Seamless Shoe Upper Integrally Knitted with Flat Bed Machine
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Solution Overview
Problem
Existing methods for producing shoe uppers with knitted fabric are limited by productivity, requiring cutting and sewing processes that can be complex and time-consuming, especially when trying to form a seamless three-dimensional shape.
Innovation Solution
A method involving flat knitting machines with multiple needle beds to integrally knit instep and sole cover sections in a seamless manner, using flechage or tubular knitting to connect portions and prevent unraveling, allowing for a multi-layered structure that enhances reinforcement and designability without seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If one knitted fabric is cut to obtain the instep cover section, then the instep cover section can be produced, but cutting process and sewing process are required which reduce productivity
Solution Approach 1:
The patent merges the instep cover section and sole cover section into a single integrally knitted shoe upper, eliminating the need for separate cutting and sewing processes. The needle bed transfer mechanism enables continuous knitting of both sections as one seamless piece, directly resolving the productivity issue caused by multiple discrete manufacturing steps.
Solution Approach 2:
The patent segments the knitting process into distinct phases (knitting instep cover, transferring needle beds, knitting sole cover) while maintaining continuous production. This segmentation allows the knitting machine to efficiently manage the complex multi-section construction without interrupting the knitting flow, thereby maintaining high productivity.
2Ease of manufacture
If fashioning is carried out to obtain the instep cover section, then the instep cover section can be produced without cutting, but sewing process is still necessary which reduces productivity
Solution Approach 1:
The patent combines the instep cover section and sole cover section into a single integrally knitted structure, eliminating the need for post-knitting sewing operations. The needle bed transfer mechanism enables both sections to be knitted continuously as one piece, removing the sewing step entirely and significantly improving productivity.
3Ease of operation
If a seamless three-dimensional shape is formed, then the shoe upper becomes more comfortable and aesthetically pleasing, but complex knitting operations are required
Solution Approach 1:
The patent employs dynamic needle bed transfer during the knitting process to create the three-dimensional seamless shoe upper. The ability to transfer needle beds between positions allows the knitting machine to adapt its configuration mid-production, enabling complex 3D shaping without requiring multiple separate knitting operations or post-processing assembly steps.
4Productivity
If one knitted fabric is used for both instep cover section and sole cover section, then productivity is improved, but the knitted fabric must be separated and connected which adds process complexity
Solution Approach 1:
The patent uses dynamic needle bed transfer to seamlessly connect the instep cover section and sole cover section during continuous knitting. The needle beds are transferred and repositioned dynamically throughout the knitting process, allowing the machine to knit both sections as one integrated piece without interruption or complex post-processing connection operations.
Data Source
Figure 1(A)~1(B)
Figure 2(A)~2(B)
Figure 3(A)~3(B)
AI summary
There is provided a method for producing a shoe upper with which a shoe upper can be produced with high productivity, and a shoe upper obtained with the method for producing the shoe upper. An instep cover section (3) and a sole cover section (2) are integrally knitted in a seamless manner by carrying out process α and then carrying out process β or by carrying out process β and then carrying out process α with a flat knitting machine including at least a pair of a front and a back needle bed. [Process α] Knitting a main body left portion (3L), which is a left side portion of the instep cover section (3), with one needle bed of the flat knitting machine and knitting a main body right portion (3R), which is a right side portion of the instep cover section (3), with the other needle bed of the flat knitting machine. [Process β] Knitting a bottom left portion (2L), which is a left side portion of the sole cover section (2) with one needle bed, and a bottom right portion (2R), which is a right side portion of the sole cover section (2), with the other needle bed.