the wide-width and high-instep customized shoe S13 the width and the instep of which are larger than those of the non-customized shoe S0, or the like, can be produced from the uppers 20 having the same dimensions by causing the second portions A2 of the shoes S11 to S13 to be stretched in the foot width direction in accordance with foot shapes of the wearers.

Furthermore, according to the first embodiment, the second portion A2 includes the stretchable material (in the first embodiment, the stretch yarn is woven thereinto). With the configuration described above, the second portion A2 having a higher stretchability than that of the first portion A1 can be easily formed.

Second Embodiment

A customized shoe S2 (which will be hereinafter simply referred to as the shoe S2) of a second embodiment illustrated in FIG. 8 and FIG. 9 is obtained by partially changing the configuration of the upper 20 in the shoe S1 of the first embodiment. The shoe S2 is configured such that the second portion A2 can be stretched at least in one of the foot width direction and the foot length direction, and can be formed into a shape corresponding to each of feet of a plurality of wearers at least ones of shapes of cross sections and sizes of which are different.

Specifically, in the second embodiment, as illustrated in FIG. 8, the second portion A2 provided at the upper bottom portion 22 of the upper 20 is configured to include a first stretchable portion A21 that is stretched and contracted mainly in the foot width direction and a second stretchable portion A22 that is stretched and contracted mainly in the foot length direction. Note that, in FIG. 8 and FIG. 9, in order to emphasize the second portion A2, the second portion A2 is hatched with dots. Moreover, in order to draw attention on the upper 20, in a lower section of FIG. 9, for the sole 10, a cross section is not illustrated but a side view as viewed from the lateral side is illustrated.

The first stretchable portion A21 is configured similar to the second portion A2 provided at the upper bottom portion 22 of the first embodiment. Specifically, the first stretchable portion A21 is formed by weaving the stretch yarn as the stretchable material into each of the outer upper 20a and the inner upper 20b, extends in the foot length direction (the fore-and-rear direction) at the center in the foot width direction, and is provided to extend from the forefoot F to the rearfoot H such that the first stretchable portion A21 is stretchable in the foot width direction. The first elastic section A21 is provided over a wide range at the upper bottom portion 22, excluding an outer edge portion in the foot width direction, so as to be largely stretched in the foot width direction. That is, in the second embodiment, the first stretchable portion A21 is provided over a wide area at the upper bottom portion 22, excluding an outer peripheral portion thereof.

Similarly to the first stretchable portion A21, the second stretchable portion A22 is formed by weaving the stretch yarn as the stretchable material into each of the outer upper 20a and the inner upper 20b, extends in the foot width direction at the center in the foot length direction (the fore-and-rear direction) of the upper bottom portion 22, and is provided to extend from a medial side end to a lateral side end such that the second stretchable portion A22 is stretchable in the foot length direction. The second stretchable portion A22 is formed at the upper bottom portion 22 so as to have a certain length (for example, a length of approximately 25 mm) in the foot length direction such that the second stretchable portion A22 can be largely stretched in the foot length direction.

Other components are similar to those of the first embodiment, and therefore, description thereof will be omitted.

-Method For Manufacturing Customized Shoe-

Even when the upper 20 is configured as in the second embodiment, similar to the first embodiment, customized shoes S2 of a plurality of types (for example, shoes each having the same shape as that of a corresponding one of the shoes S11 to S13 of the first embodiment) shapes of cross sections of which are different can be produced using the uppers 20 (of one type) having the same dimensions.

Although steps of manufacturing the shoe S2 is substantially the same as those of the first embodiment, in the second embodiment, when the upper 20 in a temporary shape is placed over each of lasts L (for example, lasts L11 to L13) in order to manufacture the shoe S2, the first stretchable portion A21 of the second section A2 provided at the upper bottom portion 22 is stretched in the foot width direction. Thus, the upper 20 is deformed into a shape conforming to each of the lasts L (including the lasts L11 to L13). The other steps are similar to those of the first embodiment.

Moreover, according to the upper 20 of the second embodiment, not only a plurality of types of shoes S2 (for example, shoes each having the same shape as that of a corresponding one of the shoes S11 to S13 of the first embodiment) the shapes of cross sections of which are different can be manufactured using the uppers 20 having the same dimensions, but also a customized shoe S21 (which will be hereinafter simply referred to as a shoe S21) in a larger size (having a larger dimension in the foot length dimension) than that of the non-customized shoe S0 can be manufactured. A method for manufacturing the shoe S21 in a larger size (having a larger dimension in the foot length dimension) than that of the non-customized shoe S0 will be described with reference to FIG. 9.

Note that, as illustrated in an upper section of FIG. 9, performing the temporary shape-retaining step first to form the upper 20 in a temporary shape is similar to the method for manufacturing the shoes S11 to S13 in the first embodiment, and therefore, detailed description thereof will be omitted.

After the temporary shape-retaining step, as illustrated in a middle section of FIG. 9, the upper 20 in the temporary shape formed in the temporary shape-retaining step is placed over the last L2 in a larger size (having a larger dimension in the foot length direction) than that of the temporary shape retaining last L0. With the last L2 in a larger size (having a larger dimension in the foot length direction) than that of the temporary shape retaining last L0, the upper 20 is deformed in a longitudinally long shape where mainly the second stretchable portion A22 of the second portion A2 provided at the upper bottom portion 22 is stretched in the foot length direction and that conforms to the last L2 (the deforming step).

Next, as illustrated in a lower section of FIG. 9, the upper bottom portion 22 of the upper 20 that has been placed over the last L2 and deformed is disposed on top of the sole 10 in a size corresponding to a size of a foot of a target wearer (the size of the last L2) while the upper 20 kept placed over the last L2, and is adhesively fixed to the sole 10. Thus, the upper 20 is adhesively fixed to the sole 10 in a state where the second stretchable portion A22 of the second portion A2 provided at the bottom portion 22 is stretched, and is retained in a shape corresponding to the shape of the foot of the target wearer (the main shape-retaining step).

Thereafter, the last L2 is taken out from inside of the upper 20 (the last taking-out step), and thus, the shoe S21 in a larger size than that of the non-customized shoe S0 is completed.

-Advantageous Effects of Second Embodiment-

As described above, in the upper 20 of the second embodiment, similar to the first embodiment, the second portion A2 having a higher stretchability than that of the first portion A1 is provided at the upper bottom portion 22 that is fixed to the sole 10. Moreover, similar to the first embodiment, the second portion A2 includes the first stretchable portion A21 extending in the foot length direction so as to be stretched and contracted in the foot width direction at the upper bottom portion 22. Therefore, also, in the second embodiment, the customized shoes S2 (for example, the shoes each having the same shape as that of a corresponding one of the shoes S11 to S13) of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers shaped of cross sections of which are different and that can give similar fit feelings can be produced from the uppers 20 having the same dimensions by causing the second portion A2 to be stretched in the foot width direction using a plurality of lasts (for example, the lasts L11 to L13) in accordance with shapes of the feet of the individual wearers and shapes of cross sections of which are different.

According to the second embodiment, the second portion A2 includes, at the upper bottom portion 2, not only the first stretchable portion A21 extending in the foot length direction 2 but also the second stretchable portion A22 extending in the foot width direction. Therefore, in the second embodiment, by using the last (for example, the last L2) the size of which is larger than that of the temporary shape retaining last L0, not only the shoes S2 (for example, the shoes each having the same shape as that of a corresponding one of the shoes S11 to S13) shapes of cross sections of which are different, but also the shoes S2 (for example, the shoes 21) the sizes of which are different can be manufactured. Moreover, also, in manufacturing the large-size shoes S2, since the size is increased by causing the second portion A2 (the second stretchable portion A22) of the upper bottom portion 22 that is fixed to the sole 10 to be stretched and the stretched second portion A2 is fixed to the sole 10, the second portion A2 does not return to the original contracted state, and thus, each of the manufactured shoes S2 corresponds to a size of a foot of a corresponding one of the wearers, regardless of whether the shoe S2 is worn or not worn. Therefore, according to the second embodiment, the customized shoes S2 (for example, the shoes 21) of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers sizes of which are different and that can give similar fit feelings can be produced.

Based on the foregoing, according to the second embodiment, the customized shoes S2 (for example, the shoes each having the same shape as that of a corresponding one of the shoes S11 to S13 and the shoes S21) of a plurality of types each of which has a shape corresponding to a corresponding one of feet of a plurality of wearers at least ones of cross-sectional shapes and sizes of which are different and that can give similar fit feelings can be produced.

Note that, in the second embodiment, the shoes S2 each having the same shape as that of a corresponding one of the shoes S11 to S13 the shapes of the cross sections of which are different and the shoes S2 (the shoes S21) each having a larger size than that of the non-customized shoe S0 have been described as examples of the shoe S2 that can be produced from the uppers 20 having the same shape. However, in the second embodiment, the shoes S2 that can be produced using the uppers 20 having the same dimensions are not limited to the shoes S2 each having the same shape as that of a corresponding one of the shoes S11 to S13 and the shoes S21. According to the upper 20 configured as in the second embodiment, the shoe S2 a shape of a cross section of which is different (at least one of a width and an instep of which is different) form that of the non-customized shoe S0 and a size of which is larger than that of the non-customized shoe S0 can be produced. Moreover, similar to the first embodiment, according to the upper 20 configured as in the second embodiment, the customized shoe S2 in various shapes in accordance with foot shapes of individual wearers (shapes of cross sections each extending from a forefoot to a rearfoot), including a customized shoe S2 in which, in the forefoot, an instep is not significantly different but a width is larger, in a midfoot, the width and the instep are larger, and in the rearfoot, the width is not significantly different, or the like, as compared to the non-customized shoe S0, can be produced. Furthermore, according to the upper 20 configured as in the second embodiment, the customized shoe S2 in various shapes in accordance with foot shapes of individual wearers (for example, in which a front end of a second toe is positioned at a fore side of a front end of a first toe, or the like), including a customized shoe S2 in which, in parts around the second or third toe, a size is large, in parts around the first, fourth, and fifth toes, the size is not significantly different, or the like, as compared to the non-customized shoe S0, can be produced.

According to the second embodiment, similar to the first embodiment, the second portion A2 includes the stretchable material (the stretch yarn is woven thereinto), and therefore, the second portion A2 having a higher stretchability than that of the first portion A1 can be easily formed.

Third Embodiment

As illustrated in FIG. 10, a shoe S3 of a third embodiment is obtained by partially changing the configuration of the upper 20 in the shoe S2 of the second embodiment.

Specifically, in the third embodiment, as illustrated in FIG. 10, the second portion A2 provided at the upper bottom portion 22 of the upper 20 is configured to include a third stretchable portion A23, in addition to a first stretchable portion A21 and a second stretchable portion A22 that are similar to those of the second embodiment. Note that in FIG. 10, in order to emphasize the second portion A2, the second portion A2 is hatched with dots.

Similar to the second stretchable portion A22, the third stretchable portion A23 is formed by weaving the stretch yarn as the stretchable material into each of the outer upper 20a and the inner upper 20b. The third stretchable portion A23 extends in the foot width direction at the center of the forefoot F of the upper bottom portion 22 in the foot length direction (the fore-and-rear direction) and is provided to extend from the medial side end to the lateral side end such that the third stretchable portion A23 is stretchable in the foot length direction. Moreover, the third stretchable portion A23 is formed at the upper bottom portion 22 so as to have a certain length (for example, a length of approximately 25 mm) in the fool length direction such that the third stretchable portion A23 can be largely stretched in the foot length direction.

Other components are similar to those of the second embodiment, and therefore, description thereof will be omitted.

Similar effects to those of the second embodiment can be achieved also by the upper 20 of the third embodiment configured as described above. Moreover, according to the upper 20 of the third embodiment, the number of stretchable portions extending in the foot width direction is increased to be larger than that of the second embodiment, so that the upper 20 of the third embodiment can be more easily stretched in the foot length direction than the upper 20 of the second embodiment. Therefore, it is enabled to form the customized shoe S3 in a larger size than that of the shoe S2 of the second embodiment using the upper 20 having the same dimensions.

Fourth Embodiment

As illustrated in FIG. 11, a customized shoe S4 of a fourth embodiment is obtained by partially changing the configuration of the upper 20 in the shoe S2 of the second embodiment.

Specifically, in the fourth embodiment, as illustrated in FIG. 11, the second portion A2 provided at the upper bottom portion 22 of the upper 20 is configured to include a fourth stretchable portion A24, in addition to a first stretchable portion A21 and a second stretchable portion A22 that are similar to those of the second embodiment. Note that, in FIG. 11, in order to emphasize the second portion A2, the second portion A2 is hatched with dots.

The fourth stretchable portion A24 is formed by weaving the stretch yarn as the stretchable material into each of the outer upper 20a and the inner upper 20b, similar to the second elastic section A22. The fourth stretchable portion A24 extends in the foot width direction at the center of the rearfoot H of the upper bottom portion 22 in the foot length direction (fore-to-rear direction) of the upper bottom portion 22 and is provided to extend from the medial end to the lateral end such that the fourth stretchable portion A24 is stretchable in the foot length direction. Moreover, the fourth stretch section A24 is formed at the upper bottom portion 22 so as to have a certain length (for example, a length of approximately 25 mm) in the foot length direction such that the fourth stretchable portion A24 can be largely stretched in the foot length direction.

Other components are similar to those of the second embodiment, and therefore, description thereof will be omitted.

Similar effects to those of the second embodiment can be achieved also by the upper 20 of the fourth embodiment configured as described above. Moreover, according to the upper 20 of the fourth embodiment, the number of stretchable portions extending in the foot width direction is increased to be larger than that of the second embodiment, so that the upper 20 of the fourth embodiment can be more easily stretched in the foot length direction than the upper 20 of the second embodiment. Therefore, it is enabled to form the customized shoe S4 in a larger size than that of the shoe S2 of the second embodiment using the upper 20 having the same dimensions.

Fifth Embodiment

As illustrated in FIG. 12, a customized shoe S5 of a fifth embodiment is obtained by partially changing the configuration of the upper 20 in the shoe S1 of the first embodiment.

Specifically, in the fifth embodiment, as illustrated in FIG. 12, the second portion A2 is provided also in a portion other than the wearing opening part 23 at the upper body 21 of the upper 20. Specifically, as illustrated in FIG. 12, in an instep part of the upper body 21 corresponding to an instep of the foot f of the wearer (see FIG. 2), a fifth stretchable portion A25 that extends in the foot length direction so as to be stretched and contracted mainly in the foot width direction is provided as the second portion A2. Note that, in FIG. 12, in order to emphasize the second portion A2, the second portion A2 is hatched by dots and, in order to draw attention to the upper 20, the sole 10 is not hatched.

The fifth stretchable portion A25 is formed by causing each of the outer upper 20a and the inner upper 20b to include the stretchable material (for example, by weaving the stretch yarn thereinto). Note that, for the fifth stretchable portion A25, a stretchable material having a lower stretchability than that of the stretchable material that is included in the second portion A2 provided at the upper bottom portion 22 is used. By configuring the fifth stretchable portion A25 as described above, when the upper 20 in a temporary shape is placed over a last (for example, the lasts L11 to L13, L2, or the like), the second portion A2 of the upper bottom portion 22 is stretched before the second portion A2 (the fifth stretchable portion A25) of the upper body 21, and thus, the upper 20 can be adhesively fixed to the sole 10 in a state where the second portion A2 at the upper bottom portion 22 is stretched.

Other components are similar to those of the first embodiment. Similar effects to those of the first embodiment can be achieved also by the fifth embodiment.

According to the fifth embodiment, with the second portion A2 provided also at the upper body 21, increase in fit feeling when a wearer wears the customized shoe S5 and performs an action and adjustment of ease of wearing and taking off or the like can be realized.

Sixth Embodiment

As illustrated in FIG. 13, a customized shoe S6 of a sixth embodiment is obtained by partially changing the configuration of the upper 20 in the customized shoe S5 of the fifth embodiment. Note that, in FIG. 13, in order to emphasize the second portion A2, the second portion A2 is hatched by dots and, in order to draw attention to the upper 20, the sole 10 is not hatched.

Specifically, in the sixth embodiment, as illustrated in FIG. 13, the fifth stretchable portion A25 is provided at two positions, that is, a lateral side and a medial side of the instep part of the upper body 21, so as to extend in the foot length direction. For the fifth stretchable portion A25, similar to the fifth embodiment, a stretchable material having a lower stretchability than that of the stretchable material that is included in the second portion A2 provided at the upper bottom portion 22 is used.

Other components are similar to those of the fifth embodiment. Similar effects to those of the customized shoe S5 of the fifth embodiment can be achieved also by the customized shoe S6 of the sixth embodiment.

Seventh Embodiment

As illustrated in FIG. 14, a customized shoe S7 of a seventh embodiment is obtained by partially changing the configuration of the upper 20 in the customized shoe S5 of the fifth embodiment. Note that, also in FIG. 14, in order to emphasize the second portion A2, the second portion A2 is hatched with dots and, in order to draw attention to the upper 20, the sole 10 is not hatched.

Specifically, in the seventh embodiment, as illustrated in FIG. 14, the fifth stretchable portion A25 is provided to extend in the foot length direction at center of the instep part of the upper body 21 in the foot width direction. Similar to the fifth embodiment, the fifth stretchable portion A25 is formed by weaving the stretch yarn as the stretchable material into each of the outer upper 20a and the inner upper 20b, and a stretchable material having a lower stretchability than that of the stretchable material that is included in the second portion A2 provided at the upper bottom portion 22 is used.

Moreover, in the seventh embodiment, a third portion A3 is provided at each of both sides of the fifth stretchable portion A25 (at the lateral side and the medial side) so as to extend in the foot length direction such that the fifth stretchable portion A25 is interposed between the third portions 3A in the foot width direction.

The third portion A3 is configured to be a low-stretchability portion that has some stretchability but the stretchability thereof is lower than that of the fifth stretchable portion A25. In the seventh embodiment, the third portion A3 is a knitted portion, similar to the first portion A1, but is configured as a portion that does not include the low melting point material (the thermal fusing yarn is not woven thereinto), unlike the first portion A1.

Other components are similar to those of the fifth embodiment. Similar effects to those of the customized shoe S5 of the fifth embodiment can be achieved also by the customized shoe S7 of the seventh embodiment.

Moreover, according to the seventh embodiment, with the third portion A3 provided at the upper body 21 such that the fifth stretchable portion A25 is interposed between the third portions A3, fine adjustment of fit feeling in accordance with design, type, intended use, or the like of the customized shoe S7 is enabled.

Eighth Embodiment

As illustrated in FIG. 15, a customized shoe S8 of an eighth embodiment is obtained by partially changing the configuration of the upper 20 in the customized shoe S5 of the fifth embodiment. Note that, also in FIG. 15, in order to emphasize the second portion A2, the second portion A2 is hatched with dots.

Specifically, in the eighth embodiment, as illustrated in FIG. 15, the second portion A2 provided at a portion of the upper body 21 of the upper 20 other than the wearing opening part 23 is configured to include the fifth stretchable portion A25 that is stretched and contracted mainly in the foot width direction and sixth to eighth stretchable portions A26 to A28 each of which is stretched and contracted mainly in the foot length direction. Each of the fifth to eighth stretchable portions A25 to A28 is formed by weaving the stretch yarn as the stretchable material into each of the outer upper 20a and the inner upper 20b, and a stretchable material having a lower stretchability than that of the stretchable material that is included in the second portion A2 provided at the upper bottom portion 22 is used for each of the fifth to eighth stretchable portions A25 to A28.

The fifth stretchable portion A25 is configured similar to that of the fifth embodiment. Specifically, the fifth stretchable portion A25 is provided at the center of the instep part of the upper body 21 corresponding to the instep of the foot f of the wearer (see FIG. 2) so as to extend in the foot length direction.

Each of the sixth to eighth stretchable portions A26 to A28 is provided at both the lateral side and the medial side so as to extend in the foot width direction such that each of the sixth to eighth stretchable portions A26 to A28 is stretchable in the foot length direction. Moreover, each of the sixth to eighth stretchable portions A26 to A28 is formed at the upper body 21 so as to have a certain length (for example, a length of approximately 20 mm) in the foot length direction such that each of the sixth to eighth stretchable portions A26 to A28 can be largely stretched in the foot length direction. The sixth stretchable portion A26 is provided at the forefoot F of the shoe S, the seventh stretchable portion A27 is provided so as to extend from the forefoot F to the midfoot M of the shoe S, and the eighth stretchable portion A28 is provided at the rearfoot H of the shoe S.

Other components are similar to those of the fifth embodiment. Similar effects to those of the customized shoe S5 of the fifth embodiment can be achieved also by the customized shoe S8 of the eighth embodiment.

Moreover, according to the eighth embodiment, not only the fifth stretchable portion A25 configured to extend in the foot length direction such that the fifth stretchable portion A25 is stretched and contracted in the foot width direction at the instep part but also the sixth to eighth stretchable portion A26 to A28 configured to extend in the foot width direction such that each of the sixth to eighth stretchable portion A26 to A28 is stretched and contracted in the foot length direction are provided at the instep at the upper body 21. Therefore, in the eighth embodiment, when the wearer wears the customized shoe S8 and performs an action, the upper 20 conforms to the foot f both in the foot length direction and in the foot width direction, and delicate adjustment of fit feeling in accordance with design, type, intended use, or the like of the customized shoe S8 is enabled. Note that, even when not all of the sixth to eighth stretchable portions A26 to A28 are provided and at least one of the sixth to eighth stretchable portions A26 to A28 is provided, similar effects to those of the eighth embodiment described above can be achieved, although there is a different in degree of effect.

Other Embodiments

In the first to eighth embodiments described above, the upper body 21 and the upper bottom portion 22 of the upper 20 are integrally formed by knitting but, as described above, the upper 20 may be formed of, for example, a woven fabric, a non-woven fabric, a mesh material, a synthetic leather, an artificial leather, a natural leather, a rubber, a resin sheet, or the like, in addition to the knitted material. Moreover, the upper body 21 and the upper bottom portion 22 may be separately formed and joined by sewing, bonding, fusing, or the like to form a pouch-like structure.

In the first to eighth embodiments described above, the upper 20 is configured to include the outer upper 20a and the inner upper 20b, but the upper 20 may be also formed of a single pouch-like member.

In the first to eighth embodiments described above, the second portion A2 having a higher stretchability than that of the first portion A1 is formed by weaving the stretch yarn, but a method for forming the second portion A2 is not limited thereto. The second portion A2 may be formed of a rubber made by a natural rubber or a synthetic rubber, or a polyurethane-based, polyester-based, or polyolefin-based elastic material itself, and may be formed to include a rubber or an elastic material so as to have a stretchability.

In the first to eighth embodiments described above, the first portion A1 is formed by weaving the thermally fusing yarn thereinto, but a method of forming the first portion A1 is not limited thereto. The first portion A1 may be formed of the low melting point material, such as nylon or the like, a melting point of which is relatively low itself, or may be coated with the low melting point material and hardened by heating and cooling the first portion A1 to cause the low melting point material to be melted and solidified. Alternatively, the first portion A1 may be formed of a material that is not stretched and contracted or by fixing (bonding, fusing, sawing, or the like) a material that is not stretched and contracted thereto without using the low melting point material so to be a non-stretchable portion.

In the first to eighth embodiments described above, in addition to the wearing opening part 23, the second portion A2 (the fifth stretchable portion A25) is provided at the upper body 21 of the upper 20 and a stretchable material having a lower stretchability than that of the stretchable material included in the second portion A2 provided at the upper bottom portion 22 is used for the fifth stretchable portion A25, but in the fifth to eighth embodiments, a stretchable material having a stretchability equal to or higher than that of the stretchable material included in the second portion A2 provided at the 22 up may be used for the fifth stretchable portion A25. In that case, in performing the deforming step and the main shape-retaining step, stretch preventing processing of temporarily regulating stretch of the second portion A2 (the fifth stretchable portion A25) of the upper body 21 such that the second portion A2 of the upper bottom portion 22 is stretched before the second portion A2 of the upper body 21 may be performed. As the stretch preventing processing, for example, in a case where eyelets are formed and the fifth stretchable portion A25 is positioned between the eyelets, the fifth stretchable portion A25 may be prevented from being stretched in the foot width direction and thus increasing a distance between the eyelets in the deforming step and the main shape-retaining step by passing a shoelace through the eyelets and then fastening the shoelace before performing the deforming step. Alternatively, it may be prevented the fifth stretchable portion A25 may be prevented from being stretched in the foot width direction in the deforming step and the main shape-retaining step by temporarily attaching a member, such as a tape of the like, that does not have a stretchability to the second portion A2 (the fifth stretchable portion A25) of the upper body 21 before performing the deforming step.

In the fifth embodiment, an example (the shoe S5) where, in the shoe S1 of the first embodiment, in addition to the wearing opening part 23 of the upper body 21, the second portion A2 is provided has been described, and in the sixth to eighth embodiments, variations (the shoes S6 to S8) of the shoe S5 of the fifth embodiment have been described. Similar to the shoes S1 and S6 to S8, in the shoes S2 to S4 of the second to fourth embodiments, similar to the fifth embodiment, in addition to the wearing opening part 23 of the upper body 21, the second portion A2 may be provided, and the second portion A2 may be deformed similar to the sixth to eighth embodiments.

INDUSTRIAL APPLICABILITY

As described above, the present disclosure is useful for uppers and shoes.

DESCRIPTION OF REFERENCE CHARACTERS

• • 10 Sole
  • 20 Upper
  • 21 Upper Body
  • 22 Upper Bottom Portion
  • A1 First Portion
  • A2 Second Portion
  • S1 to S8 Customized Shoes (Shoes)