3D Vacuum Shrinking for Silicone Shoe Vamp Shaping
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Solution Overview
Problem
Existing production processes for sock-like shoes suffer from poor wearability, shaping defects, water seepage, and low efficiency due to plane knitting methods, which result in inefficient manufacturing and suboptimal shoe quality.
Innovation Solution
A three-dimensional vacuum sucking and shrinking process and device that involves knitting, sealing, hot-pressed shaping under vacuum, cooling, membrane fixation, and assembly to create a waterproof and durable shoe vamp, eliminating the need for suturing and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plane knitting is used to manufacture sock-like shoes, then the manufacturing process is simple, but the wearability and shaping effect are poor
Solution Approach 1:
The patent transitions from plane knitting (2D) to three-dimensional knitting (3D) to manufacture the sock body. This dimensional change enables the sock to form a pre-shaped three-dimensional structure that better conforms to the foot anatomy, significantly improving wearability and shaping effect while maintaining manufacturing simplicity through automated 3D knitting machines
2Productivity
If plane knitting is used, then production efficiency is maintained, but water seepage occurs via the vamp
Solution Approach 1:
The patent combines the knitted sock body with a waterproof membrane (such as TPU or PVC material) to form a composite structure. The membrane is hot-pressed onto the three-dimensional knitted sock vamp, creating a waterproof barrier that prevents water seepage while maintaining the breathability and flexibility of the knitted fabric underneath
Solution Approach 2:
The patent employs hot-pressing technology that controls temperature and pressure parameters to bond the waterproof membrane to the knitted sock. By adjusting these physical parameters, the membrane is effectively attached to the three-dimensional sock structure, achieving waterproofing without compromising production efficiency
3Ease of manufacture
If traditional hot-pressed shaping is used, then the process is straightforward, but the shaping effect is poor and additional suturing is required
Solution Approach 1:
The patent performs hot-pressed shaping on a three-dimensional knitted sock structure rather than a flat plane-knitted fabric. This three-dimensional shaping process allows the sock to conform more accurately to the foot and shoe last, achieving superior shaping effect and eliminating the need for subsequent suturing operations to join separate pieces
4Manufacturing precision
If three-dimensional knitting with vacuum sucking and shrinking is used, then shaping precision and waterproofing are improved, but device complexity increases
Solution Approach 1:
The patent employs vacuum sucking technology using pneumatic principles to hold and shape the three-dimensional knitted sock during the hot-pressing process. The vacuum system creates negative pressure to secure the sock on the shaping mold, enabling precise three-dimensional shaping and membrane attachment while maintaining a relatively simple device structure through the use of standard pneumatic components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process enhances production efficiency and quality by forming a seamless, waterproof three-dimensional shoe structure with improved wearability and durability, eliminating the need for additional molding and splicing steps.
Implementation Method 1
shaping the sock obtained in S3 under heating and vacuum conditions
Implementation Method 2
the membrane pressing sleeve is tightly adsorbed to the surface of the sock under vacuum
Implementation Method 3
hot pressing, sucking and shrinking the sock covered with the membrane pressing sleeve in S7 under vacuum to fix the shaping membrane on the outer side of the sock
Implementation Method 4
the shaping membrane is melted on the surface of the sock and forms a shaped layer and a waterproof layer
Implementation Method 5
cooling the sock shaped in S4 in a cooling chamber at -10°C-5°C
Implementation Method 6
after the sock gets cool and is solidified
Data Source
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AI summary
The present disclosure discloses a three-dimensional vacuum sucking and shrinking process, a three-dimensional vacuum sucking and shrinking device and a method for processing a silicone shoe vamp, realizing 3D production of sock-like shoes by a series of steps including knitting, shoe last placement, shaping, cooling, fixation of a shaping membrane and vacuum sucking and shrinking. The present disclosure uses a thermoplastic membrane. The thermoplastic membrane is quickly and tightly adhered to the surface of a sock in a way of hot pressing, sucking and shrinking under vacuum to further shape the sock. Compared with prior art, the present disclosure simplifies production process, enhances production efficiency and improves quality of sock-like shoes.