Composite waterproof breathable sock with two-way extensible properties

Abstract

A composite waterproof breathable sock with two-way extensible properties, wherein each sock is formed by lamination of an outer layer, an inner layer and an intermediate waterproof and breathable sock-like film component on a one-step forming mould. The outer layer, or both the outer and inner layers, is/are knitted by deploying fine twisted elastic yarns consistently into all the knitting courses of the main body for each such layer, so as to make the composite sock therefore extensible in both weft X and warp Y directions after lamination of the layer(s) to the waterproof film component such that the composite sock will be recoverable uniformly after stretching to a relaxed conformation. The composite sock can be sewn with a water seal kit inside the cuff band, wherein the cuff band is extended from the outer component of the sock. The in-cuff seal kit can be constructed by a sew-in waterproof polyurethane elastic fabric in round shape.

Claims

1. A composite waterproof breathable sock with two-way extensible properties comprising a toe part at a first end, an opening at a second end, an outer layer, an inner layer, and an intermediate waterproof and breathable film, wherein both the outer layer and the inner layer are knitted by deploying twisted elastic yarns consistently into all knitting courses of a main body of each of the inner layer and the outer layer, said twisted elastic yarns being knitted with yarns of the main body of each of the inner layer and the outer layer, the outer layer knitted in tighter courses than the inner layer and comprising a cuff band adjacent to the second end and defining the opening, the cuff band surrounding a water seal and extending a length from the second end toward the first end, the water seal extending the length of the cuff band, the inner layer and the intermediate waterproof and breathable film both abutting and extending from an end of the water seal opposite said opening and toward the first end.

2. The composite waterproof breathable sock according to claim 1, wherein the twisted elastic yarns exhibit 350 twists per meter.

3. The composite waterproof breathable sock according to claim 1, wherein one or both of the outer and inner layers is/are knitted on a single-cylinder 4.0 inches jacquard hosiery machine.

4. The composite waterproof breathable sock according to claim 1, wherein adhesives are used to join the outer layer, the inner layer, and the intermediate waterproof breathable film, wherein the adhesives are heat activated thermoplastic polyurethane (TPU) materials.

5. The composite waterproof breathable sock according to claim 1, wherein the intermediate waterproof and breathable film has a corrugated structure in both weft X and warp Y directions and is configured to be stretched circumferentially and longitudinally.

6. The composite waterproof breathable sock according to claim 1, wherein the water seal is constructed of a two way stretchable waterproof polyurethane (PU) elastic fabric.

7. The composite waterproof breathable sock according to claim 6, wherein the two-way stretchable waterproof polyurethane (PU) elastic fabric is sewn round the inside of the cuff band.

8. The composite waterproof breathable sock according to claim 6, wherein a height along a sock length of said two way stretchable waterproof polyurethane (PU) elastic fabric is equal to or longer than 2 cm.

9. The composite waterproof breathable sock according to claim 6, wherein a height along a sock length of said two way stretchable waterproof polyurethane (PU) elastic fabric is 5 cm.

Description

DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic perspective view of the waterproof bootie by cut and sew fabric laminate using the Gore-Tex technology;

(2) FIG. 2 is a cross sectional view of the construction of a waterproof composite sock;

(3) FIG. 3 is a cross sectional view of a configuration of a composite sock exhibiting three-ply lamination using the discrete adhesive dots;

(4) FIG. 4 is a schematic diagram of a waterproof composite sock using a sock component with circumferentially lay in elastic threads;

(5) FIG. 5 is a schematic diagram of the waterproof composite sock with two-way extensible properties disclosed by the present invention.

(6) FIG. 6 is a cross sectional view of the in-cuff seal kit disclosed in the present invention.

(7) FIG. 2A is a cross sectional view of the corrugated structure for the intermediate waterproof breathable film for the sock construction illustrated in FIG. 2;

(8) FIG. 4A is an illustration diagram for the corrugated texture of the intermediate film in longitudinal direction for the sock construction illustrated in FIG. 4;

(9) FIG. 4B is a schematic diagram to illustrate the circumferentially laid in elastic threads displayed along the weft courses of the main body in its sock component for the sock construction illustrated in FIG. 4;

(10) FIG. 5A is a cross sectional view of the wave structure corrugated in both X and Y directions for the intermediate film for a composite sock as disclosed herein and shown in FIG. 5;

(11) FIG. 5B is a schematic diagram to illustrate the consistent combination of the twisted elastic yarns with the main body yarns for the composite sock in FIG. 5;

(12) The following reference numerals when used herein refer to the following components:

(13) 1, Laminated fabric;

(14) 2, Seam taping on stitching line;

(15) 3, outer sock layer;

(16) 4, intermediate waterproof breathable film;

(17) 5, inner sock layer;

(18) 6, forming mould;

(19) 7, adhesive dot for discrete securement;

(20) 8, former used in prior technology;

(21) 9, circumferentially extending elastic thread;

(22) 10, one-step heat press forming mould disclosed in the present invention;

(23) 11, fine twisted elastic yarns;

(24) 12, main body yarns;

(25) 13, cuff band extended from the outer sock; and

(26) 14, in-cuff water block kit round sewed inside the cuff band.

DESCRIPTION OF PREFERRED EMBODIMENTS

Embodiment 1

(27) A waterproof breathable composite sock with two-way extensible properties, as shown in FIG. 5, is disclosed. The sock is formed by lamination of an outer layer 3, an inner layer 5 and an intermediate waterproof and breathable film 4 on a one-step forming mould 10. The inner and outer layers 5 and 3 are bonded to the intermediate film 4 by discrete hot melt adhesive dots 7, wherein the outer layer 3, or both the outer 3 and inner 5 layers, is/are knitted by deploying fine twisted elastic yarns 11 consistently into main body yarns 12, as shown in FIG. 5B. The twisted elastic yarns 11 in this composition have excellent elasticity to make the sock layer(s) very stretchable. In preferred embodiments, the elastic yarns are made of spandex. The waterproof breathable film 4, which is made up in sock shape in advance, is at the same size as the sock-like forming mould 10, but at a larger size than the relaxed size of the outer sock layer 3 and the inner sock layer 5. By this composition and configuration, the film component 4 sandwiched in between the outer sock layer 3 and the inner sock layer 5 shrinks under the tension of the sock layers and has an internal puckered structure in both X and Y directions (like a wave texture) after lamination to the opposing layers 3 and 5 and removal of the resulting composite sock structure from the mould 10, as illustrated in FIG. 5A. The resulting composite sock therefore is extensible both circumferentially and longitudinally. The waterproof composite socks made by this technology have two-way stretchable properties in particular in sock length (longitude) direction, resulting in a large range of flexibility to accommodate a variety of foot sizes for a single sock size. The flexibility offers the wearer a stretchable, comfortable and form-fitting fit and eliminates the possibility of scrubbing the waterproof film at the toe part during the tough sports, which can result in water leakage. Also by this construction, the outer sock layer 3 can be knitted in tighter courses so it also eliminates the possible problem that the intermediate film 4 might show through between the knitting courses of the sock layer 3, as sometimes happened for composite socks with heavily laid in elastic threads. The ‘show through’ problem can easily damage the performance barrier particularly during tough outdoor sports activities.

Embodiment 2

(28) As shown in FIG. 5B, the twisted elastic yarns, which are knitted with the main body yarns and are consistently deployed in all the knitting courses, provide recovery tension in all directions, including both lateral and longitudinal, for the composite sock. The elastic yarns are preferably 350 twists per meter and the ratio of the main body yarns to the twisted elastic yarns is preferably 75:25. The adhesive system used for lamination of the outer layer 3, the inner layer 5, and the intermediate waterproof breathable film 4 is preferably hot melt TPU material spread on the interior and exterior surfaces of the film 4 in discrete dotting or powder techniques. The sock outer layer 3, or both the sock outer layer 3 and the inner layer 5, is/are knitted on a single-cylinder 4 inches jacquard hosiery machine. By said construction, the finished composite sock obtains the best elastic modulus in both circumferential and longitudinal directions. In addition, by using said hosiery machine and the disclosed yarn combination, the present technology can make the composite sock in a complex jacquard design, which is theoretically difficult to be knitted in the prior technology due to the heavily laid in elastic threads in the outer layer 3.

Embodiment 3

(29) As shown in FIG. 6, a composite sock made by the present invention can be made with an in-cuff water block seal, wherein the cuff band 13 is extended upwards from the outer layer 3, and the in-cuff seal kit 14 is constructed of two-way stretchable waterproof polyurethane fabric sewed around inside the cuff band. The waterproof PU elastic fabric preferably is of the type of modern material developed for high quality swimwear and has excellent all way elasticity. The elastic fabric sewn with the cuff of the knit sock provides a comfortable but tight (preferably leak-tight) seal over the leg calf, and therefore stops water from coming into the composite sock over the top.

Embodiment 4

(30) On the basis of the above waterproof composite sock, the height of round fabric 14 should be equal to or more than 2 cm. By internal experiments, when the waterproof sock with the in-cuff seal kit illustrated above was in use, and when water splashed onto the top of the sock, the water block kit could effectively stop the water entering in only when the height of the water block material exceeded a certain value. On the other hand, the wearer felt uncomfortable if the waterproof fabric kit was too high. A height of 5 cm was found to provide an optimal combination of water blocking and wearer comfort as per the test results.

(31) The composite sock made by the invention is waterproof and breathable, whilst being comfortable and exhibiting two-way stretchable properties. In preferred embodiments, the composite sock disclosed herein also exhibits in-cuff water block function as described above. The invention provides a way to make waterproof composite socks that have improved comfort for the wearer in real experience, and also a practical method to increase the productivity of the composite socks by using a smaller forming mould that can accommodate a hand-assembly process for making composite socks.

(32) While this document discloses several example embodiments, the invention is not limited to the embodiments herein disclosed. Persons of ordinary skill in related fields can modify and/or alter the embodiments disclosed herein without undue experimentation, and without departing from the spirit and the scope of the invention as set forth in the appended claims.