Integrally Weaving Shoe Embryo Extensions via Flat Knitting
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Solution Overview
Problem
Conventional shoe manufacturing methods require additional processes to integrate extensions or decoration pieces into knitted shoes, which can compromise the aesthetic features and increase production complexity.
Innovation Solution
A method for integrally weaving a shoe embryo using a flat knitting machine, where extensions such as vamp decoration pieces, shoe laces, or ankle straps are woven simultaneously with the shoe upper, eliminating the need for post-processing by cyclically knitting yarns in alternating directions to form the shoe structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If decoration pieces or installation pieces are added to knitted shoes to meet design requirements, then the aesthetic features and functionality of the shoe are improved, but additional production processes are required and the original aesthetic features may be compromised
Solution Approach 1:
The patent merges the decoration pieces and installation pieces into the main shoe body by integrating them during the knitting process. The extension portions are knitted simultaneously with the shoe upper, combining multiple components into a single integrated structure that eliminates separate assembly steps while maintaining design flexibility
Solution Approach 2:
The patent applies preliminary action by pre-integrating the extension portions into the knitting process before the shoe manufacturing is complete. The extensions are formed during the knitting process itself, allowing subsequent decoration or installation operations to be performed on an already-integrated structure, thereby simplifying the overall production process
2Ease of manufacture
If multiple shoe pieces are spliced together to create a shoe, then the manufacturing process is simplified, but the aesthetic integrity and seamless appearance are compromised
Solution Approach 1:
The patent merges multiple functional components (shoe upper, extensions, decoration pieces, installation pieces) into a single knitted structure. The flat knitting machine produces an integrated shoe embryo where all parts are seamlessly connected through the knitting process, eliminating visible seams and joints while maintaining manufacturing efficiency
Solution Approach 2:
The patent utilizes the three-dimensional capabilities of the flat knitting machine to create complex spatial structures in a single continuous process. The knitting machine manipulates yarns in multiple dimensions to form the shoe upper and extensions simultaneously, achieving seamless integration that would be difficult to accomplish through traditional two-dimensional fabric assembly
3Productivity
If extension portions are added after the shoe upper is knitted, then the main shoe body can be produced efficiently, but additional manufacturing steps are required and production time increases
Solution Approach 1:
The patent applies preliminary action by forming the extension portions during the main knitting process rather than adding them later. The extension portions are initiated and developed concurrently with the shoe upper production, allowing both components to be created in a single continuous operation that reduces total manufacturing time while maintaining high productivity
Solution Approach 2:
The patent maintains continuity of useful action by keeping the knitting machine operating continuously to produce both the shoe upper and extensions. The knitting process flows uninterrupted, with the machine transitioning smoothly between forming different parts of the shoe, thereby maximizing machine utilization and eliminating idle time between production stages
Data Source
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AI summary
A method for integrally weaving a shoe embryo (10) having an extension (160) is provided. The extension (160) may be a vamp decoration piece, a shoe lace installation piece, an ankle strap or a toe decoration piece. During a weaving process of the shoe embryo (10) of the method, the extension (160) may be formed simultaneously by knitting at least one of yarns (20 and 21). Thus, by weaving the shoe embryo (10) using the method of the present invention, the extension (160) may be prevented from an additional post-process that may reduce the overall aesthetic features of the woven shoe embryo (10). Further, because the extension (160) is a formed integral, a process of installing the extension (160) after the shoe embryo (10) is woven as in the prior art is eliminated.