Seamless 3D flat knit vamp and manufacturing method thereof

Abstract

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.

What is claimed is: 
     
         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, A 1 , B 1 , C 1 , D 1 , E 1 , F 1 , G 1 , H 1  from left to right; needles on a rear needle bed are denoted by a, b, c, d, e, f, g, h, a 1 , b 1 , c 1 , d 1 , e 1 , f 1 , g 1 , h 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 F 1  of the front needle bed; f 1  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 D 1  of the front needle bed; d 1  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 D 1  of the front needle bed; d 1  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 F 1  of the front needle bed; f 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 h 1  of the rear needle bed; H 1  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 H 1  of the front needle bed; h 1  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 h 1  of the rear needle bed; H 1  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 g 1  of the rear needle bed; G 1  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 e 1  of the rear needle bed; E 1  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 d 1  of the rear needle bed; D 1  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 e 1  of the rear needle bed; E 1  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 g 1  of the rear needle bed; G 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 F 1  of the front needle bed; f 1  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 D 1  of the front needle bed; d 1  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 D 1  of the front needle bed; d 1  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 F 1  of the front needle bed; f 1  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 H 1  of the front needle bed; h 1  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 g 1  of the rear needle bed; G 1  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 e 1  of the rear needle bed; E 1  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 d 1  of the rear needle bed; D 1  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 e 1  of the rear needle bed; E 1  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 g 1  of the rear needle bed; G 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 g 1  of the rear needle bed; G 1  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 e 1  of the rear needle bed; E 1  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 d 1  of the rear needle bed; D 1  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 e 1  of the rear needle bed; E 1  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 g 1  of the rear needle bed; G 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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 H 1  of the front needle bed; h 1  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.