Abstract:
The present disclosure illustrates a vamp with an embossed pattern. The vamp includes plain cloth and an embossed layer. The plain cloth is breathable fabric blended with hot-melt adhesive yarn. The embossed layer is formed on the plain cloth by a cold press process performed with cold press apparatus. The embossed layer formed on the vamp serves as a predetermined design pattern or as a structural reinforcement. The herein described process of manufacturing the vamp may be used as a basis to improve the manufacturing efficiency and quality of the vamp to produce a high quality shoe product at a reasonable price. The resulting shoe product has present-day desired characteristics and features beyond those provided in shoes made with conventional vamps, and may include added comfort, specific protection features and appear aesthetically appealing and fashionable.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of Taiwan Patent Application No. 104220547, filed Dec. 22, 2015 at the Taiwan Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present disclosure relates to a vamp with an embossed pattern, more particularly to a vamp having an embossed pattern which is formed by a manner of cold pressing. 
         [0004]    2. Description of the Related Art 
         [0005]    While high technology industries such as the semiconductor industry have rapidly developed, the textile industry has so far generally remained traditional in its practices. The textile industry faces strong competition and pressure to continuously innovate and integrate new technologies in order to develop novel, high value-added products. In recent years, textile products have to perform well, be comfortable, include protection features and appear aesthetically appealing and fashionable. As a result functional fabrics have become a hot product in the textile industry. 
         [0006]    A conventional vamp made of fabric does not have the desired physical characteristics, and in particular lacks structural reinforcement. So during the manufacturing process, some reinforced sheets (or films) are sewn on to reinforce the shoe&#39;s structure. On the other hand, commercially available polyurethane (PU) vamp does have the desired physical property of being structurally sturdy, but has the drawback of poor breathability. 
         [0007]    After much experience and study in the field, the inventor of the present disclosure has developed and designed a vamp with an embossed pattern that overcomes the aforementioned limitations of conventional shoe build and design to provide present-day desired features, while also improving on industrial practicability. 
       SUMMARY OF THE INVENTION 
       [0008]    An objective of the present disclosure is to provide a vamp with an embossed pattern, to overcome the aforementioned limitations of conventional shoe build and design. 
         [0009]    To achieve the objective, the present disclosure provides a vamp with an embossed pattern, and the vamp includes plain cloth and an embossed layer. The plain cloth is of breathable fabric blended with hot-melt adhesive yarn. The embossed layer is formed on the plain cloth by a cold press process performed with cold press apparatus, and the embossed layer on the vamp serves as a predetermined design pattern or as a structural reinforcement. 
         [0010]    Preferably, the vamp further includes a colored layer formed on the embossed layer or the plain cloth by a manner of digital printing. 
         [0011]    Preferably, the plain cloth is provided with a crop mark, and the colored layer is formed in an area enclosed by the crop mark. 
         [0012]    Preferably, the plain cloth is provided with a crop mark, and the vamp is formed by cropping the plain cloth along the crop mark. 
         [0013]    Preferably, the plain cloth can withstand a temperature range from 150° C. to 190° C. in a process of forming the embossed layer. 
         [0014]    Preferably, in the process of forming the embossed layer, the plain cloth is heated to a temperature below 190° C. and above 150° C. with hot air generated from a hot blow drying device, and the temperature of the hot air is in the range 100° C. to 200° C. 
         [0015]    Preferably, the cold press apparatus is operated to cold press on the plain cloth in a temperature range from 0° C. to 25° C. 
         [0016]    Preferably, the plain cloth is white cloth. 
         [0017]    According to the aforementioned content, the vamp of the present disclosure has at least one of advantages described below. 
         [0018]    First, during the formation of the vamp of the present disclosure, the cold press process is performed on the breathable plain cloth to melt the hot-melt adhesive yarn. The melted hot-melt adhesive yarn then hardens to form the embossed layer. The embossed layer may serve as the predetermined design pattern or the structural reinforcement for the vamp, according to what physical properties are desired for the breathable fabric vamp of the shoe to be produced. 
         [0019]    Second, during the formation of the vamp of the present disclosure, the digital printing process is performed on the white plain cloth to form the colored layer on the embossed layer or on the plain layer. This is preferable to water-polluting methods of conventional dying of the vamp. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    The detailed structure, operating principle and effects of the present disclosure will hereinafter be described in more detail with reference to the accompanying drawings that show various embodiments of the present disclosure. 
           [0021]      FIG. 1  is a schematic view of a finished vamp with an embossed pattern, in accordance with the present disclosure. 
           [0022]      FIG. 2  is a first schematic view of the vamp with the embossed pattern, in accordance with the present disclosure. 
           [0023]      FIG. 3  is a second schematic view of the vamp with the embossed pattern, in accordance with the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0024]    The following embodiments of the present invention are herein described in detail with reference to the accompanying drawings. These drawings show specific examples of the embodiments of the present invention. It is to be understood that these embodiments are exemplary implementations and are not to be construed as limiting the scope of the present invention in any way. Further modifications to the disclosed embodiments, as well as other embodiments, are also intended to be included within the scope of the appended claims. These embodiments are provided so that this disclosure is thorough and complete, and fully conveys the inventive concept to those skilled in the art. Regarding the drawings, the relative proportions and ratios of elements in the drawings may be exaggerated or diminished in size for the sake of clarity and convenience. Such arbitrary proportions are only illustrative and not limiting in any way. The same reference numbers are used in the drawings and description to refer to the same or like parts. 
         [0025]    It is to be understood that, although the terms ‘first’, ‘second’, ‘third’, and so on, may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used only for the purpose of distinguishing one component from another component. Thus, a first element discussed herein could be termed a second element without altering the description of the present invention. As used herein, the term “or” includes any and all combinations of one or more of the associated listed items. 
         [0026]    The following refers to  FIG. 1 , which shows a schematic view of a finished vamp with an embossed pattern in accordance with the present disclosure. As shown in  FIG. 1 , a vamp  1  includes a plain cloth  10  and an embossed layer  20 . In an embodiment of the present disclosure, the vamp  1  can further include a colored layer  30 , and the plain cloth  10  is implemented as breathable fabric blended with hot-melt adhesive yarn. The embossed layer  20  may partially cover the plain cloth  10  where necessary. The colored layer  30  is disposed on the plain cloth  10 , or on the embossed layer  20 , or on both the plain cloth  10  and the embossed layer  20 . 
         [0027]    The following refers to  FIGS. 2 and 3 , which respectively show the first and second schematic views of the vamp of the present disclosure. In  FIG. 2 , the embossed layer  20  is disposed on the plain cloth  10 . In  FIG. 3 , the embossed layer  20  and the colored layer  30  are both disposed on the plain cloth  10 . 
         [0028]    In one embodiment, a step of dying the plain cloth  10  may be omitted, such that the plain cloth  10  remains as a white cloth and any further water pollution due to a dying process is avoided. The plain cloth  10  is formed by weaving the hot-melt adhesive yarn together with at least one other different kind of yarn by using a knitting machine. The plain cloth  10  may be marked with a crop mark  11 , so that after the embossed layer  20  or the embossed layer  20  and the colored layer  30  are applied to the plain cloth  10 , the processed cloth can be cropped along the crop mark  11  to form the vamp  1 . A cold press apparatus is used to press onto the plain cloth  10 , which causes the hot-melt adhesive yarn to melt and then harden, and so forming the embossed layer  20  on the plain cloth  10 . The embossed layer has a 3D structure. The user may set a predetermined stamp of a press plate of the cold press apparatus, and then perform a cold press on a preset area of the plain cloth  10  where the embossed layer  20  is to be formed. The hot-melt adhesive yarn within the area melts and then hardens, so as to form the embossed layer  20  which partially covers a surface of the plain cloth  10 . In the above description, the embossed layer  20  partially covers the surface of the plain cloth  10 , and so during formation of the embossed layer  20 , where the hot-melt adhesive yarn melts and then hardens, it is possible that the embossed layer  20  may extend slightly beyond the preset area and blend with the area of the plain cloth  10  not intended to be embossed. Indeed, the description that the embossed layer  20  covers the plain cloth  10  is not intended to limit the scope of the present disclosure. 
         [0029]    The predetermined stamp may include a predetermined design pattern (such as a logo or other mark) to be formed on the vamp, or may include a structural reinforcement, which is a pattern that acts to reinforce the structure of the vamp and may be applied in areas where extra structural reinforcement is desirable, such as at the toe, edges of eyelets, or shoe heel. Shoes provided with such reinforcement of the vamp  1  may have better structural support or a greater resistance to wear and tear. To summarize, the embossed layer  20  is formed on the vamp  1 , to form the predetermined design pattern, the structural reinforcement, or a combination thereof. 
         [0030]    The plain cloth  10  may be dried in 100˜200° C. of hot air generated by a hot blow drying device, so that the plain cloth  10  is at a temperature between 150° C. and 190° C. Next, the plain cloth  10  is cold pressed with the cold press apparatus according to predetermined parameters. For example, one of these predetermined parameters is a temperature of the pressing plate of the cold press apparatus, which is in the range 0° C. to 25° C. That is, the plain cloth  10  is pressed with the pressing plate at the set temperature to form the embossed layer  20 . 
         [0031]    When the knitting machine knits the hot-melt adhesive yarn together with the at least one other different kind of yarn to form the breathable plain cloth  10 , the area to be embossed into the embossed layer  20  (for the purpose of applying the predetermined design pattern or structural reinforcement) is knitted with a higher-density of the hot-melt adhesive yarn than the other area on the plain cloth  10 . This is done in order to facilitate the formation of the embossed layer  20 , and is done in a controlled manner, for instance by setting a suitable composition configuration on the knitting machine. In another embodiment, the hot-melt adhesive yarn may be a fiber yarn that has dual melting points. For example, the inner core and outer cladding layer of the fiber yarn may differ in their melting points. The outer cladding layer may have a lower melting point that facilitates the weaving process and increases the color fastness of the yarn fiber if dyed. The inner fiber core may have a higher melting point and a higher stiffness and so provide for a more sturdy structure of the vamp  1 . The desired characteristics of the hot-melt adhesive yarn are developed as follows. Yarn of the same material but with different melting points for the inner and outer layers can be produced in the process of drawing the yarn by controlling the degree of crystallization of the fibers or by wrapping the drawn yarn with the same yarn material. Due to the inner and outer layers of the yarn originating from the same material, their physical properties are similar and this simplifies the procedure for controlling the parameters for the knitting process. Also, when the yarns are made from the same material, recovery of leftover selvage is easier, and so a greater proportion of the yarn can be recycled, thus reducing the cost, energy use, and environmental impact of the manufacture of the vamp. 
         [0032]    In another embodiment, the colored layer  30  is disposed on the plain cloth  10  or the embossed layer  20  by manner of digital printing. The colored layer  30  is formed in an area enclosed by the crop mark  11 . That is, the digital printing is performed to only stain the area of the vamp  1  that includes the embossed pattern. The leftover cloth to be cut is not stained, thereby reducing costs related to the time taken to stain and the amount of yarn material to stain. Moreover, the unstained cut leftovers may be recovered, recycled and reused, thus making further savings in the cost of the yarn material used and so reducing the environmental impact of the manufacture of the vamp. Different areas of the colored layer  30  may be stained with different colors. For example, in the plain cloth  10 , a blue or black colored layer  30  may be formed in the area without the embossed layer  20 , and a red or yellow colored layer  30  may be formed on the embossed layer  20  that is serving as the predetermined design pattern. Alternatively, a white or milky colored layer  30  may be formed on the embossed layer  20  that is serving as the structural reinforcement. 
         [0033]    In practice, and in accordance with the aforementioned, the process of manufacturing the vamp  1  of the present disclosure includes the following steps. In a step S 1 , the knitting machine is operated to knit the hot-melt adhesive yarn together with at least one other different kind of yarn to form the breathable plain cloth  10 . In a step S 2 , the cold press apparatus is operated to cold press the plain cloth  10 , and the hot-melt adhesive yarn of the plain cloth  10  melts and hardens during the cold press, so as to form the embossed layer  20  on the plain cloth  10 . Next, where staining of the plain cloth  10  is not required, in a step S 3  the plain cloth  10  having the embossed layer  20  is cropped along the crop mark  11 , so as to obtain the vamp  1  with the embossed pattern. Alternatively, where the plain cloth  10  is to be stained, in a step S 4  after the step S 2 , the digital printing is performed to faun the colored layer  30  on the embossed layer  20  or the plain cloth  10 . Next, in a step S 5 , the plain cloth  10  having the embossed layer  20  and the colored layer  30  is cropped along the crop mark  11 , to obtain the vamp  1  with the embossed pattern. 
         [0034]    The above described process provides a basis for the manufacture of the vamp of the present disclosure, and may be elaborated or adjusted to improve the manufacturing efficiency and quality of the vamp product. For instance, the vamp product may be made to have improved breathability, structural support, resistance to wear and tear, and other desirable features. Additionally, in order to reduce costs and increase the profit margin, the time taken for manufacture may be shortened and the amount of selvage leftovers may be reduced. In this way, a high quality shoe product can be manufactured that can be sold at a reasonable price. 
         [0035]    The above description is for the purpose of illustration only and shall not be interpreted in any way to limit the scope, configuration or applicability of the present invention. A person skilled in the art may carry out many changes and modifications in the described embodiments without departing from the spirit and the scope of the present invention, which is intended to be limited only by the appended claims.