Sole Structure for a Shoe and Method for Manufacturing the Same

Abstract

A sole structure includes a sole body. The sole body is a resin-made box-shaped member with a predetermined thickness and an interior space that is defined by an upper wall portion disposed on an upper side, a lower wall portion disposed on a lower side and spaced apart from the upper wall portion, and a pair of sidewall portions disposed between and interconnecting the upper wall portion and the lower wall portion in a heel region or a forefoot region that respectively corresponds to a heel portion or a forefoot portion of a foot of a shoe wearer. The sidewall portions are elastically deformable in a vertical direction and have a plurality of solid or hollow ribs that extend in a substantially vertical direction between the upper wall portion and the lower wall portion.

What is claimed is: 
     
         1 . A sole structure for a shoe having a heel region or a forefoot region that is adapted to respectively correspond to a heel portion or a forefoot portion of a foot of a wearer, at least in said heel region or said forefoot region, said sole structure comprising:
 an upper wall portion disposed on an upper side;   a lower wall portion disposed on a lower side and spaced apart from said upper wall portion; and   a pair of sidewall portions disposed between and interconnecting said upper wall portion and said lower wall portion,   wherein said upper wall portion, said lower wall portion, and said sidewall portions form a resin-made box-shaped member with a predetermined thickness and having an interior space formed therein,   wherein said sidewall portions are elastically deformable in a vertical direction and have a plurality of solid or hollow protrusions that extend continuously in a substantially vertical direction between said upper wall portion and said lower wall portion.   
     
     
         2 . The sole structure according to  claim 1 , wherein said sidewall portions have a round shape that protrudes sideways between said upper wall portion and said lower wall portion. 
     
     
         3 . The sole structure according to  claim 1 , wherein said protrusions are provided on a medial side and a lateral side of said sidewall portions in said heel region or in a ball-of-the-foot part of said forefoot region. 
     
     
         4 . The sole structure according to  claim 1 , wherein said protrusions are disposed along an entire perimeter of said sidewall portions in said heel region or said forefoot region. 
     
     
         5 . The sole structure according to  claim 1 , wherein said protrusions extend to a lower surface of said lower wall portion and a bottom surface of said protrusions forms a ground contact surface along with said lower surface of said lower wall portions. 
     
     
         6 . The sole structure according to  claim 1 , wherein said lower wall portion includes a tapered part or a round part that extends gradually upwardly toward said sidewall portions in said heel region or medial and lateral sides of said forefoot region. 
     
     
         7 . The sole structure according to  claim 1 , wherein said sidewall portions have a heel counter portion that extend upwardly above an upper surface of said upper wall portion in said heel region and that are disposed along a circumference of said heel region. 
     
     
         8 . The sole structure according to  claim 7 , wherein said heel counter portion includes a plurality of solid or hollow protrusions that extend continuously in a substantially vertical direction. 
     
     
         9 . The sole structure according to  claim 1 , wherein said sole structure includes a vent hole in connection with said interior space. 
     
     
         10 . The sole structure according to  claim 9 , wherein there are provided two or more vent holes and each of said vent holes pierces through either one or more wall portions of said upper wall portion, said lower wall portion and said sidewall portion. 
     
     
         11 . The sole structure according to  claim 9 , wherein said vent hole is in connection with said interior space through said hollow protrusion. 
     
     
         12 . The sole structure according to  claim 11 , wherein said hollow protrusion is opened at an upper end. 
     
     
         13 . The sole structure according to  claim 1 , wherein a three-dimensional elastic fiber structure formed of resin fibers is disposed in said interior space. 
     
     
         14 . The sole structure according to  claim 13 , wherein said three-dimensional elastic fiber structure along with said upper and lower wall portions and said sidewall portions is formed by additive manufacturing. 
     
     
         15 . The sole structure according to  claim 14 , wherein said additive manufacturing is a fused deposition modeling. 
     
     
         16 . A method for manufacturing a sole structure for a shoe according to  claim 1  comprising:
 a wearer data acquisition process for acquiring foot data of at least said heel portion or said forefoot portion of said foot of said shoe wearer and personal data including weight of said shoe wearer; 
 a sole designing process for designing a thickness of said upper and lower wall portions and said sidewall portions, a shape of said box-shaped member, a size, structure and array pitch of said protrusions, and a three-dimensional elastic fiber structure, based on the foot data and personal data acquired in said wearer data acquisition process; and 
 a forming process for forming by additive manufacturing said box-shape member and said three-dimensional elastic fiber structure designed in said sole designing process.