U.S. patent application number 15/849386 was filed with the patent office on 2018-12-06 for three-dimensional (3d) shoe blank made by double-bed flat knitting machine and manufacturing method thereof.
The applicant listed for this patent is Wholeknit International Co., Ltd.. Invention is credited to YI-HSING DOU, YU-LIN LI.
Application Number | 20180343955 15/849386 |
Document ID | / |
Family ID | 60813691 |
Filed Date | 2018-12-06 |
United States Patent
Application |
20180343955 |
Kind Code |
A1 |
LI; YU-LIN ; et al. |
December 6, 2018 |
THREE-DIMENSIONAL (3D) SHOE BLANK MADE BY DOUBLE-BED FLAT KNITTING
MACHINE AND MANUFACTURING METHOD THEREOF
Abstract
A 3D shoe blank is an integral knit fabric without any sewn
portion made by a double-bed flat knitting machine and includes an
upper portion having two technical surfaces and knitted from at
least a first yarn by skip-needle double-knitting, a front sole
portion connected to the upper portion by a cast-on line and two
connection lines to form a pocket structure, a rear portion
connected to the front sole portion, and a heel portion extending
from a center rear end of the rear portion. A portion of the front
sole portion corresponding to the upper portion is knitted from at
least a second yarn by skip-needle single-knitting. Two opposite
sides of the heel portion are respectively connected to left and
right rear ends of the rear portion to form a 3D rear shoe portion
with two joining lines formed between the heel portion and the rear
portion.
Inventors: |
LI; YU-LIN; (Apia, WS)
; DOU; YI-HSING; (Apia, WS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Wholeknit International Co., Ltd. |
Apia |
|
WS |
|
|
Family ID: |
60813691 |
Appl. No.: |
15/849386 |
Filed: |
December 20, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D04B 1/22 20130101; A43B
3/12 20130101; D10B 2501/043 20130101; D10B 2403/0332 20130101;
A43B 1/14 20130101; A43B 3/124 20130101; A43B 23/042 20130101; A43B
1/04 20130101; A43B 23/0255 20130101; D10B 2403/0333 20130101; A43B
3/106 20130101 |
International
Class: |
A43B 1/04 20060101
A43B001/04; A43B 1/14 20060101 A43B001/14; A43B 23/04 20060101
A43B023/04; D04B 1/22 20060101 D04B001/22 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 5, 2017 |
TW |
106118557 |
Claims
1. A method for knitting a three-dimensional (3D) shoe blank by
using a double-bed flat knitting machine, comprising: providing at
least a first yarn on a front needle bed and a back needle bed of
the double-bed flat knitting machine by skip-needle double-knitting
and providing at least a second yarn on the back needle bed
together to form a cast-on line; knitting the first yarn on the
front needle bed and the back needle bed continuing from the
cast-on line by loop-transferring and skip-needle double-knitting
to form an upper portion; knitting the second yarn on the back
needle bed continuing from the cast-on line by skip-needle
single-knitting to form a front sole portion, wherein the upper
portion and the front sole portion are alternatingly knitted, and
the front sole portion is connected to the upper portion to form a
pocket structure; knitting continuing from the front sole portion
on the front needle bed and the back needle bed to form a rear
portion, wherein when forming the rear portion, a plurality of live
stitches are preserved on the front needle bed at two sides of a
rear end of the rear portion; and knitting continuing from a center
of the rear end of the rear portion on the front needle bed and the
back needle bed by double-knitting to form a heel portion with a
predetermined number of stitches, wherein when the knitting of the
heel portion reaches the predetermined number of stitches at two
opposite sides of the heel portion, the back needle bed moves
transversely to sequentially and respectively knit the live
stitches preserved on the front needle bed at the two sides of the
rear end of the rear portion together with the two opposite sides
of the heel portion, so the heel portion and the rear portion are
combined to form a 3D rear shoe portion.
2. The method of claim 1, further comprising: knitting continuing
from one side of a rear end of the upper portion by
loop-transferring and skip-needle double-knitting to form a first
upper extension portion; knitting at least a third yarn continuing
from the other side of the rear end of the upper portion by
loop-transferring and skip-needle double-knitting to form a second
upper extension portion, wherein the first upper extension portion
and the second upper extension portion are spaced apart and
substantially symmetric, so the first upper extension portion, the
second upper extension portion, and the upper portion are combined
to form an upper assembly; and knitting the second yarn on the back
needle bed to form a front sole extension portion between the front
sole portion and the rear portion, wherein a portion of the front
sole extension portion corresponding to the first upper extension
portion and the second upper extension portion is knitted by
skip-needle single-knitting, and another portion of the front sole
extension portion not corresponding to the first upper extension
portion and the second upper extension portion is knitted by
single-knitting, so the front sole portion and the front sole
extension portion are combined to form a front sole assembly.
3. The method of claim 1, wherein the rear portion is knitted from
the second yarn or another yarn, or the rear portion is knitted
from the second yarn together with another yarn.
4. The method of claim 2, wherein the rear portion is knitted from
the second yarn or another yarn, or the rear portion is knitted
from the second yarn together with another yarn.
5. The method of claim 1, wherein the heel portion is knitted from
the second yarn or another yarn, or the heel portion is knitted
from the second yarn together with another yarn.
6. The method of claim 2, wherein the heel portion is knitted from
the second yarn or another yarn, or the heel portion is knitted
from the second yarn together with another yarn.
7. The method of claim 3, wherein the heel portion is knitted from
the second yarn or another yarn, or the heel portion is knitted
from the second yarn together with another yarn.
8. The method of claim 4, wherein the heel portion is knitted from
the second yarn or another yarn, or the heel portion is knitted
from the second yarn together with another yarn.
9. The method of claim 1, further comprising: after the 3D rear
shoe portion is formed, double-knitting on the front needle bed and
the back needle bed to form an extension strap, wherein the
extension strap is partially connected to the heel portion and
extends outward toward the two opposite sides of the heel
portion.
10. The method of claim 9, further comprising: double-knitting from
the heel portion on the front needle bed and the back needle bed to
form an extension portion connected between the heel portion and
the extension strap, so the extension strap is partially connected
to the heel portion by means of the extension portion.
11. The method of claim 2, further comprising: after the 3D rear
shoe portion is formed, double-knitting on the front needle bed and
the back needle bed to form an extension strap, wherein the
extension strap is partially connected to the heel portion and
extends outward toward the two opposite sides of the heel
portion.
12. The method of claim 11, further comprising: double-knitting
from the heel portion on the front needle bed and the back needle
bed to form an extension portion connected between the heel portion
and the extension strap, so the extension strap is partially
connected to the heel portion by means of the extension
portion.
13. A 3D shoe blank made by using a double-bed flat knitting
machine, the 3D shoe blank being an integral knit fabric without
any sewn portion, the 3D shoe blank comprising: an upper portion
having two technical surfaces knitted from at least a first yarn by
skip-needle double-knitting; a front sole portion connected to the
upper portion by a cast-on line and two connection lines, so the
front sole portion and the upper portion are connected to form a
pocket structure, wherein a portion of the front sole portion
corresponding to the upper portion is knitted from at least a
second yarn by skip-needle single-knitting; a rear portion
connected to the front sole portion; and a heel portion extending
from a center rear end of the rear portion, two opposite sides of
the heel portion respectively connected to a left rear end and a
right rear end of the rear portion, so the heel portion and the
rear portion are combined to form a 3D rear shoe portion, and two
joining lines are formed between the heel portion and the rear
portion on the two opposite sides of the heel portion,
respectively.
14. The 3D shoe blank of claim 13, wherein the two connection lines
are connected to two ends of the cast-on line and extend outward
and obliquely toward an outer side of the 3D shoe blank.
15. The 3D shoe blank of claim 13, wherein the upper portion
substantially matches the front sole portion in shape and size.
16. The 3D shoe blank of claim 14, wherein the upper portion
substantially matches the front sole portion in shape and size.
17. The 3D shoe blank of claim 13, further comprising a first upper
extension portion and a second upper extension portion connected to
two sides of a rear end of the upper portion, respectively, wherein
the 3D shoe blank further comprises a front sole extension portion
connected between the front sole portion and the rear portion; the
front sole extension portion partially corresponds to the first
upper extension portion and the second upper extension portion.
18. The 3D shoe blank of claim 17, wherein the front sole extension
portion comprises covered portions masked by the first upper
extension portion and the second upper extension portion and an
uncovered portion exposed between the first upper extension portion
and the second upper extension portion; the covered portions are
knitted from the second yarn by skip-needle single-knitting and the
uncovered portion is knitted from the second yarn by
single-knitting.
19. The 3D shoe blank of claim 14, further comprising a first upper
extension portion and a second upper extension portion connected to
two sides of a rear end of the upper portion, respectively, wherein
the 3D shoe blank further comprises a front sole extension portion
connected between the front sole portion and the rear portion; the
front sole extension portion partially corresponds to the first
upper extension portion and the second upper extension portion.
20. The 3D shoe blank of claim 19, wherein the front sole extension
portion comprises covered portions masked by the first upper
extension portion and the second upper extension portion and an
uncovered portion exposed between the first upper extension portion
and the second upper extension portion; the covered portions are
knitted from the second yarn by skip-needle single-knitting and the
uncovered portion is knitted from the second yarn by
single-knitting.
21. The 3D shoe blank of claim 13, further comprising an extension
strap partially connected to the heel portion and extending outward
toward the two opposite sides of the heel portion.
22. The 3D shoe blank of claim 21, further comprising an extension
portion connected between the heel portion and the extension strap,
so the extension strap is partially connected to the heel portion
by means of the extension portion.
23. The 3D shoe blank of claim 14, further comprising an extension
strap partially connected to the heel portion and extending outward
toward the two opposite sides of the heel portion.
24. The 3D shoe blank of claim 23, further comprising an extension
portion connected between the heel portion and the extension strap,
so the extension strap is partially connected to the heel portion
by means of the extension portion.
Description
PRIORITY
[0001] The present invention claims priority to the Application No.
106118557 filed on Jun. 5, 2017 in Taiwan (ROC), which was entitled
"3D Shoe Blank Made by Double-bed Flat Knitting Machine and
Manufacturing Method Thereof". All of which are hereby incorporated
by reference as if fully set forth herein.
FIELD OF INVENTION
[0002] This invention generally relates to a three-dimensional (3D)
shoe blank and a manufacturing method thereof. Specifically, the
present invention relates to a 3D integral knitted shoe blank made
by a double-bed flat knitting machine and a manufacturing method
thereof.
BACKGROUND
[0003] In the conventional shoe-making process, a shoe is made by
connecting multiple pieces of shoe parts. Consequently, the
materials and the processes for manufacturing the shoes become very
complicated. In recent years, owing to better permeability and
comfort, less consumables required, and lower cost in the
manufacturing process compared to conventional shoes, knitted shoes
have quickly developed and gradually occupied a place in the
market.
[0004] Knitted shoes are generally made by knitting yarns to form a
shoe blank using the knitting machine and further attaching the
shoe blank to the shoe sole. Here, the shapes of the shoe blanks
formed by knitting are varied with the various types of knitting
machines and knitting methods. Limited by the number of needle beds
and current methods of knitting, two-needle-bed flat knitting
machines commonly used in the industry generally knit and form a
two-dimensional shoe blank in a sheet fabric form first, then the
two-dimensional shoe blanks are further processed through seaming
techniques to build a three-dimensional shape. However, due to the
delicate and tedious seaming work required, it is hard to improve
the production efficiency of the knitted shoes. In addition,
two-dimensional shoe blanks usually only contain the part that
covers the foot dorsal, resulting in lack of proper protection for
the plantar, and such a two-dimensional shoe blank without the
plantar part makes its conjugation and seaming with the shoe sole
much more difficult.
SUMMARY OF THE INVENTION
[0005] In view of the prior art, it is an object of the invention
to provide a 3D shoe blank made by using a double-bed flat knitting
machine, wherein the 3D shoe blank is an integral knit fabric
without any sewn portion, so the seaming work can be eliminated to
greatly improve the production efficiency.
[0006] It is another object of the invention to provide a 3D shoe
blank, whose upper portion is enhanced in structural strength by
double-knitting to meet the needs of wearers.
[0007] In an embodiment, a 3D shoe blank made by using a double-bed
flat knitting machine includes an upper portion, a front sole
portion, a rear portion and a heel portion. The upper portion has
two technical surfaces knitted from at least a first yarn by
skip-needle double-knitting. The front sole portion is connected to
the upper portion by a cast-on line and two connection lines, so
the front sole portion and the upper portion are connected to form
a pocket structure, wherein a portion of the front sole portion
corresponding to the upper portion is knitted from at least a
second yarn by skip-needle single-knitting. The rear portion is
connected to the front sole portion. The heel portion extends from
a center rear end of the rear portion. Two opposite sides of the
heel portion are respectively connected to a left rear end and a
right rear end of the rear portion, so the heel portion and the
rear portion are combined to form a 3D rear shoe portion, and two
joining lines are formed between the heel portion and the rear
portion on the two opposite sides of the heel portion,
respectively.
[0008] In an embodiment, the two connection lines are connected to
two ends of the cast-on line and extend outward and obliquely
toward an outer side of the 3D shoe blank.
[0009] In an embodiment, the upper portion substantially matches
the front sole portion in shape and size.
[0010] In an embodiment, the 3D shoe blank further includes a first
upper extension portion and a second upper extension portion
connected to two sides of a rear end of the upper portion,
respectively. The 3D shoe blank further includes a front sole
extension portion connected between the front sole portion and the
rear portion. The front sole extension portion partially
corresponds to the first upper extension portion and the second
upper extension portion.
[0011] In an embodiment, the font sole extension portion includes
covered portions masked by the first upper extension portion and
the second upper extension portion and an uncovered portion exposed
between the first upper extension portion and the second upper
extension portion. The covered portions are knitted from the second
yarn by skip-needle single-knitting and the uncovered portion is
knitted from the second yarn by single-knitting.
[0012] In an embodiment, the 3D shoe blank further includes an
extension strap partially connected to the heel portion and
extending outward toward the two opposite sides of the heel
portion.
[0013] In an embodiment, the 3D shoe blank further includes an
extension portion connected between the heel portion and the
extension strap, so the extension strap is partially connected to
the heel portion by means of the extension portion.
[0014] In another embodiment, the invention provides a method for
knitting a three-dimensional (3D) shoe blank by using a double-bed
flat knitting machine. The method includes providing at least a
first yarn on a front needle bed and a back needle bed of the
double-bed flat knitting machine by skip-needle double-knitting and
providing at least a second yarn on the back needle bed together to
form a cast-on line; knitting the first yarn on the front needle
bed and the back needle bed continuing from the cast-on line by
loop-transferring and skip-needle double-knitting to form an upper
portion; knitting the second yarn on the back needle bed continuing
from the cast-on line by skip-needle single-knitting to form a
front sole portion, wherein the upper portion and the front sole
portion are alternatingly knitted, and the front sole portion is
connected to the upper portion to form a pocket structure; knitting
continuing from the front sole portion on the front needle bed and
the back needle bed to form a rear portion, wherein when forming
the rear portion, a plurality of live stitches are preserved on the
front needle bed at two sides of a rear end of the rear portion;
and knitting continuing from a center of the rear end of the rear
portion on the front needle bed and the back needle bed by
double-knitting to form a heel portion with a predetermined number
of stitches, wherein when the knitting of the heel portion reaches
the predetermined number of stitches at two opposite sides of the
heel portion, the back needle bed moves transversely to
sequentially and respectively knit the live stitches preserved on
the front needle bed at the two sides of the rear end of the rear
portion together with the two opposite sides of the heel portion,
so the heel portion and the rear portion are combined to form a 3D
rear shoe portion
[0015] In an embodiment, the method further includes: knitting
continuing from one side of a rear end of the upper portion by
loop-transferring and skip-needle double-knitting to form a first
upper extension portion; knitting a third yarn continuing from the
other side of the rear end of the upper portion by
loop-transferring and skip-needle double-knitting to form a second
upper extension portion, wherein the first upper extension portion
and the second upper extension portion are spaced apart and
substantially symmetric, so the first upper extension portion, the
second upper extension portion, and the upper portion are combined
to form an upper assembly; and knitting the second yarn on the back
needle bed to form a front sole extension portion between the front
sole portion and the rear portion, wherein a portion of the front
sole extension portion corresponding to the first upper extension
portion and the second upper extension portion is knitted by
skip-needle single-knitting, and another portion of front sole
extension portion not corresponding to first upper extension
portion and the second upper extension portion is knitted by
single-knitting; the front sole portion and the front sole
extension portion are combined to form a front sole assembly.
[0016] In an embodiment, the rear portion is knitted from the
second yarn or another yarn, or the rear portion is knitted from
the second yarn together with another yarn.
[0017] In an embodiment, the heel portion is knitted from the
second yarn or another yarn, or the heel portion is knitted from
the second yarn together with another yarn.
[0018] In an embodiment, the heel portion is knitted from the
second yarn or another yarn, or the heel portion is knitted from
the second yarn together with another yarn.
[0019] In an embodiment, the method further includes: after the 3D
rear shoe portion is formed, double-knitting on the font needle bed
and the back needle bed to form an extension strap, wherein the
extension strap is partially connected to the heel portion and
extends outward toward the two opposite sides of the heel
portion.
[0020] In an embodiment, the method further includes:
double-knitting from the heel portion on the font needle bed and
the back needle bed to form an extension portion connected between
the heel portion and the extension strap, so the extension strap is
partially connected to the heel portion by means of the extension
portion.
[0021] Compared to the prior art, the 3D shoe blank of the
invention is an integral knit fabric without any sewn portion made
by a double-bed flat knitting machine, so the seaming work can be
omitted to simplify the manufacturing process. The 3D shoe blank of
the invention has a strength-enhanced upper portion which is made
by double-knitting and is beneficial to sustain the shape of the
shoe body and meet the needs of wearers. The method of the
invention utilizes an innovative knitting design to form an
integral knit fabric just by using a double-bed flat knitting
machine without upgrading the knitting machine, so the equipment
cost can be effectively reduced and the production efficiency can
be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a schematic plan view of a first embodiment of the
three-dimensional (3D) shoe blank.
[0023] FIG. 2 is a schematic plan view of an upper portion of the
3D shoe blank of FIG. 1.
[0024] FIG. 3 is a schematic plan view of a front sole portion of
the 3D shoe blank of FIG. 1.
[0025] FIG. 4 is a schematic plan view of a rear portion and a heel
portion of the 3D shoe blank of FIG. 1.
[0026] FIG. 5 is a 3D schematic view of the first embodiment of the
3D shoe blank.
[0027] FIG. 6 is a 3D schematic view of a shoe body after the 3D
shoe blank of FIG. 5 is molded.
[0028] FIG. 7 is a schematic plan view of a second embodiment of
the 3D shoe blank.
[0029] FIG. 8 is a schematic plan view of an upper portion of the
3D shoe blank of FIG. 7.
[0030] FIG. 9 is a schematic plan view of a front sole portion of
the 3D shoe blank of FIG. 7.
[0031] FIG. 10 is a schematic plan view of a rear portion and a
heel portion of the 3D shoe blank of FIG. 7.
[0032] FIG. 11 is a 3D schematic view of the second embodiment of
the 3D shoe blank.
[0033] FIG. 12 is a schematic cross-sectional view of the 3D shoe
blank of FIG. 11.
[0034] FIG. 13 is a 3D schematic view of a shoe body after the 3D
shoe blank of FIG. 11 is molded.
[0035] FIG. 14 is a schematic knitting diagram of the upper portion
and the front sole portion of the 3D shoe blank according to an
embodiment of the present invention.
[0036] FIG. 15 is a schematic knitting diagram of the upper
extension portions and the front sole extension portion of the 3D
shoe blank according to another embodiment of the present
invention.
[0037] FIG. 16 is a schematic knitting diagram of the rear portion
and the heel portion of the 3D shoe blank according to an
embodiment of the present invention.
[0038] FIG. 17 is a schematic plan view of a third embodiment of
the 3D shoe blank.
[0039] FIG. 18 is a 3D schematic view of the third embodiment of
the 3D shoe blank.
[0040] FIG. 19 is a 3D schematic view of a shoe body after the 3D
shoe blank of FIG. 18 is molded.
[0041] FIG. 20 is a schematic plan view of a fourth embodiment of
the 3D shoe blank.
[0042] FIG. 21 is a 3D schematic view of the fourth embodiment of
the 3D shoe blank.
[0043] FIG. 22 is a 3D schematic view of a shoe body after the 3D
shoe blank of FIG. 21 is molded.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
[0044] For a thorough understanding of the invention, details of
steps and structures of the invention will be described. Any
manufacturing processes and specific steps of the knitting
technique that are well known in the art will not be described in
order not to impose undue limitations to the invention.
[0045] A three-dimensional (3D) shoe blank of the invention is an
integral knit fabric without any sewn portion and made by using a
double-bed flat knitting machine. For example, the 3D shoe blank
can be knitted by using a double-bed flat knitting machine with
movable cams, which can change the moving direction and drive the
actions of the needles. As shown in FIG. 1 to FIG. 5, in a first
embodiment, the 3D shoe blank 100 includes an upper portion 112, a
front sole portion 122, a rear portion 130, and a heel portion 140.
The upper portion 112 has two technical surfaces knitted from at
least a yarn (such as the first yarn 10 shown in FIG. 14) by
skip-needle double-knitting. That is, the outer surface of the
upper portion 112 that faces outward and the inner surface of the
upper portion 112 that faces the front sole portion 122 are both
technical surfaces. Further, at least one yarn stated herein is
preferably formed by twisting and combining multiple yarns with
different characteristic (such as materials, types, shapes, colors
and so on), but it is not limited thereto.
[0046] The front sole portion 122 is connected to the upper portion
112 by a cast-on line 101 and two connection lines 102, 103, so the
front sole portion 122 and the upper portion 112 are connected to
form a pocket structure. The portion of the front sole portion 122
that corresponds to the upper portion 112 is knitted from at least
a yarn (such as the second yarn 20 shown in FIG. 14) by skip-needle
single-knitting. For example, the front sole portion 122 is
preferably knitted by skip-needle single-knitting from at least a
yarn that is different from the yarn used for the upper portion
112, but not limited thereto. In this embodiment, the front sole
portion 122 substantially completely corresponds to the upper
portion 112, so the entire front sole portion 122 is knitted by
skip-needle single-knitting. In other words, the upper portion 112
substantially matches the front sole portion 122 in shape and size.
The upper portion 112 and the front sole portion 122 completely
overlap each other and are connected to form a pocket-like
structure. The front sole portion 122 and the upper portion 112 are
connected at outer perimeters, so the cast-on line 101 is located
on the front end of the front sole portion 122 and the upper
portion 112, and the connection lines 102 and 103 are respectively
located at two opposite sides of the front sole portion 122 and the
upper portion 112 with respect to the cast-on line 101.
Specifically, the front ends of the front sole portion 122 and the
upper portion 112 are connected by the cast-on line 101, while the
two connection lines 102 and 103 are connected to two ends of the
cast-on line 101 and extend outward and obliquely toward an outer
side of the rear portion 130. For example, the connection line 102
is connected to the left end of the cast-on line 101 and extends
rearward to connect the left side edge of the upper portion 112 and
the left side edge of the front sole portion 122. The connection
line 103 is connected to the right end of the cast-on line 101 and
extends rearward to connect the right side edge of the upper
portion 112 and the right side edge of the front sole portion 122.
As such, the upper portion 112 and the front sole portion 122 are
connected to form the pocket structure.
[0047] The rear portion 130 is connected to the front sole portion
122. In an embodiment, the rear portion 130 is preferably knitted
from at least a yarn by double-knitting. In an embodiment, the rear
portion 130 can be knitted from the yarns previously used (such as
the yarns 10, 20) or another yarn that is additionally introduced.
In another embodiment, the rear portion 130 can be knitted from the
yarns previously used (such as the yarns 10, 20) together with
another yarn. For example, the rear portion 130 can be knitted by
continuing using the yarn of the upper portion 112, the yarn of the
front sole portion 122, the yarns of the upper portion 112 and the
front sole portion 122, or another yarn. Alternatively, the rear
portion 130 can be knitted by using another yarn together with the
yarn of the upper portion 112, the yarn of the front sole portion
122, or the yarns of the upper portion 112 and the front sole
portion 122.
[0048] The heel portion 140 extends from a center rear end of the
rear portion 130. Two opposite sides of the heel portion 140 are
respectively connected to a left rear end and a right rear end of
the rear portion 130, so the heel portion 140 and the rear portion
130 are combined to form a 3D rear shoe portion 100a, and two
joining lines 104a and 104b are formed between the heel portion 140
and the rear portion 130 on the two opposite sides of the heel
portion 140, respectively.
[0049] In an embodiment. The heel portion 140 is preferably knitted
by continuing using the yarn of the rear portion 130 by
double-knitting.
[0050] As shown in FIG.6, after the knitting of the 3D shoe blank
100 is finished, without any seaming work, the 3D shoe blank 100
can be worn on the last and be molded to form a shoe body 1. For
example, when the 3D shoe blank 100 is knitted, a thermoplastic
yarn can be knitted simultaneously. When the 3D shoe blank 100 is
processed to form the shoe body 1, since the thermoplastic yarn is
thermal-curable, by thermal molding, the thermoplastic yarn can be
melted to be uniformly distributed over the shoe body 1 and then
hardened to support the shape of the shoe body 1. The material of
the thermoplastic yarn can be any suitable thermal curable material
including, but not limited to, nylon, polyester, acrylic, etc. It
is noted that the shoe body 1 can be shaped by other methods, not
limited to the use of thermoplastic yarn during the knitting
process.
[0051] After the 3D shoe blank 100 is molded into the shoe body 1,
the upper portion 112 and the front sole portion 122 can cover from
the foot dorsal to the front plantar, while the 3D rear shoe
portion 100a constituted by the rear portion 130 and the heel
portion 140 covers the lateral portion, the rear plantar, and the
heel of the foot. Specifically, the rear edge of the upper portion
112 and the upper edge of the 3D rear shoe portion 100a (i.e. the
outer edges of the rear portion 130 and the heel portion 140)
together define a shoe opening la of the shoe body 1 to allow the
foot to enter the interior space enclosed by the shoe body 1. The
connection lines 102 and 103 on two opposite sides of the front
sole portion 122 and the upper portion 112 respectively start from
two ends of the cast-on line 101 and extend gradually outward and
obliquely toward the 3D rear shoe portion 100a until reaching the
shoe opening 1 a, so the front sole portion 122 preferably covers
from the front plantar toward two opposite front lateral portions.
For example, the upper portion 112 can cover the dorsal surface of
the front foot, and the front sole portion 122 covers the front
plantar and extends upward to cover the front lateral portions.
Moreover, a portion of the rear portion 130 covers the rear plantar
while another portion of the rear portion 130 extends upward to
cover the rear lateral portions and extends rearward to cover the
heel with the heel portion 140. Therefore, the shoe body 1 formed
from the 3D shoe blank 100 of the invention can substantially cover
the dorsal, the plantar, the lateral sides, and the heel of the
foot.
[0052] In the first embodiment, although the 3D shoe blank 100 is
illustrated with substantially completely overlapped upper portion
112 and front sole portion 122, but not limited thereto. In other
embodiments, by changing the upper design, the 3D shoe blank may
have a different outer appearance. As shown in FIG. 7 to FIG. 12,
in a second embodiment, a shoe blank 200 includes an upper portion
212, a front sole portion 222, a rear portion 130, and a heel
portion 140 and further includes a first upper extension portion
214a, a second upper extension portion 214b, and a front sole
extension portion 224. Similarly, the upper portion 212 has two
technical surfaces knitted from at least a yarn (such as the first
yarn 10) by skip-needle double-knitting. The front sole portion 222
is connected to the upper portion 212 by a cast-on line 201 and two
connection lines 202, 203, so the front sole portion 222 and the
upper portion 212 are connected to form a pocket structure. The
portion of the front sole portion 222 that corresponds to the upper
portion 212 is knitted from at least a yarn (such as the second
yarn 20) by skip-needle single-knitting. The first upper extension
portion 214a and the second upper extension portion 214b are
connected to two sides of a rear end of the upper portion 212,
respectively. The front sole extension portion 224 is connected
between the front sole portion 222 and the rear portion 130 and
partially corresponds to the first upper extension portion 214a and
the second upper extension portion 214b. The heel portion 140
extends from a center rear end of the rear portion 130. The two
opposite sides of the heel portion 140 are respectively connected
to a left rear end and a right rear end of the rear portion 130, so
the heel portion 140 and the rear portion 130 are combined to form
a 3D rear shoe portion 100a, and two joining lines 104a and 104b
are formed between the heel portion 140 and the rear portion130 on
the two opposite sides of the heel portion 140, respectively. In
this embodiment, details of the upper portion 212, the front sole
portion 222, the rear portion 130, and the heel portion 140 can
refer to the related descriptions of the embodiment of FIG. 1 and
will not be elaborated again. Hereafter, the details of the first
upper extension portion 214a, the second upper extension portion
214b, and the front sole extension 224 are illustrated.
[0053] Specifically, the first upper extension portion 214a and the
second upper extension portion 214b are spaced apart and connected
to two sides of the rear end of the upper portion 212 (such as left
rear end and right rear end), so the first upper extension portion
214a, the second upper extension portion 214b, and the upper
portion 212 are combined to form an upper assembly 210. In an
embodiment, one of the upper extension portions 214a and 214b is
preferably knitted by continuing knitting the yarn of the upper
portion 212, and the other of the upper extension portions 214a and
214b is knitted by using another yarn (such as the third yarn 30 of
FIG. 15), but not limited thereto. In another embodiment, the upper
extension portions 214a and 214b can be knitted by using other
yarns of the same attribute or amount. Moreover, the upper
extension portions 214a and 214b are preferably symmetric in shape
(i.e. the outer appearances thereof are substantially visually
symmetric), but not limited thereto.
[0054] The front sole extension portion 224 is connected to the
rear end of the front sole portion 222, so the front sole portion
222 and the front sole extension portion 224 are combined to form a
front sole assembly 220. The front sole extension portion 224
partially corresponds to the first upper extension portion 214a and
the second upper extension portion 214b. For example, the front
sole extension portion 224 includes covered portions 224a and 224b
and an uncovered portion 224c. The covered portions 224a and 224b
are masked by the first upper extension portion 214a and the second
upper extension portion 214b, respectively. The uncovered portion
224c is exposed between the first upper extension portion 214a and
the second upper extension portion 214b. That is, the covered
portions 224a and 224b preferably respectively match the upper
extension portions 224a and 224b in shape and size, while the
uncovered portion 224c is located between the covered portions 224a
and 224b and not masked by the upper assembly 210. The front sole
portion 222 is preferably knitted by skip-needle single-knitting
from at least a yarn that is different from the yarn used for the
upper portion 212. The covered portions 224a, 224b of the front
sole extension portion 224 are preferably knitted continuing from
the yarn of the front sole portion 222 (such as the second yarn 20)
by skip-needle single-knitting. The uncovered portion 224c of the
front sole extension portion 224 is preferably knitted continuing
from the yarn of the front sole portion 222 (such as the second
yarn 20) by single-knitting. When the front sole portion 222 is
connected to the upper portion 212, the upper portion 212 and the
front sole portion 222 substantially completely overlap each other,
so the upper extension portions 214a and 214b substantially
completely overlap the covered portions 224a and 224b of the front
sole extension portion 224, respectively, while the uncovered
portion 224c of the front sole extension portion 224 is exposed by
not overlapping the upper portion 212 and the upper extension
portions 214a and 214b.
[0055] The front end of the upper portion 212 and the front end of
the front sole portion 222 are connected by the cast-on line 201,
while the two connection lines 202 and 203 are connected to two
ends of the cast-on line 201 and extend outward and obliquely
toward an outer side of the rear portion 130. For example, the
connection line 202 is connected to the left end of the cast-on
line 201 and extends rearward to connect the left side edge of the
upper portion 212 and the left side edge of the front sole portion
222 and further to connect the left side edge of the first upper
extension portion 214a and the left side edge of the covered
portion 214a. The connection line 203 is connected to the right end
of the cast-on line 201 and extends rearward to connect the right
side edge of the upper portion 212 and the right side edge of the
front sole portion 222 and further to connect the right side edge
of the second upper extension portion 214b and the right side edge
of the covered portion 214b. As such, the upper assembly 210 and
the front sole assembly 220 are connected at outer perimeters to
form the pocket structure.
[0056] It is noted that the thickness of the 3D shoe blank 200 in
FIG. 12 is exaggerated for better understanding. In practical
applications, the thickness of the 3D shoe blank 200 varies with
the choice of the yarns, the knitting density, etc.
[0057] As shown in FIG. 13, after the knitting of the 3D shoe blank
200 is finished, without any seaming work, the 3D shoe bank 200 can
be worn on the last and molded to form a shoe body 2. After the 3D
shoe blank 200 is molded into the shoe body 2, the upper assembly
210 and the front sole assembly 220 can cover from the foot dorsal
to the front plantar, while the 3D rear shoe portion 100a
constituted by the rear portion 130 and the heel portion 140 covers
the rear lateral portions, the rear plantar and the heel of the
foot. Specifically, the inner edges of the upper portion 212 and
the upper extension portions 214a and 214b and the upper edge of
the 3D rear shoe portion 100a (i.e. the outer edges of the rear
portion 130 and the heel portion 140) together define a shoe
opening 2a of the shoe body 2 to allow the foot to enter the
interior space enclosed by the shoe body 2. The connection lines
202 and 203 respectively start from two ends of the cast-on line
201 and extend gradually outward and obliquely toward the 3D rear
shoe portion 100a until reaching the shoe opening 2a, so the front
sole assembly 220 preferably covers from the front plantar toward
two opposite front lateral portions. For example, the upper portion
212 and the upper extension portions 214a and 214b can cover the
dorsal surface of the front foot, and the front sole portion 122
and at least a portion of the font sole extension portion 224 (such
as the uncovered portion 224c) covers the front plantar, while at
least a portion of the font sole extension portion 224 (such as the
covered portions 224a, 224b) extends upward to cover the front
lateral portions. Moreover, a portion of the rear portion 130
covers the rear plantar, while another portion of the rear portion
130 extends upward to cover the rear lateral portions and extends
rearward to cover the heel with the heel portion 140. Therefore,
the shoe body 2 formed from the 3D shoe blank 200 of the invention
can substantially cover the dorsal, the plantar, the lateral sides,
and the heel of the foot.
[0058] The 3D shoe blank 100 or 200 is preferably knitted by using
the double-bed flat knitting machine with movable cams, which can
change the moving direction and drive the actions of the needles.
In an embodiment, the method for knitting the 3D shoe blank by
using a double-bed flat knitting machine includes: providing at
least a first yarn (such as the yarn 10) on a front needle bed and
a back needle bed of the double-bed flat knitting machine by
skip-needle double-knitting and providing at least a second yarn
(such as the yarn 20) on the back needle bed together to form a
cast-on line (such as 101, 201); knitting the first yarn on the
front needle bed and the back needle bed by loop-transferring and
skip-needle double-knitting to form an upper portion (such as 112,
212); knitting the second yarn on the back needle bed by
skip-needle single-knitting to form a front sole portion (such as
122, 222), wherein the upper portion and the front sole portion are
alternatingly knitted, and the front sole portion is connected to
the upper portion to form a pocket structure; knitting continuing
from the front sole portion on the front needle bed and the back
needle bed to form a rear portion (such as 130), wherein when
forming the rear portion, a plurality of live stitches (such as
31a-38a, 31b-38b) are preserved on the front needle bed at two
sides of a rear end of the rear portion; and knitting continuing
from a center of the rear end of the rear portion on the front
needle bed and the back needle bed by double-knitting to form a
heel portion (such as 140) with a predetermined number of stitches,
wherein when the knitting of the heel portion reaches the
predetermined number of stitches at two opposite sides of the heel
portion, the back needle bed moves transversely to sequentially and
respectively knit the live stitches preserved on the front needle
bed at the two sides of the rear end of the rear portion together
with the two opposite sides of the heel portion, so the heel
portion and the rear portion are combined to form a 3D rear shoe
portion (such as 100a).
[0059] Hereafter, referring to FIGS. 14.about.16 and FIG. 1 to FIG.
13, the method for knitting the 3D shoe blank 100 or 200 by using
the double-bed flat knitting machine is illustrated. In an
embodiment, the method includes: providing at least a yarn (such as
the first yarn 10) on a front needle bed FB and a back needle bed
BB by skip-needle double-knitting and providing at least another
yarn (such as the second yarn 20) on the back needle bed BB
together to form a cast-on line 101 (or 201). For example, as shown
in FIG. 14, in step S10, from left to right, the first yarn 10 is
knitted alternatingly on the front needle bed FB and the back
needle bed BB with skipped needles (e.g. one stitch on the front
needle bed FB, skipped needles on front and back needle beds FB
& BB, one stitch on the back needle BB, then one stitch on the
front needle bed FB, skipped needles on front and back needle beds
FB, BB, one stitch on the back needle BB, and so on), and the
second yarn 20 is continuously knitted on the back needle bed BB,
so the first yarn 10 and the second yarn 20 together form the
cast-on line 101 (or 201) on the front needle bed FB and the back
needle bed BB. In other words, the skip-needle knitting refers to a
knitting manner that a certain needles of at least one of the front
needle bed FB and the back needle bed BB is missed or unused with
no stitches thereon. For example, the skip-needle double-knitting
refers to a knitting manner that is performed alternatingly on the
front needle bed FB and the back needle bed BB with a certain
needles thereof missed or unused with no stitches thereon. The
skip-needle single-knitting refers to a knitting manner that is
performed mainly on the front needle bed FB or the back needle bed
BB with a certain needles thereof missed or unused with no stitches
thereon. Moreover, it is noted that when forming the cast-on line
101 (or 201), the beginning and the end of the first yarn 10 and
the second yarn 20 are preferably knitted on the front needle bed
FB.
[0060] The method further includes: knitting the first yarn 10 on
the front needle bed FB and the back needle bed BB continuing from
the cast-on line 101 (or 201) by loop-transferring and skip-needle
double-knitting to form an upper portion 112 (or 212), and knitting
the second yarn 20 on the back needle bed BB continuing from the
cast-on line by skip-needle single-knitting to form a front sole
portion 122 (or 222), wherein the upper portion 112 (or 212) and
the front sole portion 122 (or 222) are alternatingly knitted, and
the front sole portion 122 (or 222) is connected to the upper
portion 112 (or 212) to form a pocket structure. For example, as
shown in step S11 of FIG. 14, during the first knitting period P1,
reverse-knitting from right to left, by using the cam at the first
order 401, the first yarn 10 is knitted alternatingly on the front
needle bed FB and the back needle bed BB with skipped needles to
connect the cast-on line 101 (or 201) and to form the upper portion
112 (or 212). In other words, the first yarn 10 is knitted
according to the stitches thereof knitted on the front needle bed
FB and the back needle bed BB in the previous step S10, so the
upper portion 112 (or 212) is knitted alternatingly on the front
needle bed FB and the back needle bed BB with skipped needles that
are unused (i.e. skip-needle double-knitting). Then, by using the
cam at the second order 402, a loop-transfer step is performed, so
the stitches of the upper portion 112 are changed from a skipped
alternating arrangement to a non-skipped arrangement. That is, the
stitches formed by the first yarn 10 on the back needle bed BB is
transferred to the non-occupied needles of the front needle bed FB
(i.e. the skipped front needles) in the previous knitting. After
the stitches of the upper portions 112 (or 212) are transferred, by
using the cam at the third order 403, the second yarn 20 is knitted
on the back needle bed BB by skip-needle knitting to connect the
cast-on line 101 (or 201) and to form the front sole portion 122
(or 222). That is, after the loop-transfer, the second yarn 20 is
knitted according to the stiches thereof on the back needle bed BB
(i.e. two adjacent stitches on the back needle bed with one skipped
needle in between), so the front sole portion 122 (or 222) is
knitted by skip-needle single-knitting.
[0061] During the second knitting period P2 of the step S11,
forward knitting from left to right, by using the cam at the first
order 401, the second yarn 20 is knitted on the back needle bed BB
by skip-needle single-knitting as described above to form another
course of the front sole portion 122 (or 222). That is, according
to the stitches of the front sole portion 122 (or 222) on the back
needle bed BB, the front sole portion 122 (or 222) is knitted on
the back needle bed BB and two adjacent stitches on the back needle
bed BB with one skipped needle in between. Then, by using the cam
at the second order 402, the loop-transfer step is performed to
change the stitches of the upper portion 112 (or 212) from the
non-skipped arrangement to the skipped alternating arrangement.
That is, the loops previously transferred to the front needle bed
FB are transferred back to their original positions on the back
needle bed BB. After the stitches of the upper portion 112 (or 212)
are transferred, by using the cam at the third order 403, the first
yarn 10 is knitted by skip-needle double-knitting on the front
needle bed FB and the back needle bed BB to form the upper portion
112 (or 212). That is, after the loop-transfer, the first yarn 10
is knitted according to the stitches of the upper portion 112 (or
212) on the front needle bed FB and the back needle bed BB to form
a next course of the upper portion 112 (or 212). It is noted that
during the knitting process, since the knitting direction
alternates between forward and reverse, the order of the cams
alternates accordingly. For example, during the second knitting
period P2 of the step S11, the cam at the first order 401 is the
cam at the third order 403 in the first knitting period P1, and the
cam at the third order 403 is the cam at the first order 401 in the
first knitting period P1. Since the cam at the second order 402 is
arranged in the middle of the order, no matter it is in the forward
or reverse knitting period, the order of the cam at the second
order 402 remains the same.
[0062] During the third knitting period P3 of the step S11, reverse
knitting from right to left, by using the cam at the first order
401 (i.e. the cam at the third order 403 in the second knitting
period P2), the first yarn 10 is knitted by skip-needle
double-knitting alternatingly on the front needle bed FB and the
back needle bed BB to from the upper portion 112 (or 212). Then, by
using the cam at the second order 402, the loop-transfer step is
performed, so the stitches of the upper portion 112 (or 212) are
changed from the skipped alternating arrangement to the non-skipped
arrangement. That is, the stitches of the upper portion 112 (or
212) formed by the first yarn 10 on the back needle bed BB are
transferred to the non-occupied needles of the front needle bed FB
(i.e. the skipped front needles) in the previous knitting. After
the stitches of the upper portions 112 (or 212) are transferred, by
using the cam at the third order 403 (i.e. the cam at the first
order 401 in the second knitting period P2), the second yarn 20 is
knitted on the back needle bed BB by skip-needle single-knitting to
form a next course of the front sole portion 122 (or 222).
[0063] During the fourth knitting period P4 of the step S11,
forward knitting from left to right, by using the cam at the first
order 401 (i.e. the cam at the third order 403 in the third
knitting period P3), the second yarn 20 is knitted on the back
needle bed BB by skip-needle single-knitting as described above to
form another course of the front sole portion 122 (or 222). Then,
by using the cam at the second order 402, the loop-transfer step is
performed to change the stitches of the upper portion 112 (or 212)
from the non-skipped arrangement to the skipped alternating
arrangement. That is, the loops of the upper portion 112 (or 212)
previously transferred to the front needle bed FB are transferred
back to their original positions on the back needle bed BB. After
the stitches of the upper portion 112 (or 212) are transferred, by
using the cam at the third order 403 (i.e. the cam at the first
order 401 in the third knitting period P3), the first yarn 10 is
knitted by skip-needle double-knitting alternatingly on the front
needle bed FB and the back needle bed BB to from another course of
the upper portion 112 (or 212). That is, the knitting in the fourth
knitting period P4 is substantially the same as the knitting in the
second knitting period P2. By repeating the knitting in the second
knitting period P2 and the third knitting period P3 of the step
S11, the upper portion 112 (or 212) and the front sole portion 122
(or 222) can be alternatingly knitted until the formation of the
upper portion 112 (or 212) and the front sole portion 122 (or 222)
is completed. Specifically, by repeating the knitting in the second
knitting period P2 and the third knitting period P3 of the step
S11, the pocket structure constituted by the upper portion 112 and
the front sole portion 122 of the 3D shoe blank 100 in FIG. 1 or
the pocket structure constituted by the upper portion 212 and the
front sole portion 222 of the 3D shoe blank 200 in FIG. 2 can be
formed.
[0064] When forming the 3D shoe blank 200 of FIG. 7, the method
further includes: knitting continuing from one side of a rear end
of the upper portion 212 by loop-transferring and skip-needle
double-knitting to form a first upper extension portion (such as
214a); knitting a third yarn (as shown in FIG. 15) continuing from
the other side of the rear end of the upper portion 212 by
loop-transferring and skip-needle double-knitting to form a second
upper extension portion (such as 214b), wherein the first upper
extension portion 214a and the second upper extension portion 214b
are spaced apart and substantially symmetric, so the first upper
extension portion 214a, the second upper extension portion 214b,
and the upper portion 212 are combined to form the upper assembly
210; and knitting the second yarn 20 on the back needle bed BB to
form a front sole extension portion (such as 224) between the front
sole portion 222 and the rear portion 130, wherein a portion of the
front sole extension portion 224 corresponding to the first upper
extension portion 214a and the second upper extension portion 214b
(such as covered portions 224a, 224b) is knitted by skip-needle
single-knitting, and another portion of the front sole extension
portion 224 not corresponding to the first upper extension portion
214a and the second upper extension portion 214b (such as the
uncovered portion 224c) is single-knitted, so the front sole
portion 222 and the front sole extension portion 224 are combined
to form the front sole assembly 220.
[0065] For example, as shown in FIG. 15, in an embodiment, a step
S12 of forming the upper extension portions 214a and 214b and the
front sole extension portion 224 includes: during the first
knitting period P1, forward knitting from left to right, by using
the cam at the third order 403, the first yarn 10 is knitted by
skip-needle knitting alternatingly on the front needle bed FB and
the back needle bed BB to form a course of the first upper
extension portion 214a. As such, the first upper extension portion
214a is connected to the left rear end of the upper portion 212 by
space double-knitting.
[0066] The step S12 further includes: during the second knitting
period P2, reverse knitting from right to left, by using the cam at
the first order 401, a third yarn 30 is provided at the left rear
end of the upper portion 212 and knitted by skip-needle
double-knitting alternatingly on the front needle bed FB and the
back needle bed BB to form a course of the second upper extension
portion 214b. As such, the second upper extension portion 214b is
connected to the right rear end of the upper portion 212 and
knitted by space double-knitting as described above. Then, by using
the cam at the second order 402, the loop-transfer step is
performed to change the stitches of the upper extension portions
214a and 214b from the skipped alternating arrangement to the
non-skipped arrangement. That is, the stitches of the upper
extension portions 214a and 214b formed by the first yarn 10 and
the third yarn 30 on the back needle bed BB is transferred to the
corresponding non-occupied needles of the front needle bed FB (i.e.
the skipped front needles) in the previous knitting. After the
loop-transfer, by using the cam at the third order 403, the second
yarn 20 of the front sole portion 222 is knitted by skip-needle
single-knitting at a location corresponding to the second upper
extension portion 214b on the back needle bed BB to form the right
covered portion 224b, continuously single-knitted at a location
corresponding between the upper extension portions 214a and 214b on
the back needle bed BB to form the uncovered portion 224c, and then
knitted by skip-needle single knitting at a location corresponding
to the first upper extension portion 214a on the back needle bed BB
to form the left covered portion 224a, so the left covered portion
224a, the uncovered portion 224c, and the right covered portion
224b together form the front sole extension portion 224, which is
connected to the rear end of the front sole portion 222.
[0067] During the third knitting period P3 of the step S12, forward
knitting from left to right, by using the cam at the first order
401 (i.e. the cam at the third order in the second knitting period
P2), the second yarn 20 is knitted by skip-needle single-knitting
at a location corresponding to the first upper extension portion
214a on the back needle bed BB to form another course of the left
covered portion 224a, continuously single-knitted at a location
corresponding between the upper extension portions 214a and 214b on
the back needle bed BB to form another course of the uncovered
portion 224c, and then knitted by skip-needle single-knitting at a
location corresponding to the second upper extension portion 214b
on the back needle bed BB to form the right covered portion 224b,
so another course of the front sole extension portion 224 is
knitted. Then, by using the cam at the second order 402, the
loop-transfer step is performed to change the stitches of the upper
extension portions 214a, 214b from the skipped alternating
arrangement to the non-skipped arrangement. That is, the loops of
the upper extension portions 214a and 214b previously transferred
to the front needle bed FB are transferred back to their original
positions on the back needle bed BB. After the loop-transfer, by
using the cam at the third order 403 (i.e. the cam at the first
order in the second knitting period P2), the first yarn 10 is
knitted by skip-needle double-knitting alternatingly on the front
needle bed FB and the back needle bed BB to from another course of
the first upper extension portion 214a, and the third yarn 30 is
knitted by skip-needle double-knitting alternatingly on the front
needle bed FB and the back needle bed BB to form another course of
the second upper extension portion 214b.
[0068] During the fourth knitting period P4 of the step S12,
reverse knitting from right to left, by using the cam at the first
order 401 (i.e. the cam at the third order 403 in the third
knitting period P3), the third yarn 30 is knitted by skip-needle
double-knitting alternatingly on the front needle bed FB and the
back needle bed BB to from another course of the second upper
extension portion 214b, and the first yarn 10 is knitted by
skip-needle double-knitting alternatingly on the front needle bed
FB and the back needle bed BB to from another course of the first
upper extension portion 214a. Then, by using the cam at the second
order 402, the loop-transfer step is performed to change the
stitches of the upper extension portions 214a, 214b from the
skipped alternating arrangement to the non-skipped arrangement.
That is, the stitches of the upper extension portions 214a, 214b
respectively formed by the first yarn 10 and the third yarn 30 on
the back needle bed BB are transferred to the corresponding
non-occupied needles of the front needle bed FB (i.e. the skipped
front needles) in the previous knitting. After the loop-transfer,
by using the cam at the third order 403 (i.e. the cam at the first
order 401 in the third knitting period P3), the second yarn 20 of
the front sole portion 222 is knitted by skip-needle
single-knitting at a location corresponding to the second upper
extension portion 214b on the back needle bed BB to form the right
covered portion 224b, continuously single-knitted at a location
corresponding to the space between the upper extension portions
214a and 214b on the back needle bed BB to form the uncovered
portion 224c, and then knitted by skip-needle single-knitting at a
location corresponding to the first upper extension portion 214a on
the back needle bed BB to form the left covered portion 224a, so
another course of the front sole extension portion 224 is knitted.
Accordingly, by repeating the third knitting period P3 and the
fourth knitting period P4 of the step S12, the knitting of the
upper extension portions 214a, 214b and the front sole extension
portion 224 can be completed, so the first upper extension portion
214a, the second upper extension portion 214b, and the upper
portion 212 together form the upper assembly 210, and the front
sole extension portion 224 and the front sole portion 222 together
form the front sole assembly 220. As such, the upper assembly 210
and the front sole assembly 220 partially corresponds to each other
to form a pocket structure. The upper assembly 210 (including the
upper portion 212 and the upper extension portions 214a and 214b)
formed by such skip-needle double-knitting can have two technical
surfaces to enhance the structural strength of the upper assembly
210. The portion of the front sole assembly 220 that corresponds to
the upper assembly 210 (such as the front sole portion 222 and the
covered portions 224a and 224b) has a skipped single-knitted
structure, while the portion of the front sole assembly 220 that
does not correspond to the upper assembly 210 (such as the
uncovered portion 224c) has a single-knitted structure.
[0069] It is noted that the number of stitches of the upper
extension portions 214a and 214b can be changed (such as gradually
reduced or increased) during the knitting process to increase the
variety of the upper assembly 210.
[0070] In an embodiment, referring to FIG. 16, a step of forming
the 3D rear shoe portion 100a of FIG. 4 or FIG. 10 is illustrated.
For example, after the formation of the upper portion 112 and the
front sole portion 122 of FIG. 1 or after the formation of the
upper assembly 210 and the front sole assembly 210 of FIG. 7, the
method includes: knitting continuing from the rear end of the front
sole portion 122 (or the font sole extension portion 224) on the
front needle bed FB and the back needle bed BB to form the rear
portion 130. As described above, the yarn used for knitting the
rear portion 130 may include the first yarn 10, the second yarn 20,
and/or the third yarn 30, or another yarn. Alternatively, the yarn
used for knitting the rear portion 130 may include the first yarn
10, the second yarn 20, and/or the third yarn 30 together with
another yarn. In this embodiment, the yarns 10 and 20 continue to
be knitted back and forth from left to right or from right to left
on the front needle bed FB and the back needle bed BB to form the
rear portion 130, so the rear portion 130 is connected to the rear
end of the front sole portion 122 (or the front sole extension
portion 224).
[0071] The heel portion 140 may be knitted from the yarns
previously used (such as 10, 20, 30) or another yarn.
Alternatively, the heel portion 140 may be knitted from the yarns
previously used (such as 10, 20, 30) together with another yarn.
For example, after forming the rear portion 130, the yarns 10 and
20 are knitted on the front needle bed FB and the rear needle bed
BB from the left side of the rear portion 130 toward the center of
the rear portion 130 to form a predetermined number of stitches of
the heel portion 140, and a plurality of live stitches (such as
31a-38a) are preserved on the front needle bed FB at the right side
of the rear end of the rear portion 130. It is noted that when the
heel portion 140 reaches the predetermined number of stitches on
the right border, the location of the rightmost stitch 41a of the
heel portion 140, which is to be knitted, corresponds to the
location of the innermost (i.e. leftmost) live stitch 31a of the
live stitches 31a-38a preserved at the right rear end of the rear
portion 130. By moving the back needle bed BB transversely, the
stitch 31a of the rear portion 130 is knitted with the heel portion
140, so the right side of the heel portion 140 is connected to the
right rear end of the rear portion 130.
[0072] Then, reversing knitting from right to left, the yarns 10
and 20 are knitted on the front needle bed FB and the rear needle
bed BB from the right border to the left border of the heel portion
140 to form a next course of the heel portion 140, and a plurality
of live stitches (such as 31b.about.38b) are preserved on the front
needle bed FB at the left side of the rear end of the rear portion
130. It is noted that when the heel portion 140 reaches the
predetermined number of stitches on the left border, the location
of the leftmost stitch 41b of the heel portion 140, which is to be
knitted, corresponds to the location of the innermost (i.e.
rightmost) live stitch 31b of the live stitches 31b.about.38b
preserved at the left rear end of the rear portion 130. By moving
the back needle bed BB transversely, the stitch 31b of the rear
portion 130 is knitted with the heel portion 140, so the left side
of the heel portion 140 is connected to the left rear end of the
rear portion 130.
[0073] The heel portion 140 is repeatedly knitted back and forth
from right to left or left to right in a similar manner, wherein
when the knitting of the heel portion 140 reaches the predetermined
number of stitches at two opposite sides of the heel portion 140,
by moving the back needle bed BB transversely, the live stitches
(such as 31a.about.38a, 31b.about.38b) preserved on the front
needle bed FB at the right and left rear ends of the rear portion
130 are sequentially and respectively knitted with the right and
left sides of the heel portion 140, so the heel portion 140 and the
rear portion 130 are combined to form a 3D rear shoe portion 100a.
For example, the number of the live stitches (such as
31b.about.38b) preserved at the left rear end of the rear portion
130 is preferably the same as the number of the live stitches (such
as 31a.about.38a) preserved at the right rear end of the rear
portion 130. Therefore, by repeating the double-knitting of the
heel portion 140 on the front needle bed FB and the back needle bed
BB as described above, the right live stitch 32a of the rear
portion 130 is knitted with the heel portion 140 at the location of
the stitch 42a at the right border, and the left live stitch 32b of
the rear portion 130 is knitted with the heel portion 140 at the
location of the stitch 42b at the left border. The right live
stitch 33a of the rear portion 130 is knitted with the heel portion
140 at the location of the stitch 43a at the right border, and the
left live stitch 33b of the rear portion 130 is knitted with the
heel portion 140 at the location of the stitch 43b at the left
border. The right live stitch 34a of the rear portion 130 is
knitted with the heel portion 140 at the location of the stitch 44a
at the right border, and the left live stitch 34b of the rear
portion 130 is knitted with the heel portion 140 at the location of
the stitch 44b at the left border. The right live stitch 35a of the
rear portion 130 is knitted with the heel portion 140 at the
location of the stitch 45a at the right border, and the left live
stitch 35b of the rear portion 130 is knitted with the heel portion
140 at the location of the stitch 45b at the left border. The right
live stitch 36a of the rear portion 130 is knitted with the heel
portion 140 at the location of the stitch 46a at the right border,
and the left live stitch 36b of the rear portion 130 is knitted
with the heel portion 140 at the location of the stitch 46b at the
left border. The right live stitch 37a of the rear portion 130 is
knitted with the heel portion 140 at the location of the stitch 47a
at the right border, and the left live stitch 37b of the rear
portion 130 is knitted with the heel portion 140 at the location of
the stitch 47b at the left border. The right live stitch 38a of the
rear portion 130 is knitted with the heel portion 140 at the
location of the stitch 48a at the right border, and the left live
stitch 38b of the rear portion 130 is knitted with the heel portion
140 at the location of the stitch 48b at the left border.
Consequently, the right border of the heel portion 140 is connected
to the right rear end of the rear portion 130, so the joining line
104a is formed. The left border of the heel portion 140 is
connected to the left rear end of the rear portion 130, so the
joining line 104b is formed. As such, the heel portion 140 and the
rear portion 130 are combined to form the 3D rear shoe portion
100a, and the 3D shoe blank 100 (or 200) is completed.
[0074] Moreover, in addition to the design change in the upper
portion, the 3D shoe blank of the invention may have other
modifications to achieve different outer appearances or to provide
other functions. As shown in FIG. 17 and FIG. 18, in a third
embodiment, the 3D shoe blank 200' further includes an extension
strap 150, which is partially connected to the heel portion 140 and
extends outward toward the two opposite sides of the heel portion
140. In this embodiment, the 3D shoe blank 200' is a modification
of the 3D shoe blank 200 of FIG. 7, but the extension strap 150 may
be applied to the 3D shoe blank 100 of FIG. 1. The extension strap
150 is preferably a strap knitted from at least a yarn and
connected to the heel portion 140. In an embodiment, the extension
strap 150 is preferably double-knitted from the yarns (such as 10,
20, and/or 30) used in the previously knitting process or another
yarn that is additional introduced. In another embodiment, the
extension strap 150 can be double-knitted from the yarns (such as
10, 20, and/or 30) used in the previously knitting process together
another yarn.
[0075] Corresponding to the design of the extension strap 150, the
method of the invention further includes: double-knitting on the
font needle bed FB and the back needle bed BB to form the extension
strap 150, which is partially connected to the heel portion 140 and
extends outward toward two opposite sides of the heel portion 140.
That is, after the 3D rear shoe portion 100a is formed, at least a
yarn is provided and knitted to form the extension strap 150, so
one side of the extension strap 150 is partially connected to the
heel portion 140 and two ends of the extension strap 150 extend
outward toward two opposite sides of the heel portion 140. For
example, in the case of knitting from right to left to form the
heel portion 140, after the left live stitch 38b of the rear
portion 130 is knitted with left border of the heel portion 140 at
the location of the stitch 48b, the yarn of the heel portion 140
continues to be knitted leftward for a predetermined number of
stitches to form the left strap portion of the extension strap 150.
Then, the knitting direction is reversed to form a next course of
the left strap portion and to connect the heel portion 140. After
connecting the heel portion 140, the knitting is continued
rightward for a predetermined number of stitches to form the right
strap portion of the extension strap 150. By repeating the knitting
process back and forth, the extension strap 150 can be formed.
[0076] As shown in FIG. 19, after the 3D shoe blank 200' is molded
into a shoe body 2', the length of the extension strap 150 is
preferably long enough to surround the ankle (indicated by the
arrow 2b) of the wear's foot and to be fastened to form a bowknot.
Therefore, not only the outer appearance of the shoe body 2' can be
enhanced, but the function of securing the shoe body 2' is also
provided.
[0077] As shown in FIG. 20 and FIG. 21, in a fourth embodiment, a
3D shoe blank 200'' further includes an extension portion 260,
which is connected between the heel portion 140 and the extension
strap 250. In this embodiment, the 3D shoe blank 200'' is a
modification of the 3D shoe blank 200 of FIG. 7, but the extension
strap 250 and the extension portion 260 may be applied to the 3D
shoe blank 100 of FIG. 1. The extension portion 260 extends upward
from the upper end of the heel portion 140, so one side of the
extension strap 250 is connected to the top side of the extension
portion 260 and further connected to the heel portion 140 by means
of the extension strap 260. For example, the extension portion 260
and the extension strap 250 are preferably double-knitted from the
yarns (such as 10, 20, and/or 30) used in the previously knitting
process or another yarn. In another embodiment, the extension
portion 260 and the extension strap 250 can be double-knitted from
the yarns (such as 10, 20, and/or 30) used in the previously
knitting process together with another yarn.
[0078] Corresponding to the design of the extension portion 260,
the method of the invention further includes: double-knitting from
the heel portion 140 on the font needle bed FB and the back needle
bed BB to form the extension portion 260 connected between the heel
portion 140 and the extension strap 250. In an embodiment, the
extension portion 260 is formed by continuing knitting the yarns of
the heel portion 140, so the extension portion 260 extends upward
from the heel portion 140 and is connected between the heel portion
140 and the extension strap 250. For example, in the case of
knitting from right to left to form the heel portion 140, after the
left live stitch 38b of the rear portion 130 is knitted with left
border of the heel portion 140 at the location of the stitch 48b,
the yarn of the heel portion 140 is reverse-knitted from left to
right to connect the heel portion 140 and to form the extension
portion 260, and then the knitting process is continued back and
forth (i.e. from right to left or left to right) to complete the
knitting of the extension portion 250. After the extension portion
260 is formed, the knitting can be continued for example leftward
for a predetermined number of stitches to form the left strap
portion of the extension strap 250. Then, the knitting direction is
reversed to form a next course of the left strap portion and to
connect the extension portion 260, and the knitting is continued
rightward for a predetermined number of stitches to form the right
strap portion of the extension strap 250. By repeating the knitting
process back and forth, the extension strap 250 can be formed.
[0079] As shown in FIG. 22, after the 3D shoe blank 200'' is molded
into a shoe body 2'', the design of the extension portion 260 can
increase the convenience of wearing shoes and maintain a certain
distance between the extension strap 250 and the heel portion 140
to vary the outer appearance of the shoe body 2''. The length of
the extension strap 250 is preferably long enough to surround the
ankle (indicated by the arrow 2b) of the wear's foot and to be
fastened to form a bowknot. Therefore, not only the outer
appearance of the shoe body 2'' can be enhanced, but the function
of securing the shoe body 2'' is also provided.
[0080] Although the preferred embodiments of the present invention
have been described herein, the above description is merely
illustrative. The preferred embodiments disclosed will not limit
the scope of the present invention. Further modification of the
invention herein disclosed will occur to those skilled in the
respective arts and all such modifications are deemed to be within
the scope of the invention as defined by the appended claims.
* * * * *