Last for Use in Making Cycling Shoes, Last and Cycling Shoe Sole, and a Method for Making Shoes Using a Last

1. FIELD OF THE INVENTION

This invention relates to lasts for use in making cycling shoes, lasts and cycling shoe soles, and a method of making shoes using the last.

2. DESCRIPTION OF THE RELATED ART

A conventional last for use in making cycling shoes has a flat, sole supporting surface, and includes no device for setting the sole in position. In making a cycling shoe, a shoe sole is simply placed on the sole supporting surface, a quarter of the shoe is placed around the last, and the sole and quarter are joined.

With the above conventional last, however, the shoe sole placed on the sole supporting surface of the last would easily become displaced relative to this surface, making it difficult to join the sole and quarter of the shoe in an accurate positional relationship. Since the positional relationship between the foot that wears the shoe and a cleat mounting bore is determined mainly by the quarter of the shoe, the relationship between the foot and the cleat attached to the mounting bore becomes inappropriate, and hence a sufficient pedaling force cannot be transmitted from the cyclist's leg to a bicycle pedal. Even where the mounting bore allows positional adjustment of the cleat, only a narrow range of adjustment is available since the center of the mounting bore does not coincide with the center of the range of adjustment. Furthermore, certain parts of the shoe interior become larger and other parts smaller than design specifications. As a result, the foot is unduly squeezed to impair circulation of the blood or insufficiently braced by the shoe to create play inside, which could result in shoe sores and the like.

An object of the present invention is to provide a last for use in making cycling shoes, a last and cycling shoe sole, and a method of making shoes using the last, in which the sole and quarter of the shoe are joined in an accurate positional relationship.

The above object is fulfilled, according to the present invention, by a last for making cycling shoes, which includes a sole supporting surface opposed to a sole of a cycling shoe, and position setting projections formed on the sole supporting surface for engaging a mounting bore defined in the sole for attaching a cleat or a shoe plate, to set position of the sole relative to the sole supporting surface.

A method of manufacturing cycling shoes according to the present invention uses the above shoemaking last. This method includes the steps of placing the shoe sole on the sole supporting surface with the position setting projections engaging the mounting bore to set position of the sole relative to the sole supporting surface; placing a quarter of the shoe around the shoemaking last; and connecting the sole and the quarter.

In the last for making cycling shoes according to the present invention, the sole supporting surface includes position setting projections for engaging the mounting bore defined in the sole for attaching a cleat or a shoe plate, to set position of the sole relative to the sole supporting surface. With the position setting projections engaging the mounting bore, the shoe sole may be placed on the sole supporting surface in an appropriate positional relationship.

In the method of making cycling shoes according to the present invention, the shoe sole placed in position on the sole supporting surface as above is connected to the quarter of the shoe placed around the last. Consequently, the sole and quarter of the shoe are joined in an accurate positional relationship. This positional relationship is determined by the engagement between the position setting projections and the mounting bore for attaching a cleat or shoe plate. The positional relationship therefore is particularly accurate in the vicinity of the mounting bore.

Since the shoe sole and quarter are joined together in an accurate positional relationship according to the present invention, the cleat attached to the mounting bore and the foot wearing the shoe are in an appropriate positional relationship as designed, to transmit a sufficient pedaling force without loss from the cyclist's leg to a pedal. Where the mounting bore allows positional adjustment of the cleat, the center of the mounting bore coincides with the center of adjusting range to enable full use of the adjusting range. Moreover, since the shoe interior is formed to have dimensions as designed, the cyclist's foot is not excessively tightened while being held securely in the shoe, to prevent shoe sores.

Other objects, features and advantages of the present invention will be apparent from the following description of preferred embodiments.

The drawings show a last for use in making cycling shoes, a last and cycling shoe sole, and a method of making shoes using a last according to the present invention, in which:

FIG. 1 is an exploded perspective view showing a relationship between a last and shoe sole.

FIG. 2 is a view in vertical section showing a way in which an insole is placed on the last after a hanging process,

FIG. 3 is a view in vertical section showing a way in which an outsole is placed on the last.

FIG. 4 is a an exploded perspective view showing a relationship between a cleat and the shoe sole.

FIG. 5 is a view in vertical section showing the cleat mounted in position, and

FIG. 6 is a perspective view of an entire shoe.

An embodiment of the present invention will be described with reference to the drawings.

As shown in FIG. 6, a cycling shoe 1 includes a quarter 2 and a sole 3.

The quarter 2 includes an opening 2a for inserting a foot into the shoe 1, a cutout 2b disposed in an instep of the shoe 1 for enlarging the opening 2a, a flap 2c overlying the cutout 2b to prevent entry of sand or the like, and two straps 2d of the felt fastener type for pressing on the flap 2c from top tighten the instep of the foot.

As shown in FIGS. 4 and 5, the sole 3 includes an outsole 4 formed of an elastic material such as rubber or an elastic resin, an insole 6 formed of a hard resin and bonded to an upper surface of the outsole 4 for attaching a cleat 5, and a platform 7 laid over an upper surface of the insole 6. The insole 6 defines first and second slots 10 and 11 in a region thereof opposed to and forwardly of the arch of the foot. These slots 10 and 11 extend substantially parallel each other longitudinally of the shoe 1, and are used to attach the cleat 5 with bolts 8 and nuts 9 as shown in FIG. 5. Further, as shown in FIG. 3, the outsole, 4 includes a groove 4a defined in a lower surface thereof and surrounding a tear-off portion 4b opposed to the slots 10 and 11. The tear-off portion 4b includes, in appropriate positions on an upper surface thereof, two outsole position setting projections 12 for engaging fore and aft ends of the first slot 10.

As shown in FIG. 1, a last 13 for use in making cycling shoes according to the present invention includes a sole supporting surface 13a having a shape substantially corresponding to the insole 6, and a quarter supporting surface 13b for tight contact with inside surfaces of the quarter 2 of the shoe. The sole supporting surface 13a includes two insole position setting projections 14 for engaging fore and aft ends of the second slots 11. The two projections in each pair of the position setting projections 12 or 14 have peripheral walls facing away from each other shaped to correspond substantially to the opposite ends of the slot 10 or 11. The last 13 is formed of a resin such as nylon, and the position setting projections 14 may be formed integrally with or separately from the last

A method of manufacturing the foregoing cycling shoe using the last 13 will be described next with reference to FIGS. 1 through 3.

(a) What is known as a hanging process is carried out with the quarter 2 of the shoe placed around and in tight contact with the quarter supporting surface 13b of the last 13.

(b) As shown in FIG. 2, the insole 6 is placed in position on the sole supporting surface 13a with the position setting projections 14 fitted in the second slot 11.

(c) As shown in FIG. 3, the outsole 4 is placed in position on the insole 6, with ends of the quarter 2 folded over side edges of the insole 6 and position setting projections 12 fitted in the first slot 10. An adhesive is applied beforehand to the insole 6, outsole 4 and quarter 2 to bond these components together. However, the tear-off portion 4b and insole 6 are not allowed to bond together.

(d) The sole 3 is held tight by clamping dies while allowing the adhesive to cure.

(e) The platform is laid on the upper surface of the insole 6, and other accessories are attached to complete the shoe.

According to the above manufacturing method, the two outsole position setting projections 12 and two insole position setting projections 14 engage the fore and aft ends of the first and second slots 10 and 11, respectively. Consequently, the sole supporting surface 13a of the last 13, outsole 4 and insole 6 may be connected together in an accurate positional relationship not only in the longitudinal and transverse directions but with respect to crossing angles thereof.

For attaching the cleat 5 to the shoe sole 3 using the two slots 10 and 11, the tear-off portion 4b is cut along the groove 4a, and then the cleat is secured to the insole 6 with the bolts 8 and nuts 9 as shown in FIG. 5.

Other embodiments of the present invention are set out hereunder.

I. In the foregoing embodiment, the insole 6 is placed on the last 13 after the quarter 2 is placed around the last 13. Instead, the insole 6 may be placed on the last 13 before the quarter 2 is placed around the last 13. The insole 6 and outsole 4 may be bonded together before placement on the last 13.

II. In the foregoing embodiment, the insole 6 is formed of a hard material, and the slots 10 and 11 for attaching the cleat 5 are formed in the insole 6. It is possible to form the outsole 4 of a hard material and to form the slots 10 and 11 in the outsole 4. In this case, an insole formed of a soft material may be bonded to the upper surface of the outsole after the outsole and quarter 2 are connected together using the last 13 as in the foregoing embodiment.

III. In the foregoing embodiment, the two outsole position setting projections 12 and two insole position setting projections 14 are provided to engage the fore and aft ends of the first and second slots 10 and 11, respectively. It is possible to provide one projection to engage the entirety of each of the first and second slots 10 and 11.

IV. In the foregoing embodiment, the sole 3 and quarter 2 of the shoe are bonded together with an adhesive. However, these components may be stitched together.

V. The foregoing embodiment includes the slots for attaching the cleat 5. Round bores may be provided instead of the slots. Further, the two position setting projections 12 and two position setting projections 14 are provided to define non-circular parts substantially corresponding in shape to the mounting bores or slots 10 and 11 in plan view of the sole supporting surface 13a of the last 13. This assures an accurate positional relationship among the sole supporting surface 13a, outsole 4 and insole 6 with respect to crossing angles as well. Accurate crossing angles may be secured also by a crosswise arrangement in plan view of the position setting projections 12 and 14 and slots 10 and 11, for example.

VI. In the foregoing embodiment, the cleat 5 is attached to the sole 3. Alternatively, a shoe plate may be attached as in a road racer shoe.

VII. In the foregoing embodiment, the position setting projections 12 and 14 have a cylindrical shape. These projections may have a tapered shape diverging toward proximal ends thereof.