3D Integrated Shoe Blank Knitting via Live Stitch Merging
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Solution Overview
Problem
Conventional shoe-making processes involve complex material usage and labor-intensive seaming, limiting production efficiency and providing inadequate protection for the plantar area, as two-dimensional shoe blanks lack necessary structural integration with the shoe sole.
Innovation Solution
A method for knitting three-dimensional shoe blanks using flat knitting machines, which form integrated structures by preserving live stitches to connect various portions, such as the heel, lateral, rear sole, front sole, toe cap, and tongue, eliminating the need for seaming and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two-dimensional shoe blanks are used, then the knitting process is simpler, but the production efficiency is reduced due to labor-intensive seaming work
Solution Approach 1:
The patent merges the shoe blank and shoe sole into a single integrated three-dimensional structure knitted in one continuous process. The needle bed forms both the shoe blank body and the shoe sole portion together, eliminating the need for separate seaming operations and improving production efficiency while maintaining knitting simplicity.
Solution Approach 2:
The patent transitions from two-dimensional flat knitting to three-dimensional integrated knitting by utilizing the needle bed's ability to form vertical structures. The shoe blank is knitted with built-in three-dimensional features including the shoe sole portion, tongue, and heel counter, transforming the manufacturing process from planar to spatial dimensionality.
2Quantity of substance
If two-dimensional shoe blanks are used, then the material usage is reduced, but the plantar protection is inadequate
Solution Approach 1:
The patent combines the shoe blank and shoe sole into one integrated structure, ensuring that the plantar area receives proper protection through the continuously knitted sole portion. This merging eliminates the gaps and weak points present in two-dimensional designs, providing reliable plantar support while optimizing material usage through the efficient continuous knitting process.
3Speed
If two-dimensional shoe blanks are used, then the knitting process is faster, but the conjugation and seaming difficulty increases
Solution Approach 1:
The patent merges the shoe blank and shoe sole into a single continuous knitting operation, eliminating the need for separate conjugation and seaming steps. The needle bed continuously forms both components in one process, reducing overall manufacturing complexity while maintaining high knitting speed through the efficient continuous formation method.
Data Source
AI summary
The present invention provides a method for knitting three-dimensional shoe blanks, comprising: knitting a heel and lateral portion; continuing knitting a rear sole portion; continuing knitting a front sole portion; continuing knitting a toe cap portion; and continuing knitting a tongue portion. When the knitting comes to the first connecting selvage edges at the two sides of the rear sole portion, the first connecting selvage edges can be knitted together with the lateral live stitches in the heel and lateral portion, so that the heel and lateral portion can be combined with the rear sole portion. Also, when the knitting comes to the second connecting selvage edges at the two sides of the toe cap portion, the second connecting selvage edges can be knitted together with the latitudinal live stitches in the front sole portion, so that the toe cap portion can be combined with the front sole portion.