Hosiery with Foot Cushions

Abstract

A hosiery product, such as a sock, footie, trouser sock or pantyhose, includes an inner layer of hosiery material, such as nylon or spandex covering the bottom and top surfaces of the wearer's foot, an outer layer of similar hosiery material, and at least one cushion section disposed between the inner and outer layers. The cushion section includes a cushioning material that conforms to the contours of the wearer's foot, such as macro-gel activated support discs or memory foam. The cushion section is permanently attached to the inner layer and/or outer layer and is positioned to cushion a particular area of the bottom surface of the wearer's foot, such as the heel, arch and/or ball of the foot.

Claims

1. A hosiery product comprising: an inner layer of hosiery material configured to cover a bottom surface of a foot and a top surface of the foot; an outer layer of hosiery material configured to cover the bottom surface of the foot and the top surface of the foot; and a support layer comprising a cushioning material disposed between the inner layer of hosiery material and the outer layer of hosiery material, wherein: the support layer is configured to cushion a metatarsal ball region of the foot; and the support layer comprises a plurality of cushions positioned from a lateral side to a medial side, wherein a first cushion of the plurality of cushions covers a smaller surface area relative to a last cushion of the plurality of cushions.

2. The hosiery product of claim 1, wherein the support layer is permanently coupled to the inner layer of hosiery material.

3. The hosiery product of claim 1, wherein the support layer is coupled by at least one coupling means selected from the group consisting of sewing, stitching, knitting, weaving and stamping.

4. The hosiery product of claim 1, wherein the support layer comprises latex foam.

5. The hosiery product of claim 1, wherein the inner layer of hosiery material and the outer layer of reinforced hosiery material comprise at least one material selected from the group consisting of nylon and spandex.

6. The hosiery product of claim 5, further comprising a padding layer located between the support layer and the outer layer of reinforced hosiery material which is configured to support the bottom surface of a wearer's foot.

7. The hosiery product of claim 1, wherein the padding layer is positioned to support the support layer.

8. The hosiery product of claim 1, wherein the hosiery product is selected from the group consisting of a sock, a footie, a knee high and a pantyhose.

9. The hosiery product of claim 8, wherein the sock is selected from the group consisting of a cushion sock and a trouser sock.

10. The hosiery product of claim 1, wherein the support layer of the hosiery product is configured to extend to an extremity of toes of a user.

11. The hosiery product of claim 1, wherein the support layer of the hosiery product is configured to terminate at a bend of toes of a user.

12. The hosiery product of claim 1, wherein the outer layer of hosiery material is reinforced.

13. The hosiery product of claim 1, wherein the plurality of cushions is comprised of at least one material from the group consisting of viscoelastic support gel, macro-gel activated support discs, memory foam, gel memory foam, and latex foam.

14. The hosiery product of claim 1, wherein the plurality of cushions further comprises intervening cushion of the plurality of cushions covering a larger surface area relative to the first cushion of the plurality of cushions and a smaller surface area relative to the last cushion of the plurality of cushions.

15. The hosiery product of claim 1, wherein the support layer is further configured to cushion an arch region and a heel region of the bottom surface of the foot.

16. The hosiery product of claim 1, wherein a border of each cushion of the plurality of cushions overlaps an adjacent border of an adjacent cushion of the plurality of cushions on at least one side of the plurality of cushions.

17. A hosiery product comprising: an inner layer of hosiery material configured to cover a bottom surface of a foot and a top surface of the foot; an outer layer of hosiery material configured to cover the bottom surface of the foot and the top surface of the foot; and a support layer comprising a cushioning material disposed between the inner layer of hosiery material and the outer layer of hosiery material, wherein: the support layer is configured to cushion a metatarsal ball region of the foot; the support layer comprises a plurality of cushions positioned from a lateral side to a medial side, wherein a first cushion of the plurality of cushions covers a smaller surface area relative to a last cushion of the plurality of cushions; and a border of each cushion of the plurality of cushions overlaps an adjacent border of an adjacent cushion of the plurality of cushions on at least one side of the plurality of cushions.

18. The hosiery product of claim 17, further comprising a padding layer located between the support layer and the outer layer of hosiery material which is configured to support the bottom surface of a wearer's foot.

19. A hosiery product comprising: an inner layer of hosiery material configured to cover a bottom surface of a foot and a top surface of the foot; an outer layer of material configured to cover bottom surface of the foot and the top surface of the foot; and a padding layer located between the support layer and the outer layer of hosiery material which is configured to support the bottom surface of a wearer's foot.

20. The hosiery product of claim 17, further comprising a support layer comprising a cushioning material disposed between the inner layer of hosiery material and the outer layer of hosiery material, wherein: the support layer is configured to cushion a metatarsal ball region of the foot; the support layer comprises a plurality of cushions positioned from a lateral side to a medial side, wherein a first cushion of the plurality of cushions covers a smaller surface area relative to a last cushion of the plurality of cushions and a border of each cushion of the plurality of cushions overlaps an adjacent border of an adjacent cushion of the plurality of cushions on at least one side of the plurality of cushions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is a bottom view of a material layer of a sock according to a preferred embodiment of the invention;

[0028] FIG. 2 is a side view of the material layer of the sock;

[0029] FIG. 3 is a bottom view of a support layer of the sock;

[0030] FIG. 4 is a side view of the support layer the sock;

[0031] FIG. 5 is a bottom view of a padding layer of the sock;

[0032] FIG. 6 is a side view of the padding layer of the sock;

[0033] FIG. 7 is a bottom view of the layers described above attached to a hosiery of the sock;

[0034] FIG. 8 is a side view of the layers attached to the hosiery of the sock;

[0035] FIG. 9 is a close up cross sectional side view of the layers of the sock;

[0036] FIG. 10 is a bottom view of a trouser sock with a support layer;

[0037] FIG. 11 is a side view of the trouser sock with the support layer;

[0038] FIG. 12 is a bottom view of either a footie sock or cushion sock with the support layer;

[0039] FIG. 13 is a side view of the footie sock with the support layer; and

[0040] FIG. 14 is a side view of the cushion sock with the support layer.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION AND BEST MODE

[0041] A hosiery product according to a preferred embodiment of the invention is illustrated in FIGS. 1-6, and shown generally at reference numeral 10. The hosiery product 10 can be a sock 10 comprised of an inner layer 412, an outer layer 432, and an elevated cushion layer at the ball of foot 420 positioned intermediate the inner layer 412 and outer layer 432. The cushion layer 420 comprises a plurality of cushion sections 21, 22, 23

[0042] The inner and outer layers 412, 432 are comprised of nylon or other elastic material suitable for hosiery, such as spandex. The cushion sections 21, 22, 23 comprise an elevated cushioning material capable of adapting to body contours. Preferably, the cushioning material is comprised of a viscoelastic support gel, such as the macro-gel support discs sold by Serta, Inc. under the mark PODSO or the gel sold by Serta, Inc. under the mark MICROSUPPORT@. Preferably, the cushioning material is substantially non-collapsible so that it does not collapse when supporting the weight of a person for extended periods of time. Alternatively, the cushion sections 21, 22, 23 can be comprised of viscoelastic polyurethane foam, known commonly as memory foam. The cushioning material can also be comprised of gel memory foam. Alternatively, the cushioning material can be comprised of latex foam, such as BiOH@ Gel Latex sold by Cargill, Inc.

[0043] The elevated cushion sections 21, 22, 23 are encased by the inner and outer layers 412, 432, and permanently attached to the sock 10. The cushion sections 21, 22, 23 can be sewn to the inner layer 412 or attached by other suitable means such as knitting or weaving. Alternatively, the elevated cushion sections 21, 22, 23 can be attached using a stamping method. Each cushion section 21, 22, 23 can include a fabric pouch containing the elevated support gel, and the fabric pouch can be attached to the inner layer 412.

[0044] In an alternative embodiment, the elevated cushion sections 21, 22, 23 can be attached to the outer layer 432. In yet another alternative embodiment, the cushion sections 21, 22, 23 can be attached to both the inner layer 412 and outer layer 432.

[0045] The cushion sections 21, 22, 23 are positioned in the sock 10 to support specific pressure points of the wearer's foot. As shown in FIG. 3, one cushion section 21 is shaped, elevated, and positioned to cushion the ball of the foot, metatarsals. The second elevated cushion section 22 is shaped, elevated, and positioned to cushion the arch of the wearer's foot, and the third elevated cushion section 23 is shaped and positioned to cushion the heel. As such, the cushion sections 21, 22, 23 provide elevated support and cushioning at the most critical and common areas of foot pain and pressure. The gel activated support material of the cushion sections 21, 22, 23 adapt to the contours of the wearer's foot.

[0046] The thin layer of the support materials adapted to the wearer's foot that extend to the extremity of the toes to provide comfort to the entire foot can be stopped at the bend of the toes.

[0047] The cushion sections 21, 22, 23 are completely and securely attached to the sock 10, such as by sewing, knitting or weaving. By so integrally attaching the cushion sections 21, 22, 23 to the sock 10, stray particles are prevented from entering and ruining the fabric of the sock 10. As such, the wear and tear on the fabric that is typically caused by removing and interchanging padding in prior art devices is avoided by the sock 10. The cushioning sections 21, 22, 23 stay securely in place under the wearer's foot and easily adjusts for a wide range of climatic conditions.

[0048] The sock 10 can be employed for general purpose and/or therapeutic applications. The sock 10 eliminates any need for a cushion/support insert typically positioned within a shoe. The cushioning material in the cushion sections 21, 22, 23 can be antimicrobial and/or hypoallergenic treated. In an alternative embodiment, the cushioning material can be inserted into a waterproof fabric and cut, weaved, stitched, knitted and placed into the sock.

[0049] As illustrated in FIGS. 1-14, the design and construction of sock 10 can be incorporated into other hosiery products. For example, FIG. 13 shows a footie 100 according to a preferred embodiment of the invention. The footie 100 has elevated cushion sections 121, 122, 123, and is identical in construction as the above described sock 10. FIG. 14 shows a cushion sock 200 according to a preferred embodiment of the invention. The cushion sock 200 includes elevated cushion sections 221, 222, 223, as shown in FIG. 14, and is identical in construction as the above described sock 10. FIG. 11 shows trouser socks 300, 300 according to a preferred embodiment of the invention. The trouser socks 300, 300 include cushion sections 321, 322, 321, 321, 322, 323, respectively, and are identical in construction as the above described sock 10.

[0050] A hosiery product according to another preferred embodiment of the invention is illustrated in FIGS. 8-11, and shown generally at reference numeral 400. The hosiery product 400 comprises pantyhose 400 comprising an inner material layer 412, a cushion support layer 420, a reinforcing layer 432 and an outer reinforced layer 442. The cushion support layer 420 comprises a plurality of cushion sections 421, 422, 423.

[0051] The inner and outer layers 412, 432 are comprised of a flexible, breathable material and/or an elastic material, such as nylon or spandex. The cushion sections 421, 422, 423 comprise a cushioning material capable of adapting to body contours. Preferably, the cushioning material is comprised of a viscoelastic support gel, such as the macro-gel support discs sold by Serta, Inc. under the mark PODS or the gel sold by Serta, Inc. under the mark MICROSUPPORT. Preferably, the cushioning material is substantially non-collapsible so that it does not collapse when supporting the weight of a person for extended periods of time. Alternatively, the cushion sections 21, 22, 23 can be comprised of viscoelastic polyurethane foam, known commonly as memory foam. The cushioning material can also be comprised of gel memory foam. Alternatively, the cushioning material can be comprised of latex foam, such as BiOH@ Gel Latex sold by Cargill, Inc.

[0052] The reinforcing layer can be comprised of a hosiery material, such as breathable nylon, and provides additional strength to support the cushion sections 421, 422, 423. The padding layer 430 can be omitted if the outer reinforced layer 442 comprises a sturdy or dense material.

[0053] The cushion sections 421, 422, 423 are positioned intermediate the inner material layer 412 and the padding layer 430, and permanently attached to the pantyhose 400. The cushion sections 421, 422, 423 can be sewn to the inner layer 412 or attached by other suitable means such as knitting or weaving.

[0054] The cushion sections 421, 422, 423 are positioned at the bottom of the feet of the pantyhose 400 to support specific pressure points of the wearer's foot. As shown in FIGS. 7 and 8, one cushion section 421 is elevated, shaped and positioned to cushion the ball of the foot metatarsals. The second cushion section 422 is elevated, shaped, and positioned to cushion the arch of the wearer's foot, and the third cushion section 423 is shaped and positioned to cushion the heel. As such, the cushion sections 421, 422, 423 provide targeted, elevated, support and cushioning at the most critical areas of foot pain and pressure. The thin layer of the support materials that extend to the extremity of the toes to provide comfort to the entire foot can be stopped at the bend of the toes. The gel activated support material of the cushion sections 421, 422, 423 adapt to the contours of the wearer's foot.

[0055] The cushion sections 421, 422, 423 can have the following preferred dimensions. The layer of support gel in the cushion section 421 positioned below the ball of the foot preferably has a thickness of about one-fourth to three-eighths inch. The support gel in the cushion section 422 positioned below the arch of the foot preferably has a thickness of about one-fourth to three-eighths inch. The layer of support gel in the cushion section 423 positioned below the heel of the foot preferably has a thickness of about one-eighth to one-fourth inch.

[0056] The cushion sections 421, 422, 423 are completely and securely attached to the pantyhose 400, such as by sewing, knitting or weaving. By so integrally attaching the cushion sections 421, 422, 423 to the pantyhose 400, stray particles are prevented from entering and ruining the fabric of the pantyhose 400. As such, the wear and tear on the fabric that is typically caused by removing and interchanging padding in prior art devices is avoided by the sock 400. The cushioning sections 421, 422, 423 stay securely in place under the wearer's foot and easily adjusts for a wide range of climatic conditions.

[0057] The pantyhose 400 can be employed for general purpose and/or therapeutic applications. The pantyhose 400 eliminates any need for a cushion/support insert typically positioned within a shoe. The cushioning material in the cushion sections 421, 422, 423 can be antimicrobial and/or hypoallergenic treated. The four layer construction of the pantyhose 400 can be incorporated into other hosiery products, such as socks, footies, cushion socks and trouser socks. In an alternative embodiment, the cushioning material can be inserted into a waterproof fabric and cut, weaved, stitched, knitted and placed into the pantyhose.

[0058] A hosiery product and method of making same are described above. Various changes can be made to the invention without departing from its scope. The above description of the preferred embodiments and best mode of the invention are provided for the purpose of illustration only and not limitationthe invention being defined by the claims and equivalents thereof.