LEG GARMENT WITH EXPANSIVE PANEL

Abstract

A flexible garment combining knitted portions with an expansive panel comprised of expansive materials and specifically four way stretch materials to accommodate a range of leg sizes and provide a compression gradient when worn. An article of manufacture and a method of producing a flexible garment with an expansive panel are disclosed.

Claims

1. A sock comprising: a wedge shaped heel section; a foot section connected below said heel section; a leg section connected above said foot, said leg section including a U-shaped opening above said heel section; an expansive panel extending from a panel bottom adjacent said heel section to a panel border; a U-shaped seam formed by joining said expansive panel to said leg section; and wherein said expansive panel is wider at said panel border than at said panel bottom and is configured to provide compression around said panel bottom that is greater than compression around said panel border.

2. The sock of claim 1 wherein said leg section comprises a first material and said expansive panel comprises a second material.

3. The sock of claim 2 wherein said first material comprises cotton and said second material comprises a four way stretch material.

4. The sock of claim 3 wherein said panel border is positioned at least six inches from said heel section.

5. The sock of claim 4 wherein said U-shaped seam extends from a panel first top to said panel bottom to a panel second top and measures a distance of at least twelve inches.

6. The sock of claim 5 wherein said panel bottom is positioned less than three inches from said heel section.

7. The sock of claim 3 wherein said expansive panel is configured to double in size upon stretching.

8. The flexible garment of claim 5 wherein said leg section comprises a region of continuous circumference adjacent said heel section and said panel border can expand to at least twice the circumference of said region of continuous circumference.

9. The flexible garment of claim 8 wherein said expansive panel comprises spandex material having a weight of at least 150 grams per square meter.

10. The flexible garment of claim 7 wherein said expansive panel comprises a panel height and a panel width, and said panel height is at least 3 times said panel width.

11. The flexible garment of claim 10 wherein said foot section is knitted with at least two colors of yarn to create a pattern in said foot section.

12. The flexible garment of claim 10 wherein said leg section is knitted with at least two colors of yarn to create a pattern in said leg section and said expansive panel is free of float yarn.

13. A flexible garment for the foot comprising: a foot section produced by knitting; a leg section produced by knitting; an expansive panel comprising a four way stretch material and connected to said leg section by stitching said expansive panel to said leg section to create a continuous U-shaped seam; said leg section comprises a band and said expansive panel comprises a panel border and said band and said panel border combine to define an opening; said leg section extends at least seven inches from said opening; and said expansive panel extends to a panel bottom located at least six inches from said opening.

13. The flexible garment of claim 12 wherein a pressure gradient is provided when worn by a user and compression of said garment is higher around said panel bottom than compression around said opening.

14. The flexible garment of claim 13 wherein said opening comprises a circumference of less than twelve inches at rest and said can expand to at least 24 inches when worn.

15. A method of making the flexible garment of claim 1 comprising the steps of: providing a knitted sock; removing a U-shaped cutout from said knitted sock; providing an expansive panel; and connecting said expansive panel to said knitted sock by joining means.

16. A method as recited in claim 15 wherein: said joining means comprises a serged stitch to create an overlock seam between said expansive panel and said leg section of said knitted sock.

17. A method as recited in claim 16 wherein said leg section comprises a knitted decorative pattern.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, will become apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which:

[0013] FIG. 1 is a side view of a human foot and leg

[0014] FIG. 2 is a side view of a foot and leg of a human with a high body mass.

[0015] FIG. 3 is a side view of a conventional sock.

[0016] FIG. 4 is a side view of a knitted sock with a U-shaped cutout.

[0017] FIG. 5 is a front view of an expansive panel in an embodiment of the invention.

[0018] FIG. 6 is a perspective view of a garment in an embodiment of the invention.

[0019] FIG. 7 is a perspective view of a garment in an embodiment of the invention worn by a person.

[0020] FIG. 8 is a perspective view of a patterned garment in an embodiment of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.

[0022] The present inventive concept relates to an accommodative garment, such as a sock, that combines a knitted sock with an expansive panel to provide a sock that will accept and conform to a variety of leg sizes.

[0023] FIG. 1 presents a view of a human foot and lower leg. The human foot has several different features that provide for walking and standing. The toes 10 are in the front of the foot. The heel 12 is positioned at the back of the foot. The arch 14 is positioned at the bottom of the foot while the instep 16 is positioned at the top of the foot. The ankle 18 defines the transition between the foot and the lower leg 20. The lower leg 20 generally presents a flat profile in the leg front 22. The shin bone or tibia contributes to the geometry of the leg front 22. The calf 24 is positioned at the rear of the leg. The rear of the leg presents an expanding profile so that the lower leg 20 presents ankle circumference 17 at the ankle 18 and a calf circumference 21 measured around the calf 24. A typical woman's ankle can have a circumference of 8 to 11 inches and a typical calf can have a circumference of 13 to 14 inches. A typical man's ankle can have a circumference of 10 to 13 inches and a calf circumference of 14 to 17 inches.

[0024] FIG. 2 presents a side view of a foot and leg of a human with a high body mass. While weight is distributed differently among people, most commonly the foot does not reflect increased body mass as much as the lower leg 30. Ankle 19 may have an increased ankle circumference of 9 to 13 inches. Calf 34 may be increased in size and contribute to increased calf circumference 31 of from 15 to 17 inches and in some cases more than 17 to 24 inches. The leg front 32 still presents a relatively smooth profile dominated by the underlying shin bone, not shown. The calf 34 is shown as enlarged and presents a profile that slopes outward. Men and women can have calf sizes ranging to 24 inches or more. Medical conditions or disorders can lead to increased calf sizes. Lymphedema, diabetes, and other conditions can contribute to swelling or increased leg sizes. The application of a pressure gradient to the lower leg can help reduce swelling.

[0025] FIG. 3 presents a side view of a conventional sock. Socks are typically knitted on a circular knitting machine. Tube socks are knitted without any regard to foot geometry and are produced as a tube or cylinder that is closed at the bottom and remains open at the top for insertion of the foot. More sophisticated methods include incorporating a toe section and an arcuate heel section to increase conformity with the foot as shown in FIG. 3. Toe section 50 can be knitted and left open and then sewn to create a toe seam to close the cylinder of the foot section 55, or produced by other methods known in the art. Foot section 55 can be produced by knitting and configured to receive a foot of a wearer. Heel section 52 is knit and finished on a boarding machine as is known in the art to create a heel curve or arcuate heel section. Heel section 52 helps to form the sock into an L shape so that it mimics the shape of the foot and lower leg. Leg section 51 comprises leg front 58 and leg rear 59. Leg section 51 can be produced by knitting in a generally tube shape and configured to receive a portion of a leg of a wearer, and terminates in band 56 where the knitting is finished. Band 56 can be ribbed and can be formed of elastic materials such as expansive threads or yarns. Band 56 can be knitted around an elastic material such as an elastic band (not shown) or other expandable material to provide compression and retain fit when worn on the leg. The limitations of this approach are discussed above. In a particular embodiment providing a knee sock, leg rear 59 can be 13 inches in length to 16 inches in length measured from heel section 52 to band 56.

[0026] FIG. 4 presents a side view of a knitted sock with a U-shaped cutout. In order to accommodate the larger leg features shown in FIG. 2, a knitted sock is provided, and the knitted material is partially removed and shown at the right of the figure. Cutaway 60 may be a U-shaped cutout. Cutaway 60 can be removed by cutting, with scissors, or other means known in the art. Use of a mechanical shear or other automated device can be employed to remove cutaway 60 such as a piercing or punching process analogous to the use of a punch and die. The size of cutaway 60 is a portion of leg rear 59 as shown in FIG. 3. Cutaway 60 is a portion of the leg section 51 and the size may vary depending on the height of the sock or garment. Cutaway 60 can be six inches in length or more with a preferable range of 13 to 16 inches to provide coverage of the lower leg beneath the knee. Removal of cutaway 60 reveals opening bottom 62, opening first side 64, opening second side 66, first opening top 67 and second opening top 68. After removal of cutaway 60, leg section 51 is partially tubular; being tubular, with a continuous circumference near the ankle of a wearer, adjacent heel section 52, and non-continuous where cutaway 60 has been removed.

[0027] FIG. 5 is a front view of an expansive panel 70. Expansive panel 70 can be parabolic shaped or U-shaped with panel bottom 72, panel first side 74, panel second side 76, panel first top 77 and panel second top 78. Panel border 79 is shown and defines the upper edge of the expansive panel. It can be understood that expansive panel 70 would be provided in a shape substantially similar to cutaway 60 to facilitate replacement of cutaway 60 with expansive panel 70. In an embodiment of the invention providing a knee sock, the expansive panel 70 can have panel width 73 of about 4 inches and panel height 75 of about 16 inches. It is preferable to provide a panel height 75 at least 1.5 times the panel width 73, or in a knee sock embodiment it is preferable to provide a panel height 75 in a range of three to four times the panel width 73. A panel width of 4 to 6 inches enables the sock opening to stretch to at least 24 inches in circumference.

[0028] Conventional materials such as cotton thread, wool yarn, etc. include little inherent elasticity and can be stretched to a limited degree. Different knitting patterns provide an interlocking web configuration that can be pulled or stretched to provide additional elasticity. However, most interlocking stitching provides for cross stretching in either a vertical or horizontal direction at a time. The interlocking threads or fibers can be form a diamond shape that can be pulled horizontally or vertically, or some combination, but the ability of the knit to expand is limited. Conventional socks can stretch from 20% to 50% of the sock circumference.

[0029] A sock knitted with yarn composed of cotton/polyester/spandex blend in a proportion of 61/37/2% in a single solid color with no knitted patterns can provide a stretch of about 25% of the circumference of the garment. Desirable materials for expansive panel 70 include materials such as stretch lace and Spandex. Spandex can stretch up to almost 500% to provide significant elasticity. Stretch fabrics, or elastomerics such as spandex (aka elastane) are suited for use in clothing. Materials such as spandex provide a four way stretch and are known as four way stretch materials. One suitable spandex material can be utilized in an embodiment with a weight greater than 150 grams per square meter, and in another embodiment with a weight of about 200 grams per square meter. Another suitable material is lace spandex having a weight of about 120 grams per square meter. Four way stretch material having a weight of 80 g to 300 g per square meter can be suitable for providing an expansive panel.

[0030] Stretch fabrics are produced by a flat knit machine with yarn or thread comprising spandex fibers that are inherently expandable, and the fabric will expand in all directions at the same time. This is known in the industry as four way stretch fabric. The fabric does not rely solely on interlock or cross stretch but provides elasticity to expand in all directions by utilizing yarn or threads that are elastic and can expand. It is known that feet perspire, and socks have been constructed from materials that provide cushioning and allow the moisture to wick away from the foot. Cotton socks, for example, provide both cushioning and wicking. Materials such as spandex can be too slippery to be optimal for a foot section 55 of a sock. The current invention combines the advantages of different materials to provide different functions in the areas of a sock where they are needed. Knitted socks and hosiery garments have been traditionally knitted on a circular knitting machine that produces a tubular garment of a first material with a consistent or fixed diameter, especially in the leg section of the garment. An expansive panel 70 of a second material can be connected to the leg section 51 of a knitted sock, replacing cutaway 60 as shown in FIG. 4. Expansive panel 70 can be finished at panel border 79 prior to attachment to leg section 51. In one embodiment, panel border 79 is finished with an overlock hem, also known as a serged hem. The finished hem can be between .sup.th of an inch, and one inch, for example, to create a clean finish and create panel border 79. One particular method of creating the overlock hem is to utilize an overlock machine to produce two straight rows of stitching on the outside surface (not shown) and an interlocked stitch on the inside surface (not shown) to prevent fraying of the material of expansive panel 70. Other stitching or joining means known in the art can also be utilized to create panel border 79.

[0031] Expansive panel 70 is shown with panel width 73 and panel height 75. In various embodiments, the shape of expansive panel 70 may vary. For example, in a child's sock, panel width 73 may be 2 inches while panel height may be 3 inches. Other ranges of intermediate dimensions may be utilized to produce different hosiery, socks, or other garments. Additional dimensions can be utilized in crew length socks and knee high length socks.

[0032] FIG. 6 presents a perspective view of an expansive garment in an embodiment of the invention. As discussed herein, the expansive panel 70 can comprise different sizes, and FIG. 6 is not drawn to scale, and represents one possible embodiment of the invention. Expansive panel 70 has been attached to the sock by joining means, namely sewing the expansive panel 70 to leg section 51 and the two can be connected by machine stitch and clean finished. A serger machine can be used to machine stitch and clean finish the seam. This provides what is known as a serged stitch or overlock stitch. Other joining means of attachment can be utilized. Joining means can include hand sewing, machine sewing, gluing, or heat fusing synthetic threads or yarns. A shown in FIG. 6, opening bottom 62 has been joined to panel bottom 72 opening first side 64 has been joined to panel first side 74, opening second side 66 has been joined to panel second side 76, panel first top 77 has been attached to first opening top 67, while panel second top 78 has been joined to second opening top 68. One method of attachment of expansive panel 70 is to turn the sock inside out, align the panel as described herein, and stitch the expansive panel 70 to the leg section 51 using a serged stitch or overlock stitch. Expansive panel 70 can be connected to leg section 51 by stitching to create a single U-shaped seam 95 (as shown in FIG. 7) extending from panel first top 77 to panel second top 78. Upon turning the sock right side out, the stitching is hidden on the inside of the sock garment. Other joining means for attachment are suitable including hand sewing, machine sewing, adhesive glue, heat fusing or a combination of joining means.

[0033] The expansive panel 70 of the invention provides the additional benefit of retaining the sock against drooping or sagging as the tension required to resist gravity is distributed across a greater area. Further, the garment of the present invention provides increased comfort. The retaining tension of a convention sock is concentrated at the band while the device of the present invention distributes the retaining tension through the area of the expansive panel 70. Expansive panel 70 enables the sock to stretch and recover much more than the conventional sock. A sock in an embodiment of the invention with an expansive panel 70 composed of a four way stretch fabric can provide a stretch of about 100% of the circumference of the garment. For example, a 100% stretch can accommodate an ankle circumference of 12 inches and a calf circumference of 24 inches or more while maintaining position and comfort about both the ankle and the calf of the user. Utilizing a four way stretch fabric that can stretch to five times its original size, a sock comprising an opening circumference that is one half conventional knitted sock material and one half expansive panel can expand to more than two and a half times its original opening circumference. An opening circumference comprising one third expansive panel can expand to more than 1.5 times the original opening circumference due the stretch of the expansive panel. For example a sock with a twelve inch opening circumference at rest and having a panel border that occupies four inches of the opening circumference provides one third of the opening circumference at rest and can be expected to provide stretch of 166% percent of the opening circumference at rest from the expansive panel plus the limited stretch provided by the knitted materials comprising the remaining two thirds of the opening circumference.

[0034] Four way stretch spandex fabric including stretch lace, stretch mesh, or spandex knits with high elasticity and recovery are suitable materials for expansive panel 70. The expansive panel 70 can be incorporated into a variety of socks and garments including, but not limited to those made from cotton, polyester blend, nylon blend, cashmere, wool, silk, linen, or bamboo blend. Spandex is a polyester-polyurethane copolymer that provides desirable elasticity and durability and can be used in garments. A full length sock from seven inches to 30 inches can be knit in the conventional manner on a circular knitting machine.

[0035] FIG. 7 presents a side view of a flexible garment on the foot and leg of a person. As shown, the expansive panel 70 panel is expanded to accommodate a user's leg. Finished hem 80 is shown at the top of expansive panel 70. U-shaped seam 95 is shown between leg section 51 and expansive panel 70. Socks worn with pants are typically only visible below the hem or cuff of the pants and the ankle region of the sock is revealed. Positioning the expansive panel above the hem line of the pants means that it is not visible. The ankle section is visible and can look like a conventional sock made of conventional knitted materials. The portion of the finished garment as shown in FIG. 7 that is tubular can surround the ankle of a user, not shown. This is the lower portion of leg section 51 adjacent to heel section 52. The garment can accommodate an ankle of a wearer that has, for example, an ankle circumference of 10 inches shown as ankle circumference 19 in FIG. 2. The garment can expand as shown in the figure to accommodate a calf 34 that has an increased calf circumference 31 as shown in FIG. 2; thus an embodiment of the invention can expand to accommodate a calf circumference of 20 inches representing 100% garment expansiveness from the ankle region to the calf region of a wearer. FIG. 7, although not drawn to scale shows an approximate 50% increase in diameter from ankle to calf, corresponding to the leg shown in FIG. 2, and assuming circular geometry, this represents 100% increase in circumference.

[0036] Compression force was measured for a sixteen inch high knee sock when stretched to different sizes. A compression force gradient was measured where the compression force provided by the circumference of the sock around panel border 79 was lower than the compression force provided by the circumference of the sock at panel bottom 72. In this particular embodiment, panel bottom 72 was located near the ankle of the wearer. Panel border 79 was located around the calf of the wearer. Exemplary data is included below.

TABLE-US-00001 A B C Calf 15-18 in. 18-21 in. 21-24 in. circumference Panel bottom 15 mm Hg 20 mm Hg 30 mm Hg compression force Panel border 8 mm Hg 15 mm Hg 20 mm Hg compression force Compression 7 mm Hg 5 mm Hg 10 mm Hg Gradient
For each column A, B, and C, the panel bottom compression force was measured at the ankle region of the wearer corresponding to panel bottom 72. The panel border compression force was measured at the top of the sock approximately around band 56 and panel border 79, surrounding a portion of the calf 34 region of the wearer. A sock in the embodiment of the invention provides a pressure gradient where increased compression force is provide at the ankle region. This is opposite of the conventional sock that provides compression at the top of the sock. In data column A, a calf circumference of a user was utilized in the range of 15 to 18 inches. The panel bottom compression force was measured at 15 millimeters of mercury and the panel border compression force was measured at 8 millimeters of mercury. The difference, or compression gradient, is 7 millimeters of mercury. The sock, when used in this manner, provides light compression. In data column B, a calf circumference of a user was utilized in the range of 18 to 21 inches. The panel bottom compression force was measured at 20 millimeters of mercury and the panel border compression force was measured at 15 millimeters of mercury. The difference, or compression gradient, is 5 millimeters of mercury. The sock, when used in this manner, provides mild compression. In data column C, a calf circumference of a user was utilized in the range of 21 to 24 inches. The panel bottom compression force was measured at 30 millimeters of mercury and the panel border compression force was measured at 20 millimeters of mercury. The difference, or compression gradient, is 10 millimeters of mercury. The sock, when used in this manner, provides moderate compression. One sock can be utilized to provide three levels of gradient compression, depending on the size of the lower leg of the user. The present invention can be used to provide a pressure gradient to the lower leg of a person and help reduce swelling or fluid retention in the lower leg, for example below the knee. Expansive panel dimensions can be provided in different configurations to provide different amounts of accommodation and compression. The total expansive properties of the top of the garment are influenced by the width of the expansive panel. The compression gradient is influenced by the difference in the expansive panel width at the top of the garment compared to the width near the panel bottom. The width and length of the expansive panel can be selected to provide more absolute expansion with a larger expansive panel and can be selected to provide a greater pressure gradient by increasing the difference in width between the panel border and the region near the panel bottom.

[0037] FIG. 8 presents a perspective view of an embodiment of the invention as worn by a user. Numerous knitting patterns are known in the art and novel patterns are continuously created. Knitting can utilize threads of different colors to created knitted patterns that are appealing or fashionable. Socks and hosiery with patterns can be more visually appealing and attractive and therefore more desirable. The present invention allows for colored threads or colored yarns to be utilized in providing or constructing a knitted sock. At least two colors of yarn can be utilized to create a contrasting pattern knitted into the sock. The method of the present invention can utilize a sock with a pattern in a leg section 51 or in a foot section 55. Novel or conventional patterns and designs can be incorporated into a circular knit sock by means known in the art or newly discovered. FIG. 8 shows a flexible garment with pattern elements 82, 84, and 86 present in leg section 51 and foot section 55. Expansive panel 70 comprises four way stretch material and can be selected in a complimentary color to pattern elements, for example pattern element 82. U-shaped seam 95 is shown between expansive panel 70 and leg section 51. Finished hem 80 is shown at the top of expansive panel 70. In one particular embodiment, float yarns can be present in leg section 51, to create, for example pattern element 82, and expansive panel 70 is free of float yarns. Similarly, float yarns can be present in foot section 55 to create, for example, pattern element 84 and pattern element 86.

[0038] Further, the materials operations described herein can be replaced by any sensible substitute materials. The many features and advantages of the invention are apparent from the detailed specification and, thus, it is intended by the appended claims to cover all such features and advantages of the invention that fall within the true spirit and scope of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact article e of manufacture illustrated and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.