3D Knitted Shoe Blank Using Double-Bed Flat Knitting
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Solution Overview
Problem
Conventional shoe-making processes involve complex assembly of multiple pieces, leading to inefficient production and inadequate protection for the plantar area, as two-dimensional knitted shoe blanks require tedious seaming and lack coverage for the heel and lateral sides.
Innovation Solution
A three-dimensional shoe blank is created using a double-bed flat knitting machine, featuring an integral knit fabric without sewn portions, with a structure that includes a double-knitted upper portion, connected front and rear sole portions, and a heel portion, forming a pocket-like design for enhanced strength and coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two-needle-bed flat knitting machines are used to knit shoe blanks, then the manufacturing process is simple, but the shoe blanks are two-dimensional and require tedious seaming to form three-dimensional shapes
Solution Approach 1:
The patent merges the upper portion and sole portion into a single integral knitted structure using a double-needle-bed knitting machine. The first yarn forms the upper portion while the second yarn forms the sole portion, and both are knitted simultaneously in the same machine bed to create a unified three-dimensional shoe blank without requiring separate seaming operations.
Solution Approach 2:
The patent transitions from two-dimensional flat knitting to three-dimensional integral knitting by utilizing the double-needle-bed machine's capability to knit in multiple layers and dimensions simultaneously. The upper portion and sole portion are formed in different spatial dimensions within the same knitting process, creating a volumetric three-dimensional structure directly from the knitting machine.
2Ease of manufacture
If two-dimensional shoe blanks are produced, then the knitting process is simple, but the plantar area lacks proper protection and seaming with shoe sole is difficult
Solution Approach 1:
The patent combines the upper portion and sole portion into a single integral knitted structure. The second yarn is fed through the first yarn during the knitting process to simultaneously create both the upper and sole portions, ensuring they are structurally integrated and providing complete foot coverage including the plantar area.
Solution Approach 2:
The patent applies different yarns and knitting patterns to different regions of the shoe blank. The first yarn with larger denier is used for the upper portion requiring durability, while the second yarn forms the sole portion with appropriate thickness and texture for foot protection. Each region is optimized for its specific functional requirements.
3Reliability
If multiple shoe parts are assembled conventionally, then the shoe structure is complete, but the manufacturing process becomes complicated with many consumables
Solution Approach 1:
The patent merges multiple separate shoe components (upper portion and sole portion) into a single integral knitted product. Both portions are formed simultaneously in the same knitting machine using multiple yarns fed through the same needle bed, eliminating the need for separate assembly operations and reducing manufacturing complexity.
Solution Approach 2:
The double-needle-bed knitting machine performs multiple functions simultaneously: it knits both the upper portion and sole portion, creates three-dimensional structure, and forms integral connections all in one operation. This multi-functionality replaces what would traditionally require multiple separate machines and assembly steps.
Data Source
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AI summary
A 3D shoe blank (100, 200, 200', 200") is an integral knit fabric without any sewn portion made by a double-bed flat knitting machine and includes an upper portion (112, 212) having two technical surfaces and knitted from at least a first yarn (10) by skip-needle double-knitting, a front sole portion (122, 222) connected to the upper portion (112, 212) by a cast-on line (101, 201) and two connection lines (102, 103; 202, 203) to form a pocket structure, a rear portion (130) connected to the front sole portion (122, 222), and a heel portion (140) extending from a center rear end of the rear portion (100a). A portion of the front sole portion (122, 222) corresponding to the upper portion (112, 212) is knitted from at least a second yarn (20) by skip-needle single-knitting. Two opposite sides of the heel portion (140) are respectively connected to left and right rear ends of the rear portion (130) to form a 3D rear shoe portion (100a) with two joining lines (104a, 104b) formed between the heel portion (140) and the rear portion (130).