An integrally formed 3D flyknit upper and method of production thereof

Abstract

The application provides a one-piece 3D flyknit vamp, which comprises a 3D flyknit vamp, the 3D flyknit vamp is integrally formed by cooperation of a flat knitting machine, a middle section material preparation mechanism and a rear section laser cutting mechanism, the flat knitting machine is used for knitting a semi-finished 3D flyknit vamp, first and second material clamping mechanisms are horizontally arranged at the lower end of the flat knitting machine, and the flat knitting machine, the first and second material clamping mechanisms, a contact sensor, the middle section material preparation mechanism, the rear section laser cutting mechanism and a control box are combined to form a one-piece equipment for producing roll-shaped knitted materials for 3D flyknit vamp, the equipment has the functions of continuous knitting, material moving and preparation, image scanning and laser, edge material winding and automatic material taking and storing, and has practical significance and popularization value, and can generate good economic benefits.

Description

Technical Field

[0001] This invention relates to a one-piece molded 3D flyknit shoe upper and its production method, belonging to the field of one-piece molding equipment for manufacturing 3D flyknit shoe uppers. Background Technology

[0002] With social development and the accelerated pace of life, people have higher and higher requirements for the comfort and convenience of shoes. Of course, with the continuous innovation of technology, there are more and more varieties of shoes, and 3D flyknit uppers are one of them.

[0003] However, existing 3D flyknit uppers generally involve first weaving semi-finished 3D flyknit upper pieces using a knitting machine, and then cutting them manually with a cutting machine or using a laser cutting machine. These methods are cumbersome, time-consuming, labor-intensive, and have low production efficiency. Furthermore, the weaving method for semi-finished 3D flyknit upper pieces requires a larger reserved area for the scraps, which also reduces the weaving efficiency of the knitting machine and increases production costs. Therefore, this invention proposes an integrated 3D flyknit upper and its production method to solve the above problems. Solving these problems will have a positive impact on promoting the technological development in this field. Summary of the Invention

[0004] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a one-piece molded 3D flyknit shoe upper and its production method to solve the existing problems.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution: a one-piece molded 3D flyknit upper, the structure of which includes a 3D flyknit upper, wherein the 3D flyknit upper is woven and cut in one piece by a horizontal knitting machine, a mid-section material preparation mechanism and a rear-section laser cutting mechanism working together. The horizontal knitting machine weaves and forms a semi-finished 3D flyknit upper. A first clamping mechanism and a second clamping mechanism are horizontally aligned on both sides of the lower end of the horizontal knitting machine. A contact sensor is also included, located on the lower right side of the first clamping mechanism. A control box is provided on the mid-section material preparation machine. A plurality of material boxes are placed on one side of the rear-section laser cutting mechanism. The horizontal knitting machine, the contact sensor, the mid-section material preparation mechanism and the rear-section laser cutting mechanism are electrically connected to the control box.

[0006] A further improvement is that the lower end of the knitting machine is provided with a material gathering chamber, and also includes a feed inlet on one side of the top surface of the material gathering chamber, a first material loading port and a third material loading port on the left and right sides of the material gathering chamber, and a plurality of second material loading ports are provided at the front and rear ends of the material gathering chamber.

[0007] A further improvement is that the first clamping mechanism includes a clamping bracket, a movable roller movably disposed at the lower end of the clamping bracket, a plurality of springs disposed on the bottom surfaces of both sides of the movable roller, and a plurality of lifting slide rods, the lower ends of each of the lifting slide rods passing through the clamping bracket and extending outside the clamping bracket. A fixed roller is disposed above the movable roller. The first clamping mechanism has the same structure as the second clamping mechanism.

[0008] A further improvement is that the intermediate material preparation mechanism includes a material preparation bracket, a feeding roller and a driven adjusting roller group located at the upper right end of the material preparation bracket, a drive motor connected to one end of the feeding roller, a material preparation roller frame group located in the middle of the material preparation bracket, and a support roller located at the upper left end of the material preparation bracket.

[0009] A further improvement is that the driven adjusting roller assembly is composed of a lifting adjusting screw, a driven roller frame, a driven roller, and a plurality of stabilizing rods.

[0010] A further improvement is that the rear laser cutting mechanism includes a laser cutting bracket, an image scanning laser machine located at the upper end of the laser cutting bracket, a laser conveyor belt located below the image scanning laser machine, an operating table located at the front side of the laser cutting bracket, an edge material winding machine located at the left end of the laser cutting bracket, a first support roller located below the left side of the edge material winding machine, a shoe upper material picking component located in close contact with the left side of the bottom surface of the laser conveyor belt, a sliding plate located below the shoe upper material picking component, and a material box frame located below the left side of the sliding plate. The image scanning laser machine, the laser conveyor belt, and the edge material winding machine are electrically connected to the operating table.

[0011] A further improvement is that the material preparation roller frame assembly has an arc-shaped structure, and the material preparation roller frame assembly consists of a roller frame and a plurality of rollers.

[0012] A further improvement is that the image scanning laser machine has a lateral and longitudinal coordinating shift image scanning function, as well as a lateral and longitudinal coordinating shift laser cutting function.

[0013] A further improvement is that the conveyor belt inside the laser conveyor belt needs to be coated with self-adhesive adhesive in advance.

[0014] A further improvement is that the upper material taking component consists of an installation frame and a scraper plate, the scraper plate being made of plastic.

[0015] Furthermore, this invention also provides a method for producing the aforementioned one-piece molded 3D flyknit upper: the production steps are as follows: S1: First, place the various yarns required for weaving the 3D flyknit upper on the yarn racks of the horizontal knitting machine; then thread the yarns sequentially through the triangular knitting heads on the horizontal knitting machine, and then horizontally knit the semi-finished 3D flyknit upper through the triangular knitting heads. The woven semi-finished 3D flyknit upper continues to enter the material gathering chamber from the feed inlet. Then, the worker uses the four material loading ports on the material gathering chamber to pass one end of the semi-finished 3D flyknit upper material through the first clamping mechanism and the second clamping mechanism in sequence; and continues to load the material through the middle material preparation mechanism. Finally, the material is bonded with adhesive on the right side of the laser conveyor belt on the rear laser cutting mechanism, completing the weaving and loading of the initial semi-finished 3D flyknit upper material.

[0016] S2: When the semi-finished 3D flyknit upper being woven by the triangular knitting head gathers and touches the contact sensor, the control box controls the drive motor on the middle material preparation mechanism to rotate servo and drive the feeding roller to rotate and feed the semi-finished 3D flyknit upper to the material preparation roller frame. During this process, the driven adjustment roller group will roll accordingly, while the first clamping mechanism and the second clamping mechanism ensure that the material is transported smoothly and prevent folding or folding during the material transport process.

[0017] S3: Only after the intermediate material preparation mechanism performs one intermediate material preparation can the laser conveyor belt on the rear laser cutting mechanism perform servo conveying of a section of material to the top surface of the conveyor belt. Then, the image scanning laser machine is operated on the operating table to perform image scanning and positioning of the section of material on the top surface of the conveyor belt, and then the material after scanning and positioning is laser-cut to separate the 3D flyknit shoe upper.

[0018] S4: Then, when the semi-finished 3D flyknit upper on the laser conveyor belt is separated into edge material and 3D flyknit upper, the edge material is servo-wound through the first support roller and edge material winding machine. Because the laser conveyor belt is coated with self-adhesive, each 3D flyknit upper will be transported to the bottom of the conveyor belt after separation. When it reaches the upper picking part, it will be scraped off and slide down from the sliding plate into each of the material boxes in sequence, completing the one-piece molding operation of the 3D flyknit upper.

[0019] The beneficial effects of this invention are: This invention provides a one-piece molded 3D flyknit shoe upper. Through a structural combination design of a horizontal knitting machine, a first clamping mechanism, a second clamping mechanism, a contact sensor, a mid-section material preparation mechanism, a rear-section laser cutting mechanism, and a control box, it constitutes an one-piece molding device for producing roll-shaped woven materials for 3D flyknit shoe uppers. This device features continuous weaving, material transfer and preparation, image conveying and laser functions, edge material winding, and automatic material handling and storage. It provides continuous, uninterrupted weaving, thus significantly improving production efficiency. It eliminates the need for multiple pre-reserved ends, reducing ineffective weaving and further enhancing production efficiency. It also prevents yarn waste, significantly reducing production costs. Furthermore, it eliminates the need for complex subsequent cutting and material handling operations, saving time and effort. Through the more rational structural design and combined production method of this invention, 3D flyknit shoe uppers can be produced in one piece, with simple operation, high production efficiency, and low cost. It has practical significance and promotional value, and is expected to generate good economic benefits. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the equipment used to manufacture the 3D flyknit upper of this invention; Figure 2 This is a schematic diagram of the structure of the flat knitting machine of the present invention; Figure 3 This is a schematic diagram of the first clamping mechanism of the present invention; Figure 4 This is a schematic diagram of the material preparation mechanism in the middle section of the present invention; Figure 5 This is a schematic diagram of the laser cutting mechanism in the latter part of the present invention.

[0021] Figure 6 This is an enlarged schematic diagram of part A of the present invention; Figure 7 This is a schematic diagram of the semi-finished 3D flyknit shoe upper of the present invention. Implementation

[0022] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0023] Please see Figures 1-7This invention provides a schematic diagram of a one-piece molded 3D flyknit shoe upper: its structure includes a 3D flyknit shoe upper, which is woven and cut in one piece by a horizontal knitting machine 1, a mid-section material preparation mechanism 5, and a rear-section laser cutting mechanism 6. The horizontal knitting machine 1 weaves and forms a semi-finished 3D flyknit shoe upper 9. A first clamping mechanism 2 and a second clamping mechanism 3 are horizontally aligned on both sides of the lower end of the horizontal knitting machine 1. It also includes a contact sensor 4 located on the lower right side of the first clamping mechanism 3. A control box 7 is provided on the mid-section material preparation machine. A plurality of material boxes 8 are placed on one side of the rear-section laser cutting mechanism 6. The horizontal knitting machine 1, the contact sensor 4, and the mid-section material preparation mechanism 6 are all integrated into the overall structure. Mechanism 5 and the rear laser cutting mechanism 6 are electrically connected to the control box 7. The lower end of the horizontal knitting machine 1 is provided with a material gathering chamber 11, and also includes a feed inlet 12 provided on one side of the top surface of the material gathering chamber 11, a first material loading port 13 and a third material loading port 15 provided on the left and right sides of the material gathering chamber 11. The front and rear ends of the material gathering chamber 11 are provided with a plurality of second material loading ports 14. The first clamping mechanism 2 includes a clamping bracket 21, a movable roller 22 movably provided at the lower end of the clamping bracket 21, a plurality of springs 23 provided on the bottom surfaces of both sides of the movable roller 22, and a plurality of lifting slide rods 24. The lower end of each of the lifting slide rods 24 passes through the clamping bracket 21 and extends to the clamping bracket. Outside the frame 21, a fixed roller 25 is provided above the movable roller 22. The first clamping mechanism 2 and the second clamping mechanism 3 have the same structure. The middle section material preparation mechanism 5 includes a material preparation bracket 51, a feeding roller 52 located at the upper right end of the material preparation bracket 51, a driven adjusting roller group 53, a drive motor 54 connected to one end of the feeding roller 52, a material preparation roller frame group 55 located in the middle of the material preparation bracket 51, and a support roller 56 located at the upper left end of the material preparation bracket 51. The driven adjusting roller group 53 is composed of a lifting adjusting screw 531, a driven roller frame 532, a driven roller 533, and a plurality of stabilizing rods 534. The rear section laser cutting mechanism 6 includes a laser cutting... The laser cutting support 61, the image scanning laser machine 62 located at the upper end of the laser cutting support 61, the laser conveyor belt 63 located below the image scanning laser machine 62, the operating table 64 located at the front side of the laser cutting support 61, the edge material winding machine 65 located at the left end of the laser cutting support 61, the first support roller 66 located below the left side of the edge material winding machine 65, the shoe upper material picking component 67 located with gaps on the left side of the bottom surface of the laser conveyor belt 63, the sliding plate 68 located below the shoe upper material picking component 67, and the material box frame 69 located below the left side of the sliding plate 68 are all electrically connected to the operating table 64.

[0024] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects. The scope of the invention is defined by the appended claims rather than the foregoing description, and thus all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0025] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A method for producing a one-piece molded 3D flyknit shoe upper, the structure of which includes a 3D flyknit shoe upper, characterized in that: The 3D flyknit upper is formed by the cooperation of a horizontal knitting machine (1), a middle material preparation mechanism (5) and a rear laser cutting mechanism (6). The horizontal knitting machine (1) knits and forms a semi-finished 3D flyknit upper (9). The horizontal knitting machine (1) has a first clamping mechanism (2) and a second clamping mechanism (3) horizontally aligned on both sides of its lower end. It also includes a contact sensor (4) located on the lower right side of the first clamping mechanism (2). The middle material preparation machine is equipped with a control box (7). The rear laser cutting mechanism (6) has multiple material boxes (8) on one side. The horizontal knitting machine (1), the contact sensor (4), the middle material preparation mechanism (5) and the rear laser cutting mechanism (6) are electrically connected to the control box (7). The lower end of the horizontal knitting machine (1) is provided with a material gathering chamber (11), and also includes a feed inlet (12) provided on one side of the top surface of the material gathering chamber (11), a first material loading port (13) and a third material loading port (15) provided on the left and right sides of the material gathering chamber (11), and a plurality of second material loading ports (14) provided at the front and rear ends of the material gathering chamber (11). The first clamping mechanism (2) includes a clamping bracket (21), a movable roller (22) movably disposed at the lower end of the clamping bracket (21), a plurality of springs (23) disposed on the bottom surfaces of both sides of the movable roller (22), and a plurality of lifting slide rods (24). The lower ends of each lifting slide rod (24) pass through the clamping bracket (21) and extend to the outside of the clamping bracket (21). A fixed roller (25) is disposed above the movable roller (22). The first clamping mechanism (2) has the same structure as the second clamping mechanism (3). The middle section material preparation mechanism (5) includes a material preparation bracket (51), a feeding roller (52) located at the upper right side of the material preparation bracket (51), a driven adjustment roller group (53), a drive motor (54) connected to one end of the feeding roller (52), a material preparation roller frame group (55) located in the middle of the material preparation bracket (51), and a support roller (56) located at the upper left side of the material preparation bracket (51). The driven adjusting roller group (53) is composed of a lifting adjusting screw (531), a driven roller frame (532), a driven roller (533), and a plurality of stabilizing rods (534); The rear laser cutting mechanism (6) includes a laser cutting bracket (61), an image scanning laser machine (62) set at the upper end of the laser cutting bracket (61), a laser conveyor belt (63) set below the image scanning laser machine (62), an operating table (64) set at the front side of the laser cutting bracket (61), an edge material winding machine (65) set at the left end of the laser cutting bracket (61), a first support roller (66) set below the left side of the edge material winding machine (65), a shoe upper material picking component (67) set with gaps on the left side of the bottom surface of the laser conveyor belt (63), a sliding plate (68) set below the shoe upper material picking component (67), and a material box frame (69) set below the left side of the sliding plate (68). The image scanning laser machine (62), the laser conveyor belt (63), and the edge material winding machine (65) are electrically connected to the operating table (64). The production steps also include the following: S1: First, place the various yarns required for weaving the 3D flyknit upper at the yarn racks on the horizontal knitting machine (1); and thread the yarns sequentially through the triangular knitting head on the horizontal knitting machine (1), and then weave the semi-finished 3D flyknit upper (9) through the triangular knitting head. The woven semi-finished 3D flyknit upper (9) continues to enter the material gathering chamber (11) from the feed inlet (12). Then, the workers pass one end of the semi-finished 3D flyknit upper (9) material through the four material loading ports on the material gathering chamber (11) sequentially through the first clamping mechanism (2) and the second clamping mechanism (3); and continue to load the material through the middle section material preparation mechanism (5). Finally, perform self-adhesive bonding on the right side of the laser conveyor belt (63) on the rear section laser cutting mechanism (6) to complete the weaving and loading operation of the initial semi-finished 3D flyknit upper (9) material. S2: When the semi-finished 3D flyknit upper (9) woven by the triangular knitting head gathers and touches the contact sensor (4), the control box (7) controls the drive motor (54) on the middle material preparation mechanism (5) to perform servo rotation to drive the feeding roller (52) to rotate and feed the semi-finished 3D flyknit upper (9) to the material preparation roller frame group (55). During this process, the driven adjustment roller group (53) will roll along with it, while the first clamping mechanism (2) and the second clamping mechanism (3) play a role in ensuring the smooth transport of materials and preventing folding and folding during the material transport process. S3: Only after the intermediate material preparation mechanism (5) performs intermediate material preparation once can the laser conveyor belt (63) on the rear laser cutting mechanism (6) perform servo conveying of a section of material to the top surface of the conveyor belt. Then, the image scanning laser machine (62) on the operating table (64) is operated to perform image scanning and positioning of the section of material on the top surface of the conveyor belt, and then the material after scanning and positioning is laser-cut to separate the 3D flyknit shoe upper. S4: Then, when the semi-finished 3D flyknit upper (9) on the laser conveyor belt (63) is separated into edge material and 3D flyknit upper, the edge material is servo-wound through the first support roller (66) and edge material winding machine (65). Because the laser conveyor belt (63) is coated with self-adhesive, each 3D flyknit upper will be conveyed to the bottom of the conveyor belt after separation. When it reaches the upper picking part (67), it will be scraped off and slide down from the sliding plate (68) into each material box (8) in sequence, completing the one-piece molding operation of the 3D flyknit upper.

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