Integral Shoe Blank with Hidden Reinforcement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional knitted shoes lack sufficient structural strength due to the limited reinforcement provided by thin fabric and yarns with lower melting points, leading to a short lifespan and inability to withstand frequent use.
Innovation Solution
A method for manufacturing an integral shoe blank using a flat knitting machine that incorporates a reinforcement piece woven during the knitting process, which is hidden within the shoe and provides additional structural support, along with extensions that can act as toe support or sole pieces, enhancing both strength and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shoe is made from thin knitted fabric, then the shoe can be seamlessly woven and have simple construction, but the structural strength is insufficient and lifespan is short
Solution Approach 1:
The patent combines multiple functional elements (knitted fabric, reinforcement pieces, extensions) into a single integrated shoe blank that is knitted as one piece. The reinforcement pieces and extensions are incorporated during the knitting process itself, merging the structural support function with the upper material, thereby maintaining seamless construction while significantly improving structural strength.
Solution Approach 2:
The patent uses composite construction by integrating reinforcement pieces made of different materials (such as synthetic fibers, plastics, or metals) into the knitted fabric matrix. This creates a composite structure where the knitted fabric provides flexibility and comfort while the reinforcement pieces provide structural strength and durability, resolving the contradiction between ease of manufacture and structural strength.
2Shape
If yarns with lower melting point are used for knitting, then the shoe can be thermally shaped, but the structural strength is limited and cannot withstand frequent use
Solution Approach 1:
The patent applies local quality by using different material properties in different parts of the shoe. The main body uses thermally shapeable yarns for comfort and fit, while strategic reinforcement pieces use high-strength, heat-resistant materials in areas requiring durability (toe, heel, eyelets). This localized differentiation allows thermal shaping where needed while providing enhanced lifespan where required.
Solution Approach 2:
The reinforcement pieces are pre-integrated into the shoe blank during the knitting process before final assembly and thermal shaping. This preliminary integration ensures that the high-strength elements are properly positioned and secured before any thermal processing, allowing the shoe to undergo thermal shaping without compromising the integrity or lifespan provided by the reinforcement pieces.
3Strength
If multiple shoe pieces are spliced together, then structural strength can be improved, but the construction becomes complex and time-consuming
Solution Approach 1:
The patent merges multiple separate components (upper, reinforcement pieces, extensions, lining) into a single integrated shoe blank that is knitted as one continuous piece. This eliminates the need for splicing multiple pieces together, maintaining structural strength through integrated design while dramatically improving manufacturing efficiency by reducing assembly steps and production time.
4Ease of manufacture
If only two yarns are adhered together for knitting, then the shoe can be seamlessly woven, but the structural strength falls short for numerous application scenarios
Solution Approach 1:
The patent achieves universality by designing a multi-functional shoe blank that can adapt to numerous application scenarios. The integrated construction with strategically placed reinforcement pieces and extensions allows the same basic knitting process to produce shoes suitable for various uses (athletic, casual, protective) by simply changing the reinforcement material or placement, thereby maintaining ease of manufacture while achieving broad adaptability.
Data Source
AI summary
A method for manufacturing an integral shoe blank is provided. In the method, a reinforcement piece is woven by a flat knitting machine during a weave process, and the reinforcement piece is made unperceivable through a subsequent side overturning step when viewing from an exterior of a shoe. Thus, with the reinforcement piece, structural strength of the shoe blank is reinforced while better comfort is provided to the foot by a shoe manufactured from the shoe blank.