Shoe structure and manufacturing method thereof

Abstract

A shoe structure includes a shoe body knitted from at least one yarn in unitary structure with only one opening for receiving a foot of a wear therein. The shoe body includes an upper section, a sole section, and a rear section connected by knitting without any sewing portion when the shoe body is formed. The upper section corresponds to fore and lateral portions of the foot. The sole section supports a sole portion of the foot. The rear section corresponds to a heel portion of the foot, wherein the shoe body consists of multiple courses and wales formed by the at least one yarn. The wales in the upper section extend along a direction perpendicular to a receiving direction of the opening into the shoe body.

What is claimed is: 
     
         1 . A shoe structure, comprising:
 a shoe body knitted from at least one yarn in unitary structure with only one opening for receiving a foot of a wear therein, the shoe body comprising an upper section, a sole section, and a rear section connected by knitting without any sewing portion when the shoe body is formed, the upper section corresponding to fore and lateral portions of the foot, the sole section supporting a sole portion of the foot, the rear section corresponding to a heel portion of the foot, wherein the shoe body consists of multiple courses and wales formed by the at least one yarn, the wales in the upper section extend along a direction perpendicular to a receiving direction of the opening into the shoe body.   
     
     
         2 . The shoe structure of  claim 1 , wherein the wales in the rear section and the sole section extend along the same direction as the wales in the upper section. 
     
     
         3 . The shoe structure of  claim 1 , wherein the wales in the rear section extend along a direction parallel to the receiving direction of the opening. 
     
     
         4 . The shoe structure of  claim 1 , further comprising a reinforcement layer knitted from a thermal plastic yarn on the shoe body, wherein the reinforcement layer and the shoe body are simultaneously knitted together when the shoe body is formed, and the reinforcement layer is thermal-curable. 
     
     
         5 . The shoe structure of  claim 4 , further comprising an auxiliary shoe body knitted from at least one yarn in unitary structure, the auxiliary shoe body having a shape conformal to the shoe body, wherein the auxiliary shoe body is inserted into the shoe body through the opening and the reinforcement layer is sandwiched between the shoe body and the auxiliary shoe body and cured to attach the auxiliary shoe body to the shoe body. 
     
     
         6 . A method for manufacturing a shoe structure, comprising:
 knitting at least one yarn to form a shoe body in unitary structure with an opening for receiving a foot of a wearer, the shoe body comprising an upper section, a sole section, and a rear section connected by knitting without any sewing portion, the upper section corresponding to fore and lateral portions of the foot, the sole section supporting a sole portion of the foot, the rear section corresponding to a heel portion of the foot; and   knitting a thermal plastic yarn to form a reinforcement layer on the shoe body, wherein the reinforcement layer and the shoe body are simultaneously knitted together when the shoe body is formed.   
     
     
         7 . The method of  claim 6 , wherein the at least one yarn is knitted so that the shoe body consists of multiple courses and wales formed by the at least one yarn; the wales in the rear section, the sole section, and the upper section are knitted along a same direction substantially perpendicular to a receiving direction of the opening into the shoe body. 
     
     
         8 . The method of  claim 6 , wherein the at least one yarn is knitted so that the shoe body consists of multiple courses and wales formed by the at least one yarn, and the wales in the rear section extend along a direction different from the wales in the upper section and the sole section. 
     
     
         9 . The method of  claim 8 , wherein the at least one yarn is knitted along a first direction in the upper section and changes to a second direction in the rear section, the first direction and the second direction are two cross directions. 
     
     
         10 . The method of  claim 6 , further comprising curing the reinforcement layer to form a reinforcement structure for the shoe body and shape the shoe body by thermal plastic molding. 
     
     
         11 . The method of  claim 6 , further comprising:
 knitting at least one yarn to form an auxiliary shoe body, the auxiliary shoe body having a shape conformal to the shoe body;   inserting the auxiliary shoe body into the shoe body through the opening and the reinforcement layer is sandwiched between the shoe body and the auxiliary shoe body; and   curing the reinforcement layer to attach the auxiliary shoe body to the shoe body to form the shoe structure and shape the shoe structure by thermal plastic molding.   
     
     
         12 . A shoe structure, comprising:
 a first shoe body comprising a first upper section, a first sole section, and a first rear section;   a second shoe body comprising a second upper section, a second sole section, and a second rear section;   a connection section connected between the first shoe body and the second shoe body,   wherein the second shoe body is inserted into the first shoe body to form the shoe structure with an opening in a manner that the first upper section overlaps the second upper section, the first sole section overlaps the second sole section, the first rear section overlaps the second rear section, and the connection section is folded to define the opening for receiving a foot of a wear into the shoe structure.   
     
     
         13 . The shoe structure of  claim 12 , wherein the first shoe body, the connection section, and the second shoe body are knitted sequentially from at least one yarn in unitary structure with an adjustable interior before the second shoe body is inserted into the first shoe body. 
     
     
         14 . The shoe structure of  claim 13 , further comprising a reinforcement layer simultaneously knitted from a thermal plastic yarn on at least one of the first shoe body and the second shoe body when the unitary structure is formed, wherein the reinforcement layer is disposed within the adjustable interior and is thermal-curable. 
     
     
         15 . The shoe structure of  claim 14 , wherein the second shoe body is inserted into the first shoe body in a manner that the reinforcement layer is sandwiched between the first shoe body and the second shoe body, and the first shoe body and the second shoe body are attached to each other by the reinforcement layer after the reinforcement layer is cured. 
     
     
         16 . The shoe structure of  claim 14 , wherein the reinforcement layer is knitted substantially on the first shoe body, the connection section, and the second shoe body within the adjustable interior. 
     
     
         17 . A method for manufacturing a shoe structure, comprising:
 knitting a first shoe body from at least one yarn, the first shoe body comprising a first upper section, a first sole section, and a first rear section connected by knitting without any sewing portion;   knitting a second shoe body from at least one yarn, the second shoe body comprising a second upper section, a second sole section, and a second rear section connected by knitting without any sewing portion;   knitting a connection section from at least one yarn to connect the first shoe body and the second shoe body; and   inserting the second shoe body into the first shoe body to form the shoe structure with an opening in a manner that the first upper section overlaps the second upper section, the first sole section overlaps the second sole section, the first rear section overlaps the second rear section, and the connection section is folded to define the opening for receiving a foot of a wear into the shoe structure.   
     
     
         18 . The method of  claim 17 , wherein the first shoe body, the connection section, and the second shoe body are knitted sequentially to form a unitary structure with an adjustable interior before the second shoe body is inserted into the first shoe body. 
     
     
         19 . The method of  claim 18 , further comprising knitting a reinforcement layer from a thermal plastic yarn on at least one of the first shoe body and the second shoe body when the unitary structure is formed, wherein the reinforcement layer is disposed within the adjustable interior and is thermal-curable. 
     
     
         20 . The method of  claim 19 , further comprising curing the reinforcement layer to attach the second shoe body to the first shoe body and shape the shoe structure by thermal plastic molding.