Seamless 3D flat knit vamp and manufacturing method thereof
The present invention relates to a seamless 3D flat knit vamp comprising a vamp body integrally woven by flat knitting machine, wherein the vamp body comprises an outer layer and an inner layer coupled to the outer layer; the outer layer comprises an outer toe portion, an outer shoe body portion, an outer heel portion and an outer shoe mouth portion; the inner layer comprises an inner toe portion correspondingly disposed in relation to the outer toe portion, an inner shoe body portion correspondingly disposed in relation to the outer shoe body portion, an inner heel portion correspondingly disposed in relation to the outer heel portion, and an inner shoe mouth portion correspondingly disposed in relation to the outer shoe mouth portion. It has the advantages of convenient to process, good integrity, and comfortable to wear.
The present invention relates to a seamless 3D flat knit vamp and manufacturing method thereof.
Woven vamp has become a new product line which has the advantages of light, breathable and stylable, thus is welcomed by the market. However, current woven vamps are formed by firstly weaving a planar woven fabric, laying out several extended shoe-shaped vamps on the planar woven fabric, forming jacquard or hollow patterns on corresponding parts of the shoe-shaped vamps, and thereafter cutting the vamps by laser machines. However, it takes a long time for the laser machines to cut the vamps; the costs of the machines are also high. For some vamps, after being embroidered or adhered to other fabrics, it is necessary to carry out second cutting operation by laser machines. The manufacturing process is complex, and a large amount of edges, corners and remaining fabric will be wasted. Precise sewing is required for combining the planar vamp and the sole, otherwise the size and shape of the shoe will be affected, resulting in inconsistent shoe size and jeopardizing comfortability and aestheticness. All the aforementioned causes high manufacturing costs of the shoes. Besides, common woven vamps are made of softer fabric, thus the vamps are not firm enough and easily collapse, affecting the outer appearance of the vamps.
Upon long-term research, the applicant provides a vamp manufacturing method in Chinese invention patent application number 201610585301.4 titled “An integral vamp manufacturing method and an integral woven vamp” which comprises the following steps: (1) Weaving preparation: according to pattern and technical requirements of the vamp, supply raw color yarns, fusible yarns and elastic yarns to the main color yarn feeder, matching color yarn feeder and elastic yarn feeder, import predetermined program to the vamp machine, and input corresponding parameters; (2) Weaving U-shaped tubular fabric, wherein one side of the U-shaped tubular fabric forms the outer layer of the vamp and the other side forms the inner layer of the vamp; both the outer side and the inner side of the vamp are in tubular shape; the bending portion in the middle of the U-shaped tubular fabric forms the shoe mouth portion at the intersection of the inner layer and outer layer of the vamp; the vamp machine sequentially weaves the setup portion, the outer toe portion, the outer shoe body portion, the outer heel portion, the outer shoe mouth portion to the inner shoe mouth portion, the inner heel portion, the inner shoe body portion and the inner toe portion; partial jacquard patterns, partial elasticity enhancement effects are applied to the outer layer of the vamp according to different techniques and functions required at different parts of the vamp during weaving; (3) Sewing together the inner toe portion sewing eye, and positioning the woven U-shaped tubular fabric to the sewing machine by automatic robotic arm so that the inner toe portion sewing eye is positioned at the needle position of the machine for automatic sewing of the inner toe portion sewing eye; (4) Sewing together the outer toe portion sewing eye, and sucking the U-shaped tubular fabric to the outlet by suction pipe, then obtaining from the outlet the U-shaped tubular fabric with the inner toe portion sewing eye already sewn together, and then sewing together the outer toe portion sewing eye; (5) Forming an integral semi-finished vamp, sleeving the U-shaped tubular fabric with both sewing eyes already sewn together from the shoe mouth portion, and sleeving the inner layer of the vamp into the outer layer of the vamp at the shoe mouth portion to form a double-layer integral semi-finished vamp; (6) Shaping, shape-setting the vamp and sleeving the integral semi-finished vamp onto the shoe last, performing steaming by steam, adjusting and aligning the vamp and the patterns during the steaming process, melting the fusible yarns to adhere the inner layer and outer layer of the vamp together, and removing the shoe last after cooling to form an integral vamp.
The aforementioned vamp manufacturing method could increase production efficiency to a certain extent, yet during the manufacturing process, it is necessary to independently sew together the inner toe portion sewing eye and outer toe portion sewing eye. The production efficiency therefore still needs improvement; besides, there are glitches at intersecting portions of the sewn parts, thus affecting comfortability.
In view of the above, the inventor conducted in-depth research in respect of the aforementioned problems and devised the present invention.
BRIEF SUMMARY OF THE INVENTIONAn object of the present invention is to provide a seamless 3D flat knit vamp which is convenient to process and manufacture, better in stability and comfortable to wear.
Another object of the present invention is to provide a manufacturing method of a seamless 3D flat knit vamp which could increase production efficiency and manufacture shoes which are comfortable to wear and have stable structure.
To attain the above objects, the present invention adopts the following technical proposal:
A seamless 3D flat knit vamp comprising a vamp body integrally woven by flat knitting machine, wherein the vamp body comprises an outer layer and an inner layer coupled to the outer layer; the outer layer comprises an outer toe portion, an outer shoe body portion, an outer heel portion and an outer shoe mouth portion; the inner layer comprises an inner toe portion correspondingly disposed in relation to the outer toe portion, an inner shoe body portion correspondingly disposed in relation to the outer shoe body portion, an inner heel portion correspondingly disposed in relation to the outer heel portion, and an inner shoe mouth portion correspondingly disposed in relation to the outer shoe mouth portion.
In a preferred embodiment of the present invention, the outer shoe mouth portion and the inner shoe mouth portion are both interwoven by spandex core yarns, wherein the spandex core yarns are core yarns formed by wrapping 150D polyester or 150D polyester elastic yarns around 20D spandex.
In a preferred embodiment of the present invention, first ventilation holes are disposed on the outer layer, wherein the first ventilation holes each extends from an exterior surface of the outer layer to an interior surface of the outer layer.
In a preferred embodiment of the present invention, second ventilation holes are disposed on the inner layer, wherein the second ventilation holes each extends from an exterior surface of the inner layer to an interior surface of the inner layer.
In a preferred embodiment of the present invention, the outer layer is disposed with a plurality of lateral ridges corresponding to an instep position, wherein the lateral ridges extend from a left side of the vamp body to a right side of the vamp body, and the plurality of lateral ridges are disposed along a front-rear direction of the vamp body.
In a preferred embodiment of the present invention, a mat body is provided inside the inner layer and coupled to an upper surface of a bottom of the inner layer; alternatively, the mat is fixed to a lower surface of a bottom of the outer layer.
The present invention also provides a manufacturing method for a seamless 3D flat knit vamp which comprises the following steps:
A, Supply required yarns to yarn feeders of flat knitting machine according to vamp patterns and technical requirements, and import weaving program to the flat knitting machine;
B, Integrally weaving a U-shaped tubular fabric by the flat knitting machine, wherein one side of the U-shaped tubular fabric forms an outer layer of the vamp and an other side of the U-shaped tubular fabric forms an inner layer of the vamp;
wherein, the outer layer comprises an outer toe portion, an outer shoe body portion, an outer heel portion and an outer shoe mouth portion;
the inner layer comprises an inner toe portion correspondingly disposed in relation to the outer toe portion, an inner shoe body portion correspondingly disposed in relation to the outer shoe body portion, an inner heel portion correspondingly disposed in relation to the outer heel portion, and an inner shoe mouth portion correspondingly disposed in relation to the outer shoe mouth portion;
a middle portion of the U-shaped tubular fabric forms the inner shoe mouth portion and the outer shoe mouth portion where the inner layer intersects with the outer layer;
weaving the U-shaped tubular fabric from the outer layer to the inner layer: the flat knitting machine sequentially weaves a setup portion, the outer toe portion, the outer shoe body portion, the outer heel portion, the outer shoe mouth portion, the inner shoe mouth portion, the inner heel portion, the inner shoe body portion and the inner toe portion.
C, sleeving the inner layer into the outer layer from the outer shoe mouth portion and the inner shoe mouth portion to form a double-layer vamp body.
In a preferred embodiment, the present invention further comprises step D, which is to sleeve the vamp body formed in step C onto a shoe last, and then perform steaming with steam at 100° C.-120° C., and adjust and align the vamp and patterns during steaming.
With the technical proposal of the present invention, the vamp body is integrally woven by flat knitting machine. It is convenient to process, integral and structurally stable. There is no need to sew the toe portions, thus the vamp body is smooth and comfortable to wear.
The manufacturing method of the present invention increases production efficiency, and the manufactured shoes are seamless shoes which are comfortable to wear.
In the drawings:
10 denotes the outer layer; 11 denotes the outer toe portion; 12 denotes the outer shoe body portion; 13 denotes the outer heel portion; 14 denotes the outer shoe mouth portion; 20 denotes the inner layer; 21 denotes the inner toe portion; 22 denotes the inner shoe body portion; 23 denotes the inner heel portion; 24 denotes the inner shoe mouth portion; 30 denotes the lateral ridges; 40 denotes the first ventilation holes; 50 denotes the mat body; 60 denotes the second ventilation holes.
DETAILED DESCRIPTION OF THE INVENTIONTo further explain the technical proposal of the present invention, the present invention is hereinafter described in detail with the accompanying drawings.
As illustrated in
As a preferred embodiment of the present invention, the outer shoe mouth portion 14 and the inner shoe mouth portion 24 are both interwoven by spandex core yarns. More particularly, the spandex core yarns are core yarns formed by wrapping 150D polyester around 20D spandex or by wrapping 150D polyester elastic yarns around 20D spandex. With this configuration, the elasticity of the shoe mouth could be improved, and the shoe mouth is curved in shape. The outer toe portion 11, the outer shoe body portion 12, the outer heel portion 13, the inner toe portion 21, the inner shoe body portion 22 and the inner heel portion 23 are interwoven by one or more of polyester, polyester elastic yarns, nylon and polyester air covered yarns.
As a preferred embodiment of the present invention, first ventilation holes 40 are disposed on the outer layer 10, wherein the first ventilation holes 40 each extends from an exterior surface of the outer layer 10 to an interior surface of the outer layer.
As illustrated in
As illustrated in
As illustrated in
During the weaving process of the vamp body, the outer toe portion 11 is provided with sewing eyes; when the inner layer 20 is sleeved into the outer layer 10 to form a sock type shoe, the mat body 50 is inserted via the sewing eyes to a position between the lower surface of the bottom of the inner layer 20 and the upper surface of the bottom of the outer layer 10. Afterwards, inserting the shoe last and adjusting various parts of the vamp body so that the bottom of the sock type shoe corresponds to the bottom of the shoe last at a standard position. The bottom of the sock type shoe then undergoes shape-setting by steam; the lower surface of the bottom of the inner layer 20 and the upper surface of the mat body 50, and also the lower surface of the mat body 50 and the upper surface of the bottom of the outer layer 10, are integrally glued by fusible yarns or environmental friendly glue. The shoe last is removed after cooling. The sewing eyes are then sewn together by stitching machine or sewing machine. The shoe last is inserted again and the sock type shoe is subject to heat setting to ensure all patterns on the vamp are positioned in standard positions. The shoe last is removed after cooling. Heat setting may be performed by steaming with steam at 100° C.-120° C. As a further enhancement of the present invention, the present invention further comprises the mat body 50, which may be in one of the two forms below:
1. When forming the vamp body into shoe shape, the mat body 50 is inserted into the inner layer 20 so that the mat body 50 is positioned corresponding to the upper surface of the bottom of the inner layer 20. When the mat body 50 is positioned at the upper surface of the bottom of the inner layer 20, the mat body 50 and the inner layer 20 are coupled together by the fusible yarns in the vamp body according to the shape-setting procedure described below. The mat body 50 may function as an insole.
2. After the vamp body is formed into shoe shape by shape-setting procedure, the mat body 50 is fixed to the lower surface of the bottom of the outer layer 10 of the vamp body. The mat body 50 functions to provide support and wear resistance to the sole. The mat body 50 may be coupled to the vamp body by sewing or heat pressing. In this way, the present invention may be worn directly as a sock; the mat body 50 may be added to the bottom of the vamp body and the present invention may be worn as a shoe.
The present invention also provides a manufacturing method of a seamless 3D flat knit vamp which comprises the following steps:
A, Supply required yarns to yarn feeders of flat knitting machine according to vamp patterns and technical requirements, and import weaving program to the flat knitting machine;
B, Integrally weaving a U-shaped tubular fabric by the flat knitting machine, wherein one side of the U-shaped tubular fabric forms an outer layer 10 and an other side of the U-shaped tubular fabric forms an inner layer 20. The outer layer 10 comprises an outer toe portion 11, an outer shoe body portion 12, an outer heel portion 13 and an outer shoe mouth portion 14. The inner layer 20 comprises an inner toe portion 21 correspondingly disposed in relation to the outer toe portion 11, an inner shoe body portion 22 correspondingly disposed in relation to the outer shoe body portion 12, an inner heel portion 23 correspondingly disposed in relation to the outer heel portion 13, and an inner shoe mouth portion 24 correspondingly disposed in relation to the outer shoe mouth portion 14. A middle portion of the U-shaped tubular fabric forms the inner shoe mouth portion 24 and the outer shoe mouth portion 14 where the inner layer 20 intersects with the outer layer 10. The flat knitting machine sequentially weaves a setup portion, the outer toe portion 11, the outer shoe body portion 12, the outer heel portion 13, the outer shoe mouth portion 14, the inner shoe mouth portion 24, the inner heel portion 23, the inner shoe body portion 22 and the inner toe portion 21.
C, Sleeving the inner layer 20 into the outer layer 10 from the outer shoe mouth portion 14 and the inner shoe mouth portion 24 to form a double-layer vamp body.
As illustrated in
The needles on the front needle bed are denoted by A, B, C, D, E, F, G, H, A1, B1, C1, D1, E1, F1, G1, H1 from left to right. The needles on the rear needle bed are denoted by a, b, c, d, e, f, g, h, a1, b1, c1, d1, e1, f1, g1, h1 from left to right.
The arrows “” and “” indicate movement directions of the yarn feeders, which are respectively moving from right to left and moving from left to right.
“” indicates a miss stitch;
“” indicates a front need bed stitch;
“” indicates a rear needle bed stitch;
“” indicates a rib stitch;
The weaving process is detailed as below:
In row 1, yarn feeder k feeds yarns to needles A, B of the front needle bed and needles a, b of the rear needle bed for rib knitting; the knitting operation is repeated from left to right;
In row 2, yarn feeder k performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 3, yarn feeder k performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 4, yarn feeder k performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 5, yarn feeder t performs knitting at b of the rear needle bed; B of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 6, yarn feeder t performs knitting at F1 of the front needle bed; f1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 7, yarn feeder t performs knitting at d of the rear needle bed; D of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 8, yarn feeder t performs knitting at D1 of the front needle bed; d1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left; stitch decrease is performed in rows 5-8;
In row 9, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 10, yarn feeder t performs knitting at D1 of the front needle bed; d1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 11, yarn feeder t performs knitting at d of the rear needle bed; D of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 12, yarn feeder t performs knitting at F1 of the front needle bed; f1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 13, yarn feeder t performs knitting at b of the rear needle bed; B of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 14, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left; stitch increase is performed in rows 11-14;
In row 15, yarn feeder t performs knitting at A of the front needle bed; a of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 16, yarn feeder k performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 17, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 18, yarn feeder k performs knitting at h1 of the rear needle bed; H1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 19, yarn feeder t performs knitting at A of the front needle bed; a of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 20, yarn feeder k performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 21, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 22, yarn feeder k performs knitting at h1 of the rear needle bed; H1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 23, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 24, yarn feeder t performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 25, yarn feeder t performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 26, yarn feeder t performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 27, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right; stitch decrease is performed in rows 23-27;
In row 28, yarn feeder t performs knitting at d1 of the rear needle bed; D1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 29, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 30, yarn feeder t performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 31, yarn feeder t performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 32, yarn feeder t performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 33, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right; stitch increase is performed in rows 30-33;
In row 34, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 35, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 36, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 37, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 38, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 39, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 40, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 41, yarn feeder k performs knitting at B of the front needle bed; b of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 42, yarn feeder k performs knitting at F1 of the front needle bed; f1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 43, yarn feeder k performs knitting at D of the front needle bed; d of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 44, yarn feeder k performs knitting at D1 of the front needle bed; d1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left; stitch decrease is performed in rows 40-44;
In row 45, yarn feeder k performs knitting at E of the front needle bed; e of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 46, yarn feeder k performs knitting at D1 of the front needle bed; d1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 47, yarn feeder k performs knitting at D of the front needle bed; d of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right; stitch increase is performed in rows 47-50;
In row 48, yarn feeder k performs knitting at F1 of the front needle bed; f1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 49, yarn feeder k performs knitting at B of the front needle bed; b of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 50, yarn feeder k performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 51, yarn feeder k performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 52, yarn feeder k performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 53, yarn feeder k performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 54, yarn feeder k performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 55, yarn feeder k performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right; stitch decrease is performed in rows 51-55;
In row 56, yarn feeder k performs knitting at d1 of the rear needle bed; D1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 57, yarn feeder k performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right; stitch increase is performed in rows 57-61;
In row 58, yarn feeder k performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 59, yarn feeder k performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 60, yarn feeder k performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 61, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 62, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 63, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 64, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 65, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 66, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 67, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 68, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 69, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right; stitch decrease is performed in rows 69-73;
In row 70, yarn feeder t performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 71, yarn feeder t performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 72, yarn feeder t performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 73, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 74, yarn feeder t performs knitting at d1 of the rear needle bed; D1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 75, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 76, yarn feeder t performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 77, yarn feeder t performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 78, yarn feeder t performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 79, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right; stitch increase is performed in rows 75-79;
In row 80, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 81, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 82, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 83, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 84, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
In row 85, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
In row 86, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left; knitting of the outer layer is completed; then, complete knitting of the inner layer with the knitting sequence from row 23 to row 86.
As an alternative embodiment of the present invention, during weaving of the flat knit vamp, the flat knitting machine may sequentially weaves the setup portion, the inner toe portion 21, the inner shoe body portion 22, the inner heel portion 23, the inner shoe mouth portion 24, the outer shoe mouth portion 14, the outer heel portion 13, the outer shoe body portion 12 and the outer toe portion 11.
The seamless 3D flat knit vamp of the present invention may be worn directly as a sock; the mat body may be added so that the present invention may be worn as a shoe. It has the advantages of light and comfortable, yet it could maintain its shape and is aesthetic to wear.
The vamp provided by the present invention is also known as fly knit vamp.
The present invention is not limited by the accompanying drawings and the above embodiments. All other similar variation or decoration falls within the scope of protection of the present invention.
Claims
1. A seamless 3D flat knit vamp comprising a vamp body integrally woven by flat knitting machine, wherein the vamp body comprises an outer layer and an inner layer coupled to the outer layer; the outer layer comprises an outer toe portion, an outer shoe body portion, an outer heel portion and an outer shoe mouth portion; the inner layer comprises an inner toe portion correspondingly disposed in relation to the outer toe portion, an inner shoe body portion correspondingly disposed in relation to the outer shoe body portion, an inner heel portion correspondingly disposed in relation to the outer heel portion, and an inner shoe mouth portion correspondingly disposed in relation to the outer shoe mouth portion.
2. The seamless 3D flat knit vamp as in claim 1, characterized in that: the outer shoe mouth portion and the inner shoe mouth portion are both interwoven by spandex core yarns, wherein the spandex core yarns are core yarns formed by wrapping 150D polyester or 150D polyester elastic yarns around 20D spandex.
3. The seamless 3D flat knit vamp as in claim 1, characterized in that: first ventilation holes are disposed on the outer layer, wherein the first ventilation holes each extends from an exterior surface of the outer layer to an interior surface of the outer layer; second ventilation holes are disposed on the inner layer, wherein the second ventilation holes each extends from an exterior surface of the inner layer to an interior surface of the inner layer; the outer layer is disposed with a plurality of lateral ridges corresponding to an instep position, wherein the lateral ridges extend from a left side of the vamp body to a right side of the vamp body, and the plurality of lateral ridges are disposed along a front-rear direction of the vamp body.
4. The seamless 3D flat knit vamp as in claim 1, characterized in that: a mat body is provided between a lower surface of a bottom of the inner layer and an upper surface of a bottom of the outer layer.
5. The seamless 3D flat knit vamp as in claim 1, characterized in that: a mat body is provided inside the inner layer and coupled to an upper surface of a bottom of the inner layer, or the mat is fixed to a lower surface of a bottom of the outer layer.
6. A manufacturing method for a seamless 3D flat knit vamp which comprises the following steps:
- A, Supply required yarns to yarn feeders of flat knitting machine according to vamp patterns and technical requirements, and import weaving program to the flat knitting machine;
- B, Integrally weaving a U-shaped tubular fabric by the flat knitting machine, wherein one side of the U-shaped tubular fabric forms an outer layer of the vamp and an other side of the U-shaped tubular fabric forms an inner layer of the vamp;
- wherein,
- the outer layer comprises an outer toe portion, an outer shoe body portion, an outer heel portion and an outer shoe mouth portion;
- the inner layer comprises an inner toe portion correspondingly disposed in relation to the outer toe portion, an inner shoe body portion correspondingly disposed in relation to the outer shoe body portion, an inner heel portion correspondingly disposed in relation to the outer heel portion, and an inner shoe mouth portion correspondingly disposed in relation to the outer shoe mouth portion;
- a middle portion of the U-shaped tubular fabric forms the inner shoe mouth portion and the outer shoe mouth portion where the inner layer intersects with the outer layer;
- weaving the U-shaped tubular fabric from the outer layer to the inner layer: the flat knitting machine sequentially weaves a setup portion, the outer toe portion, the outer shoe body portion, the outer heel portion, the outer shoe mouth portion, the inner shoe mouth portion, the inner heel portion, the inner shoe body portion and the inner toe portion;
- C, sleeving the inner layer into the outer layer from the outer shoe mouth portion and the inner shoe mouth portion to form a double-layer vamp body.
7. The manufacturing method for a seamless 3D flat knit vamp as in claim 6, characterized in that: the outer toe portion is provided with sewing eyes in Step B; after Step C, a mat body is inserted to a position between a lower surface of a bottom of the inner layer and an upper surface of a bottom of the outer layer; afterwards, sleeving the vamp body onto a shoe last; by means of shape-setting, coupling together the lower surface of the bottom of the inner layer and an upper surface of the mat body, and coupling together the upper surface of the bottom of the outer layer and a lower surface of the mat body; then the sewing eyes are sewn together.
8. The manufacturing method for a seamless 3D flat knit vamp as in claim 7, characterized in that: it further comprises step D, which is to sleeve the vamp body with its sewing eyes sewn together onto a shoe last, and then perform steaming with steam at 100° C.-120° C., and adjust and align the vamp and patterns during steaming.
9. The manufacturing method for a seamless 3D flat knit vamp as in claim 6, characterized in that: weaving in Step B is performed by a double needle bed flat knitting machine with two yarn feeders denoted by k and t respectively; needles on a front needle bed are denoted by A, B, C, D, E, F, G, H, A1, B1, C1, D1, E1, F1, G1, H1 from left to right; needles on a rear needle bed are denoted by a, b, c, d, e, f, g, h, a1, b1, c1, d1, e1, f1, g1, h1 from left to right; weaving process is detailed as follows:
- In row 1, yarn feeder k feeds yarns to needles A, B of the front needle bed and needles a, b of the rear needle bed for rib knitting; the knitting operation is repeated from left to right;
- In row 2, yarn feeder k performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 3, yarn feeder k performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 4, yarn feeder k performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 5, yarn feeder t performs knitting at b of the rear needle bed; B of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 6, yarn feeder t performs knitting at F1 of the front needle bed; f1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 7, yarn feeder t performs knitting at d of the rear needle bed; D of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 8, yarn feeder t performs knitting at D1 of the front needle bed; d1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 9, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 10, yarn feeder t performs knitting at D1 of the front needle bed; d1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 11, yarn feeder t performs knitting at d of the rear needle bed; D of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 12, yarn feeder t performs knitting at F1 of the front needle bed; f1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 13, yarn feeder t performs knitting at b of the rear needle bed; B of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 14, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 15, yarn feeder t performs knitting at A of the front needle bed; a of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 16, yarn feeder k performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 17, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 18, yarn feeder k performs knitting at h1 of the rear needle bed; H1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 19, yarn feeder t performs knitting at A of the front needle bed; a of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 20, yarn feeder k performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 21, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 22, yarn feeder k performs knitting at h1 of the rear needle bed; H1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 23, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 24, yarn feeder t performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 25, yarn feeder t performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 26, yarn feeder t performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 27, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 28, yarn feeder t performs knitting at d1 of the rear needle bed; D1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 29, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 30, yarn feeder t performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 31, yarn feeder t performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 32, yarn feeder t performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 33, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 34, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 35, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 36, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 37, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 38, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 39, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 40, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 41, yarn feeder k performs knitting at B of the front needle bed; b of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 42, yarn feeder k performs knitting at F1 of the front needle bed; f1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 43, yarn feeder k performs knitting at D of the front needle bed; d of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 44, yarn feeder k performs knitting at D1 of the front needle bed; d1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 45, yarn feeder k performs knitting at E of the front needle bed; e of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 46, yarn feeder k performs knitting at D1 of the front needle bed; d1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 47, yarn feeder k performs knitting at D of the front needle bed; d of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 48, yarn feeder k performs knitting at F1 of the front needle bed; f1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 49, yarn feeder k performs knitting at B of the front needle bed; b of the rear needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 50, yarn feeder k performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 51, yarn feeder k performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 52, yarn feeder k performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 53, yarn feeder k performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 54, yarn feeder k performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 55, yarn feeder k performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 56, yarn feeder k performs knitting at d1 of the rear needle bed; D1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 57, yarn feeder k performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 58, yarn feeder k performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 59, yarn feeder k performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 60, yarn feeder k performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 61, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 62, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 63, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 64, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 65, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 66, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 67, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 68, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 69, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 70, yarn feeder t performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 71, yarn feeder t performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 72, yarn feeder t performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 73, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 74, yarn feeder t performs knitting at d1 of the rear needle bed; D1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 75, yarn feeder t performs knitting at e of the rear needle bed; E of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 76, yarn feeder t performs knitting at e1 of the rear needle bed; E1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 77, yarn feeder t performs knitting at c of the rear needle bed; C of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 78, yarn feeder t performs knitting at g1 of the rear needle bed; G1 of the front needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 79, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 80, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 81, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 82, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 83, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 84, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left;
- In row 85, yarn feeder t performs knitting at a of the rear needle bed; A of the front needle bed is a miss stitch; the knitting operation is repeated from left to right;
- In row 86, yarn feeder t performs knitting at H1 of the front needle bed; h1 of the rear needle bed is a miss stitch; the knitting operation is repeated from right to left; knitting of the outer layer is completed; then, complete knitting of the inner layer with the knitting sequence from row 23 to row 86.
10. A manufacturing method for a seamless 3D flat knit vamp, characterized in that, it comprises the following steps:
- A, Supply required yarns to yarn feeders of flat knitting machine according to vamp patterns and technical requirements, and import weaving program to the flat knitting machine;
- B, Integrally weaving a U-shaped tubular fabric by the flat knitting machine, wherein one side of the U-shaped tubular fabric forms an outer layer of the vamp and an other side of the U-shaped tubular fabric forms an inner layer of the vamp;
- wherein,
- the outer layer comprises an outer toe portion, an outer shoe body portion, an outer heel portion and an outer shoe mouth portion;
- the inner layer comprises an inner toe portion correspondingly disposed in relation to the outer toe portion, an inner shoe body portion correspondingly disposed in relation to the outer shoe body portion, an inner heel portion correspondingly disposed in relation to the outer heel portion, and an inner shoe mouth portion correspondingly disposed in relation to the outer shoe mouth portion;
- a middle portion of the U-shaped tubular fabric forms the inner shoe mouth portion and the outer shoe mouth portion where the inner layer intersects with the outer layer;
- weaving the U-shaped tubular fabric from the inner layer to the outer layer: the flat knitting machine sequentially weaves a setup portion, the inner toe portion, the inner shoe body portion, the inner heel portion, the inner shoe mouth portion, the outer shoe mouth portion, the outer heel portion, the outer shoe body portion and the outer toe portion;
- C, sleeving the inner layer into the outer layer from the outer shoe mouth portion and the inner shoe mouth portion to form a double-layer vamp body.
Type: Application
Filed: May 10, 2017
Publication Date: Jul 26, 2018
Inventors: Qinglai CAI (Fujian), Lizhi CAI (Fujian), Jinwei CAI (Fujian)
Application Number: 15/592,187
