3D Shoe Blank Integral Knitting for Seamless Footwear
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Solution Overview
Problem
Conventional shoe-making processes involve complex materials and labor-intensive seaming, limiting the efficiency and coverage of knitted shoes, particularly in forming three-dimensional shapes that include both dorsal and plantar protection.
Innovation Solution
A three-dimensional (3D) shoe blank is created using a flat knitting machine as an integral knit fabric without sewn portions, comprising an upper portion, front sole portion, rear portion, and heel portion, connected through folding lines and extension straps to form a seamless, efficient, and comprehensive shoe design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two-dimensional shoe blanks are knitted using conventional knitting machines, then the knitting process is simple, but the production efficiency remains low due to tedious seaming work
Solution Approach 1:
The patent merges the upper portion and sole portion into a single integral knitted shoe blank, eliminating the need for separate seaming operations. The flat knitting machine knits both portions in one continuous process, with the upper portion forming the dorsal coverage and the sole portion extending to provide plantar protection, thereby resolving the contradiction between manufacturing simplicity and production efficiency.
Solution Approach 2:
The patent transitions from two-dimensional shoe blanks to three-dimensional integral knitted structures by utilizing the flat knitting machine's capability to create varied stitch patterns and fabric densities. The shoe blank is knitted with different fabric characteristics in different regions (e.g., more dense in the sole portion, more flexible in the upper portion), adding functional dimensionality while maintaining manufacturing simplicity.
2Ease of manufacture
If two-dimensional shoe blanks are used, then the knitting process is straightforward, but the foot coverage is insufficient without proper plantar protection
Solution Approach 1:
The patent combines the upper portion and sole portion into one integral knitted structure, ensuring that the shoe blank provides complete foot coverage including both dorsal and plantar protection. The flat knitting machine knits the sole portion as an integrated part of the upper portion, with the heel portion extending to cover the heel area, thereby achieving comprehensive foot coverage while maintaining knitting process simplicity.
3Adaptability or versatility
If conventional shoe-making processes are used, then multiple shoe parts can be assembled, but the materials and processes become very complicated
Solution Approach 1:
The patent merges multiple shoe parts (upper portion, sole portion, heel portion) into a single integral knitted shoe blank, eliminating the need for separate assembly processes. The flat knitting machine creates the entire shoe blank in one continuous knitting operation, with different regions of the blank providing different functions (dorsal coverage, plantar protection, heel support), thereby reducing manufacturing process complexity while maintaining shoe part configuration versatility.
4Shape
If seaming techniques are used to build three-dimensional shape, then the shoe structure can be formed, but the seaming work is delicate and tedious
Solution Approach 1:
The patent merges the formation of three-dimensional shape with the knitting process itself, eliminating the need for separate seaming operations. The flat knitting machine knits the shoe blank with inherent three-dimensional structure through varied stitch patterns and fabric densities in different regions. The upper portion and sole portion are connected through integral knitting, with the heel portion forming the three-dimensional rear structure, thereby achieving three-dimensional shaping without delicate and tedious seaming work.
Solution Approach 2:
The patent replaces the mechanical seaming process with a knitting-based formation process. Instead of using separate seaming machines or manual sewing operations to create three-dimensional shapes, the flat knitting machine uses yarn manipulation and stitch pattern variation to directly form the three-dimensional structure during the knitting process, substituting a simpler, more integrated mechanical system.
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 flat knitting machine and includes an upper portion (112, 212) knitted from at least a yarn (10, 20), a front sole portion (120, 220) knitted from the upper portion (112, 212) with a folding line (101, 201) therebetween and two connection lines (102, 202; 103, 203) at two sides of the front sole portion (120, 220) and the upper portion (112, 212), so the front sole portion (120, 220) is folded and connected to the upper portion (112, 212) to form a pocket structure, a rear portion (130) knitted from the front sole portion (120, 220), and a heel portion (140) extending from a center rear end of the rear portion (130), two opposite sides of the heel portion (140) respectively connected to a left rear end and a right rear end of the rear portion to form a 3D rear shoe portion (100a) with two joining lines (104a, 104b) between the heel portion (140) and the rear portion (130) on the two opposite sides.