SOCK HAVING RAISED FEATURES, A MOLD ASSEMBLY AND A METHOD OF MANUFACTURE

Abstract

A sock having raised features includes one or more three-dimensional paw pads affixed thereon. More in particular, a plurality of individual three-dimensional paw pads are affixed to a bottom portion of the sock to provide a visual effect of having animal paws, and to further provide a wearer a tactile sensation of having animal paws on the wearer's foot while walking. A mold assembly and a method for the manufacture of a plurality of three-dimensional paw pads to be affixed to a sock includes at least one mold.

Claims

1. A sock having raised features to be worn by a person comprising: a sock body including a sock bottom surface having a sock toe portion and an oppositely disposed sock heel portion; a plurality of pads affixed proximate said sock toe portion; and said plurality of pads arranged to provide a visual effect and a tactile sensation to the person wearing said sock.

2. The sock as recited in claim 1, wherein said plurality of pads are affixed to said sock bottom surface proximate said sock toe portion.

3. The sock as recited in claim 1, wherein said plurality of pads are securely affixed to said sock bottom surface proximate said sock toe portion with an adhesive.

4. The sock as recited in claim 1, wherein said plurality of pads are formed of a urethane foam material.

5. The sock as recited in claim 1, wherein said plurality of pads are formed of a polyurethane foam material.

6. The sock as recited in claim 1, wherein said plurality of pads further provide an audible effect as said plurality of pads compress and decompress as the person wearing said sock walks.

7. The sock as recited in claim 1, wherein said plurality of pads comprise a plurality of three-dimensional pads.

8. The sock as recited in claim 1, wherein said plurality of pads comprise a plurality of three-dimensional paw pads.

9. The sock as recited in claim 8, wherein said plurality of three-dimensional paw pads are at least partially defined by a pad height, a pad length, and a pad width.

10. The sock as recited in claim 8, wherein said plurality of three-dimensional paw pads are arranged on said sock bottom surface to provide said visual effect representative of an animal paw.

11. The sock as recited in claim 8, wherein said plurality of three-dimensional paw pads are arranged on said sock bottom surface to provide said tactile sensation representative of an animal paw.

12. A mold assembly for forming a plurality of three-dimensional paw pads to be affixed to a sock comprising: a base; a multi-member portion mountable onto said base, said multi-member portion comprising: a mold having at least one individual paw pad mold impression formed therein for receiving an amount of material from which said plurality of three-dimensional paw pads are formed; a pressure backing member having at least one first pressure relief vent formed therethrough; a paw pad backing member disposed between said mold and said pressure backing member and having at least one second relief vent formed therethrough and aligned over said at least one individual paw pad mold impression and with said first pressure relief vent formed through said pressure backing member; and a plurality of alignment members interconnected to said base to facilitate alignment of said pressure backing member and said paw pad backing member with said mold; and a plurality of fasteners each operable with a corresponding one of said plurality of alignment members to at least temporarily secure said multi-member portion to said base.

13. The mold assembly as recited in claim 12, wherein said mold comprises a plurality of individual paw pad mold impressions formed therein for receiving an amount of material from which each of said plurality of three-dimensional paw pads are formed.

14. The mold assembly as recited in claim 13, wherein said pressure backing member comprises a plurality of first pressure relief vents formed therethrough with at least one first pressure relief vent corresponding to a different one of each of said plurality of individual paw pad mold impressions.

15. The mold assembly as recited in claim 14, wherein said paw pad backing member comprises a plurality of second relief vents formed therethrough, wherein at least one of said plurality of second relief vents is aligned over a different one of said plurality of individual paw pad mold impressions and with a corresponding one of said plurality of first pressure relief vents formed through said pressure backing member.

16. The mold assembly as recited in claim 12, wherein said mold comprises a plurality of mold alignment apertures disposed therethrough, each of said plurality of mold alignment apertures dimensioned to receive a corresponding one of said plurality of alignment members therethrough to align said mold in an operable orientation relative to said base.

17. The mold assembly as recited in claim 12, wherein said paw pad backing member comprises a plurality of paw pad backing alignment apertures disposed therethrough, each of said plurality of paw pad backing alignment apertures dimensioned to receive a corresponding one of said plurality of alignment members therethrough to align said paw pad backing member in an operable orientation relative to at least said mold.

18. The mold assembly as recited in claim 12, wherein said pressure backing member comprises a plurality of pressure backing alignment apertures disposed therethrough, each of said plurality of pressure backing alignment apertures dimensioned to receive a corresponding one of said plurality of alignment members therethrough to align said pressure backing member in an operable orientation relative to at least said paw pad backing member.

19. The mold assembly as recited in claim 12, wherein said plurality of fasteners are further operable with a corresponding one of said plurality of alignment members to apply pressure to said pressure backing member to facilitate compression of said amount of material in said individual paw pad mold impression during formation of at least one of said plurality of three-dimensional paw pads therein.

20. A method of manufacturing a sock having a plurality of three-dimensional paw pads affixed thereto, the method comprising: positioning a mold having a plurality of individual three-dimensional paw pad mold impressions formed therein onto a base; pouring an amount of material from which each of the three-dimensional paw pads are to be formed into each of the plurality of individual three-dimensional paw pad mold impressions; aligning a paw pad backing member over the mold such that at least one of a plurality of pressure relief vents formed through the paw pad backing member is disposed over each of the plurality of individual three-dimensional paw pad mold impressions having the amount of material therein; aligning a pressure backing member over the paw pad backing member such that at least one of a plurality of pressure relief vents formed through the pressure backing member is disposed over a corresponding one of the plurality of pressure relief vents formed through the paw pad backing member; compressing the pressure backing member, the paw pad backing member and the mold together thereby compressing the amount of material in each of the plurality of individual three-dimensional paw pad mold impressions; venting excess amounts of the material in each of the plurality of individual three-dimensional paw pad mold impressions through corresponding ones of the pressure relief vents formed through the paw pad backing member and the pressure relief vents formed through the pressure backing member; allowing each of the plurality of three-dimensional paw pads to cure within corresponding ones of the plurality of individual three-dimensional paw pad mold impressions while compressing the pressure backing member, the paw pad backing member and the mold together; releasing each of the plurality of three-dimensional paw pads after curing from corresponding ones of the plurality of individual three-dimensional paw pad mold impressions; arranging at least some of the plurality of three-dimensional paw pads on a sock bottom surface proximate a sock toe portion of the sock; and securely affixing the plurality of three-dimensional paw pads onto the sock bottom surface proximate the sock toe portion with an amount of adhesive.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The various embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, where like designations denote like elements, and in which:

[0020] FIG. 1 presents a top isometric view of a mold assembly in accordance with a first illustrative embodiment of the present invention;

[0021] FIG. 2 presents an exploded top isometric view of the mold assembly illustrated in FIG. 1, in accordance with the present invention;

[0022] FIG. 3 presents a top isometric view of the partially-assembled mold assembly of FIG. 1, more particularly with the base, mold and alignment members in an assembled configuration, in accordance with the present invention;

[0023] FIG. 4 presents a partially exploded, top isometric view of the mold assembly of FIG. 1, more particularly with the pressure backing member in exploded view and the partially-assembled mold assembly, in accordance with the present invention;

[0024] FIG. 5 presents a top isometric view of the mold assembly illustrated in FIG. 1 after injection of the mold material and application of pressure in accordance with one illustrative embodiment of a method of manufacture, in accordance with the present invention;

[0025] FIG. 6 presents a cross-sectional side elevation of the mold assembly illustrated in FIG. 5, in accordance with the present invention;

[0026] FIG. 7 presents a top plan view of a plurality of three-dimensional paw pads formed and demolded with a fabric backing using the mold assembly illustrated in FIGS. 5 and 6, in accordance with the present invention;

[0027] FIG. 8 presents a plan view of an illustrative embodiment of an exemplary paw comprising a plurality of three-dimensional paw pads formed in accordance with one embodiment of the present invention;

[0028] FIG. 9 presents a perspective view of the plurality of three-dimensional paw pads shown in FIG. 8 in process of being applied to a sock bottom surface in accordance with one embodiment of the present invention; and

[0029] FIG. 10 presents a bottom plan view of one illustrative embodiment of an exemplary sock having a plurality of three-dimensional paw pads arranged and securely affixed to the sock bottom surface proximate a sock toe portion thereof in accordance with one embodiment of the present invention.

[0030] Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0031] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 1. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0032] Shown throughout the figures, in one embodiment, the present invention is directed toward a sock having a plurality of three-dimensional paw pads thereon, and in one further embodiment, the present invention is directed to an apparatus and method for the manufacture thereof.

[0033] FIGS. 1-6 present several views of a mold assembly 100 in accordance with a first illustrative embodiment of the present invention. With reference initially to FIGS. 1 and 2, the mold assembly 100 includes a multi-member portion 102 and a base 104. Illustratively, the base 104 may comprise a wood material but can be any of a number of other hard and/or solid materials to provide support to mold assembly 100. As best shown in FIG. 2, the multi-member portion 102 includes a pressure backing member 106, a mold 118, and a paw pad backing member 114 sandwiched between the pressure backing member 106 and the mold 118. In some embodiments, a pressure backing member 106 may be formed from a slightly flexible plastic material including but not limited to plexiglass, acrylic or, more particularly, polymethyl methacrylate, just to name a few. A paw pad backing member 114 may also be formed from a somewhat flexible material such as, once again, by way of example only, canvas material and/or a vinyl material. As best shown in FIG. 2, the paw pad backing member 114 may have a larger footprint than the pressure backing member 106 and the mold 118 such that a portion of paw pad backing member 114 extends outside the footprint of the pressure backing member 106 for purposes that will be described in further detail herein below.

[0034] As further shown in the illustrative embodiment of FIGS. 1 and 2, a pair of alignment members 108 extends through the multi-member portion 102, and more specifically, through alignment apertures that run through the entirety of the multi-element portion 102. As shown best in FIG. 2, the pair of alignment members 108 may extend through alignment apertures 107, 115 and 119 formed in the pressure backing member 106, the paw pad backing member 114 and the mold 118, respectively. The pair of alignment members 108 may also thread into a pair of alignment apertures 122 formed in the base 104 in registration with the alignment apertures 107, 115 and 119 formed through the pressure backing member 106, the paw pad backing member 114 and the mold 118 of multi-element portion 102. In at least some embodiments, a bottom end of the alignment members 108 may be threaded, and the alignment apertures 122 formed in the base 104 may be cooperatively counter-threaded to allow the bottom ends of the alignment members 108 to thread thereinto. In some embodiments, the alignment members 108 may be threaded in their entirety, i.e., along their entire length. The alignment apertures 107, 115, 119 and/or 122 may be pre-drilled, scored, punctured or otherwise formed into the respective members of multi-member portion 102 and base 104 prior to assembly.

[0035] As shown in FIG. 1, when inserted through the multi-member portion 102, the alignment members 108 extend upwardly and perpendicular from the pressure backing member 106, such that a threaded top end of the alignment members 108 protrude outwardly and upwardly from the pressure backing member 106. In one embodiment, a fastener 110 is threaded onto each of the alignment members 108 to affix the multi-member portion 102 to the base 104, thereby completing the formation of the mold assembly 100. It will be understood that the configuration shown in FIGS. 1 and 2 with the pair of alignment members 108 and the pair of fasteners 110 is solely for illustrative purposes, and other configurations of post(s) and corresponding fastener(s) are possible that are consistent with the spirit and intent of the present invention as disclosed herein. As one example, and without limitation, the mold assembly 100 may include an alternative number of alignment members 108 and corresponding fasteners 110.

[0036] With continued reference to FIG. 2, the pressure backing member 106 comprises a first plurality of pressure relief vents 112 and the paw pad backing member 114 is provided with a second plurality of pressure relief vents 116. In turn, the mold 118 includes a plurality of individual mold impression recesses, cavities or elements 120 formed therein for accepting a mold material. The configuration and alignment of the first plurality of pressure relief vents 112 and the second plurality of pressure relief vents 116 corresponds to the configuration and placement of the plurality of individual mold impressions 120 formed in the mold 118. In particular, a specific one of the first plurality of pressure relief vents 112 through the pressure backing member 106 and a corresponding specific one of the second plurality of pressure relief vents 116 through the paw pad backing member 114 is aligned with a corresponding one of the plurality of mold impressions 120 formed in the mold 118, such as is best seen in the illustrative embodiment of FIG. 2. Furthermore, the first plurality of pressure relief vents 112 and second plurality of pressure relief vents 116 are formed and configured to be arranged in registration with and disposed in communication with one another during operation of the mold assembly 100. This will facilitate the release of excess mold material from the plurality of mold impressions 120 of the mold assembly 100 while the mold assembly 100 is compressed, as further detailed herein below.

[0037] The illustrative embodiments of FIGS. 3-6 show a method of use of the mold assembly 100 of FIG. 1 to manufacture a plurality of raised features, i.e., a plurality of three-dimensional paw pads, to be attached to socks, in accordance with the present invention. With reference initially to FIG. 3, the mold 118 is operatively positioned on the base 104. The pair of alignment members 108 are connected to the base 104 via alignment apertures 122 and the mold 118 is operatively positioned onto the base 118 over the extending the posts 108 through the corresponding alignment apertures 119 through the mold 118. In at least some embodiments, the alignment members 108 are threaded into the alignment apertures 122 of the base 104. Once the mold 118 has been operatively positioned on the base 104, an amount of mold material 124 is introduced, such as, poured or injected, into each of the plurality of individual mold impressions 120 formed within the mold 118 to realize the fabrication of individual three-dimensional paw pads that may be affixed to a bottom portion of a sock or other area of another fabric material to provide the wearer, for instance, with the visual effect of having paws on the wearer's foot and a tactile sensation when walking in accordance with the disclosed embodiments.

[0038] In at least one embodiment, each three-dimensional paw pad has a length, height, width as determined by the individual mold impressions 120 formed within the mold 118 and an elasticity defined by the mold material 124. In some embodiments, the mold 118 may be fabricated from silicone and the mold impressions 120 may be formed using resin casted duplicates of original clay sculptures, for example, oil-based non-drying clay, of the desired paw pads in terms of shape and size. Further, illustratively, the mold material 124 may be a urethane foam mixture that expands and facilitates the formation the three-dimensional paw pads with a desired shape and elasticity in accordance with the embodiment. In a further embodiment, the mold material 124 is a polyurethane foam mixture. In this way, when the wearer of the sock configured in accordance with the embodiments herein walks across a surface, the three-dimensional paw pads will compress and decompress providing tactile feedback to the user including an audible sound, e.g., a “squishing” feeling and sound, thereby simulating actual animal paws.

[0039] The illustration of FIG. 4 depicts a further stage of the method of manufacture in accordance with the present disclosure. Specifically, as shown, the paw pad backing member 114 has been positioned over the base 104 and mold 118 and aligned via the alignment members 118 which are inserted through the alignment apertures 115 in the paw pad backing member 114. In the event that the paw backing member 114 has a larger footprint as described heretofore, the paw pad backing member 114 may hang over the sides of the mold 118 and, optionally, the base 104.

[0040] Next, the pressure backing member 106 is been positioned over the paw pad backing member 114 and the mold 118 in alignment via the alignment members 119 which are inserted through the alignment apertures 107 in the pressure backing member 106, such that the paw backing member 114 is sandwiched between the mold 118, having mold impressions 120 filled with amounts of mold material 124, and the pressure backing member 106, after which, pressure is applied onto the pressure backing member 106. For instance, as shown in FIG. 5, a plurality of clamps 126 may be attached externally to the mold assembly 100 and tightened to apply pressure onto the mold to force the pressure backing member 106 closer to the mold 118 and compress the mold material 124 located therebetween. Tightening of the clamps 126 may be carried out by rotating corresponding handles 128 to apply the desired pressure.

[0041] In one embodiment, the mold material 124 is an expanding urethane foam. Urethane foam is commercially available and is a commonly used two part expanding foam having good thermal insulation and expansion characteristics, such that the urethane foam will conform to the shape of a cavity or a form into which the material is poured, such as, a plurality of mold impressions 120 of mold 118. Urethane foam is also soft in terms of texture to provide comfort to the wearer of the sock manufactured in accordance with the present invention. The molded material 124 is also substantially tear proof once cured, thereby providing important wear characteristics for the sock features herein. In a further embodiment, the mold material 124 is an expanding polyurethane foam that provides similar advantages as described above with respect to the expanding urethane foam. Typically, a urethane foam product is mixed and applied at room temperature with an optimum temperature of about 24 to about 27 degrees Celsius. If the ambient temperature is too cold, the reaction is inhibited and in such cases, the urethane will shrink back after rising, losing much of its strength. Further, a two part urethane foam must be poured immediately after a quick mixing together of the component parts. The cavities or a forms to be filled, e.g., the plurality of mold impressions 120 of mold 118, must be clean and accessible, and prepared ahead of time. All surfaces should be clean of contaminants for proper bonding. As will be appreciated, urethane foam will expand, e.g., 20:1 by volume. In doing so the material can exert, for example, as much as thirty kilopascals or more of pressure in a contained area. As detailed herein, the first set of pressure relief vents 112 and the second set of pressure relief vents 116 are provided, inter alia, to permit the release of pressure buildup during fabrication of a plurality of three-dimensional paw pads in the mold impressions 120 of a mold 118.

[0042] As shown in FIGS. 5 and 6, excess mold material 124 contained in the mold impressions 120 may flow through the aligned second and first plurality of pressure relief vents 116 and 112 formed in an aligned relation through the paw pad backing member 114 and the pressure backing member 106, respectively, and outward of the mold assembly 100. The excess mold material 124 is removed during the demolding and final forming of a plurality of three-dimensional paw pads from a corresponding plurality of mold impressions 120. The configuration of the plurality of clamps 126 shown in FIGS. 5 and 6 is one of several configurations that may be utilized as will be readily understood and appreciated.

[0043] As is well known, an animal paw is a soft foot-like part of a mammal having paw pads. The pads act as a cushion for the load-bearing limbs of the animal. A paw generally consists of a large, heart-shaped metacarpal paw pad at the paw's center, and which is generally surrounded by, in part, four load-bearing digital paw pads that are smaller in size than the metacarpal paw pad. As is well-known, animals with paws include felids such as cats and tigers, canids such as dogs and foxes, rabbits, bears and raccoons, to name just few.

[0044] The illustration of FIG. 7 presents a plan view of a plurality of three-dimensional paw pads formed and demolded from mold 118, and attached to paw pad backing member 114 using the mold assembly 100 as described with reference to FIGS. 3-6. In accordance with the various embodiments herein, a metacarpal paw pad 130 may be manufactured representative of a heart-shaped metacarpal pad of an actual animal, and digital paw pads 132, 134 and 136 may be manufactured to resemble load-bearing digital pads of the actual animal. As shown, the metacarpal paw pad 130 and digital paw pads 132, 134 and 136 may be fully formed using mold assembly 100 as described in detail herein. Illustratively, certain of the paw pads shown in FIG. 7 may be removed by cutting along outlines 138 to remove the respective demolded paw pads from the collective shown. Each such removed paw pad will retain a portion of paw pad backing member 114 thereon and be used to form a specific configuration of the plurality of three-dimensional paw pads for application to a sock in accordance with at least one embodiment, as is further detailed herein below. As shown in the illustrative embodiment of FIG. 7, a total of eight (8) metacarpal paw pads 130 and thirty (30) digital paw pads 132, 134 and 136 may be formed, in accordance with the number of mold impressions 120 provided in the illustrative mold 118 shown in the drawings. In at least one embodiment, digital paw pads 132 are formed as middle, or straight, digital paw pads, digital paw pads 134 are formed in a left paw pad orientation, and digital paw pads 136 are formed in a right paw pad orientation. It must be noted, however, that alternative number and/or shapes of paw pads, or other decorative elements, may be formed without departing from the scope and intent of the present invention.

[0045] The illustrative embodiment of FIG. 8 is a plan view of an exemplary paw 150 comprising a plurality of three-dimensional paw pads 140 including one (1) metacarpal paw pad 130, two (2) digital paw pads 132, one (1) digital paw pad 134, and one (1) digital paw pad 136, wherein the plurality of three-dimensional paw pads 140 are thereby arranged so as to be representative of an actual animal paw. The view shown of the exemplary paw 150 in FIG. 8 is of the underside of each respective paw pad of the plurality of three-dimensional paw pads 140 to further highlight that, when each such paw pad is demolded from mold 118, the paw pad will retain a portion of the paw pad backing member 114 thereon. For example, as described heretofore, the paw pad backing member 114 may be a canvas, in which case the retained portion of the paw pad backing member 114 is a portion of canvas.

[0046] The illustrative embodiment of FIG. 9 shows a perspective view of the plurality of three-dimensional paw pads 140 of FIG. 8 in the process of being applied to a sock 200 thereby forming the paw 150 thereon. As shown, the sock 200 comprises a sock body 204 which may include a sock toe portion 202, a sock heel portion 206 and a sock leg portion 208. As will be appreciated, in at least one embodiment, a pair of socks 200 are provided, one to be worn on each foot of a wearer. The sock 200 depicted herein is a so-called “knee-high” sock; however, alternative socks may be used. The sock 200 may be made from cotton, a cotton blend or other applicable materials. It will be understood that sock 200 has a sock top surface (not shown) and an opposite sock bottom surface 210 that ultimately surround the wearer's foot when inserted therein. To simulate the sensation of animal paws, the plurality of three-dimensional paw pads 140 may be affixed on or about the sock toe portion 202 of the sock bottom surface 210 in accordance with one embodiment. More particularly, the plurality of three-dimensional paw pads 140 may be affixed to and extend outwardly from the sock toe portion 202. The plurality of three-dimensional paw pads 140 provide a visual effect and a tactile sensation to a person wearing sock 200. In accordance with an embodiment, a stencil (not shown) may be used to assist with the placement and alignment of the plurality of three-dimensional paw pads 140 as they are affixed to the sock 200. In at least one embodiment, the plurality of three-dimensional paw pads 140 may be affixed to sock toe portion 202 using an adhesive or bonding agent such as, but not limited to, Infinity PUR MP75 polyurethane hot melt adhesive, or E6000® craft adhesive. The latter, for instance, is a commercially available bonding agent formulated to meet high performance industrial requirements, and is a non-flammable, vibration proof product that forms a permanent, waterproof bond and offers extreme flexibility in terms of application, and is also paintable.

[0047] Each paw pad of the plurality of three-dimensional paw pads 140 has a substantially similar thickness 142 resulting from the fabrication steps detailed herein above. In some embodiments, a height 142 may have a thickness of approximately 2 centimeters, e.g., 1.9 centimeters. Once adhered to a sock 200, a plurality of three-dimensional paw pads 140 are raised and extend away from the sock toe portion 202 and, therefore, from the sock body 204 of the sock 200 as well, and are alternatively compressed and decompressed when the wearer of sock 200 walks across a surface. Advantageously, in accordance with at least one embodiment, the sock 200 delivers a certain tactile feedback to the wearer, essentially a sponge-like sensation, in addition to providing a visual effect and appearance that a wearer's foot or feet have animal paw pads. Given the elasticity of the plurality of three-dimensional paw pads 140 and their raised features on a sock 200, a wearer may also discern certain audible feedback as the three-dimensional paw pads 140 compress and decompress while the wearer is walking while donning the sock or socks 200.

[0048] In summary, as detailed above, a method of fabricating a plurality of three-dimensional paw pads 140 and a sock or socks 200 having the plurality of three-dimensional paw pads 140 securely affixed thereto comprises providing a mold assembly 100 for fabricating the plurality of three-dimensional paw pads 140 from an amount of mold material 124, e.g., foaming urethane. The mold assembly 100, in at least one embodiment, comprises: a base 104; a mold 118 for accepting an amount of mold material 124 for forming a plurality of three-dimensional paw pads 140, the mold 118 having one or more individual paw pad mold impressions 120 thereon for retaining the amount of mold material 124 from which the individual three-dimensional paw pads 140 will be formed; a pressure backing member 106 having a first plurality of pressure relief vents 112 formed therethrough, wherein each individual pressure relief vent 112 is aligned with a respective one of the individual paw pad mold impressions 120; a paw pad backing member 114 having a second plurality of pressure relief vent 116 formed therethrough, wherein each individual pressure relief vent 116 is aligned with a respective one of the plurality of pressure relief vents 112 in the pressure backing member 106, the paw pad backing member 114 being disposed between the pressure backing member 106 and the mold 118; one or more alignment members 108 and corresponding fasteners 110, such as, by way of example, wing nuts such as are shown throughout the figures, to hold the individual portions of the mold assembly 100 together with the base 104 and applying pressure thereto; and, one or more clamps 126 or other pressure-exerting tool for applying pressure, which may optionally be applied in combination with the alignment members 108 and fasteners 110.

[0049] The method, in one further embodiment, comprises pouring an amount of mold material 124 into one or more paw pad mold impressions 120 of a mold 118 and applying pressure via a plurality of clamps 126, which may be in combination with alignment members 108 and corresponding fasteners 110, or other such fastener, and allowing the mold material 124 to cure. After which, a plurality of three-dimensional paw pads 140 may be removed from the mold 118 with a portion of the fabric backing of the paw pad backing member 114 intact and affixed to each of the plurality of three-dimensional paw pads 140 upon extraction from the mold assembly 100. Select ones of the plurality of three-dimensional paw pads 140, such as, by way of example, a total of five (5) three-dimensional paw pads 140, so as to represent and construct a desired paw pattern, are removed, e.g., by cutting, individually with the fabric backing of the paw pad backing member 114 intact and affixed thereto. The individual three-dimensional paw pads 140 are then adhered to a sock 200 by applying an adhesive to permanently bond each of the individual three-dimensional paw pads 140 to the sock 200.

[0050] FIG. 10 is a bottom plan view of one illustrative embodiment of a sock 200 with a paw 150 configured in accordance with the present invention securely affixed thereto. Illustratively, once affixed to a toe portion 202 of a sock 200, the plurality of three-dimensional paw pads 140 may encompass an area approximately 8 centimeters long by approximately 8 centimeters wide, and may be approximately 2 centimeters high. As shown In FIG. 10, the plurality of three-dimensional paw pads 140 are affixed to the sock 200 such that they cover the front ball of the person's foot when wearing the sock 200. As detailed above, the plurality of three-dimensional paw pads 140 are affixed to and extend outward from the sock toe portion 202 and, further, the plurality of three-dimensional paw pads 140 provide a visual effect and a tactile sensation to a person wearing the sock 200. A sock 200 having the plurality of three-dimensional paw pads 140 securely affixed thereto in accordance with the present invention is intended primarily for casual use in a variety of indoor environments and settings including but not limited to lounging, cosplay, boudoir and photo shoots, to name just a few.

[0051] Alternative embodiments are contemplated to those depicted herein. For instance, the three-dimensional paw pads 140 may be made with different color orientations to contrast with or match the sock color to which the paw pads are affixed. In another example, the various steps of the method of manufacture described herein may be manually performed or automated in nature. Further embodiments are contemplated in which the present mold assembly 100 and method are used to provide protruding pads to an item other than a sock 200.

[0052] Since many modifications, variations, and changes in detail can be made to the described embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.