Abstract
Multi-layered socks with elastomeric padding in accordance with embodiments of the invention are disclosed. In one embodiment, a sock for reducing foot movement is provided, the sock including: a toe region connected to a mid-foot region, connected to a heel region, further connected to an ankle region, the ankle region including an opening; a sole positioned from the toe region through the mid-foot region to the heel region, the sole comprising an inner layer, a middle layer, and an outer layer; the middle layer being attached to the inner layer and encapsulated between the inner layer and the outer layer; the middle layer of the sole varies in thickness; a thickness of the middle layer of the sole is greater in the heel region and the toe region; and the sock forms a hollow tubular shape that is closed at the toe region and open at the ankle region.
Claims
1. A sock for reducing foot movement, the sock comprising: a toe region that is positioned at a first end of the sock for receiving at least one toe of a user's foot; a mid-foot region comprising a ball region and having a first side connected to the toe region and a second side connected to a heel region, wherein the first side is positioned opposite the second side; the heel region positioned for receiving a heel of a user's foot; an ankle region connected to the heel region, wherein the ankle region comprises an opening; a sole positioned from the toe region through the mid-foot region to the heel region, the sole comprising an inner layer, a middle layer, and an outer layer, wherein: the inner layer makes contact with the user's foot when the sock receives the user's foot; the middle layer is attached to the inner layer and is encapsulated between the inner layer and the outer layer, wherein: the middle layer of the sole varies in thickness; a thickness of the middle layer of the sole is greater in the heel region, ball region, and the toe region; and wherein the sock forms a hollow tubular shape that is closed at the toe region and open at the ankle region.
2. The sock of claim 1, wherein the thickness of the middle layer is greater in the toe region in an area corresponding to a first metatarsal of the user's foot.
3. The sock of claim 1, wherein the middle layer of the sole comprises an elastomeric material.
4. The sock of claim 3, wherein the elastomeric material has a geometric grid pattern that allows for adequate air and moisture transfer while providing localized support.
5. The sock of claim 4, wherein the inner layer comprises a blend of all natural fibers.
6. The sock of claim 4, wherein the inner layer comprises a blend of all synthetic fibers.
7. The sock of claim 4, wherein the inner layer comprises a combination blend of synthetic and natural fibers including cellulosic fibers.
8. The sock of claim 3, wherein the elastomeric material has a Shore hardness between 00-0 and A-40.
9. The sock of claim 8, wherein the elastomeric material has a water absorption rate no greater than 3.00%.
10. The sock of claim 9, wherein the elastomeric material has a thickness not to exceed 2.00 mm.
11-20. (canceled)
21. The sock of claim 2, wherein the greater thickness of the middle layer in the toe region in the area corresponding to the first metatarsal forms a first metatarsal cushion.
22. The sock of claim 2, wherein the thickness of the middle layer is greater in the toe region in an area corresponding to a fifth metatarsal of the user's foot.
23. The sock of claim 22, wherein the greater thickness of the middle layer in the toe region in the area corresponding to the fifth metatarsal forms a fifth metatarsal cushion.
24. The sock of claim 1, wherein the greater thickness of the middle layer in the heel region forms a heel cushion.
25. The sock of claim 1, wherein the greater thickness of the middle layer in the ball region forms a ball cushion.
26. The sock of claim 1, wherein the thickness of the middle layer is greater in the ankle region.
27. The sock of claim 26, wherein the greater thickness of the middle layer in the heel region and the ankle region forms an extended heel cushion.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The various embodiments of the present multi-layered socks now will be discussed in detail with an emphasis on highlighting the advantageous features. These embodiments depict the novel and non-obvious multi-layered socks shown in the accompanying drawings, which are for illustrative purposes only. These drawings include the following figures:
[0027] FIG. 1 illustrates a cross-sectional view of a multi-layered sock in accordance with an embodiment of the invention.
[0028] FIG. 2 illustrates a bottom view of an inner and middle layer of a multi-layered sock in accordance with an embodiment of the invention.
[0029] FIG. 3 illustrates a top view of a multi-layered sock in accordance with an embodiment of the invention.
[0030] FIG. 4 is a schematic diagram illustrating layers of a multi-layered sock in accordance with an embodiment of the invention.
[0031] FIG. 5 illustrates a cross-sectional view of another multi-layered sock in accordance with an embodiment of the invention.
[0032] FIG. 6 illustrates a cross-sectional view of a multi-layered sock with a single-layered ankle region in accordance with an embodiment of the invention.
[0033] FIG. 7. illustrates a cross-sectional view of a multi-layered sock with a single-layered ankle region and middle-layer cushions in accordance with an embodiment of the invention.
[0034] FIG. 8. illustrates a bottom view of an inner and middle layer of a multi-layered sock with middle-layer cushions in accordance with an embodiment of the invention.
[0035] FIG. 9 illustrates a bottom view of an inner and middle layer of a multi-layered sock where the right and left socks have identically shaped middle-layer cushions in accordance with an embodiment of the invention.
[0036] FIG. 10 illustrates a cross-sectional view of a multi-layered sock with ankle cushions according to an embodiment of the invention.
[0037] FIGS. 11A-11D illustrate a method of constructing a multi-layered sock with cushions in a ball region and a heel region of a middle layer in accordance with an embodiment of the invention.
[0038] FIG. 12 is a flow chart illustrating a process for creating a multi-layered sock in accordance with an embodiment of the invention.
[0039] FIG. 13 is a flow chart illustrating another process for creating a multi-layered sock by applying a screen print to a knitted circular tube in accordance with an embodiment of the invention.
[0040] FIG. 14 is a flow chart illustrating another process for creating a multi-layered sock by securing a middle layer to a knitted circular tube with an adhesive in accordance with an embodiment of the invention.
[0041] FIG. 15 is a flow chart illustrating another process for creating a multi-layered sock where a second portion of a circular tube is made with material different than that of a first portion in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0042] The following detailed description describes the present embodiments with reference to the drawings. In the drawings, reference numbers label elements of the present embodiments. These reference numbers are reproduced below in connection with the discussion of the corresponding drawing features.
[0043] Socks can also provide medical benefits and be used therapeutically. For example, socks may be used to reduce the formation of blisters on the individual's feet. Friction from moving results in the individual's skin layers pulling away from each other, leading to blister formation. Socks may reduce the friction that an individual experiences while moving and accordingly reduces the likelihood of blisters forming. Socks may also have compressive qualities and can be used to reduce swelling. Socks with compressive qualities are able to facilitate the return of blood and fluids to the individual's body and may be used as a form of medical treatment for conditions involving swelling.
[0044] Turning now to the drawings, multi-layered socks utilizing elastomeric padding in accordance with embodiments of the invention are provided. In various embodiments, multi-layered socks provide foot support and reduce foot motion when worn by a user, as further described below. In many embodiments, multi-layered socks may include a toe region positioned at a first end for receiving one or more toes of a user's foot. In several embodiments, multi-layered socks may also include a mid-foot region having a first side connected to the toe region and a second side connected a heel region. In various embodiments, the heel region may be positioned for receiving a heel of the user's foot. In some embodiments, multi-layered socks may also include an ankle region connected to the heel region, where the ankle region may include an opening for the user to slide a foot in and out of the multi-layered sock. In several embodiments, the multi-layered sock may form a hollow tubular shape that is closed at the toe region and open at the ankle region, as further described below.
[0045] In many embodiments, multi-layered socks may include a sole positioned from the toe region through the mid-foot region to the heel region. In various embodiments, the sole of multi-layered socks may include a plurality of layers. For example, a sole may include various layers including, but not limited to, an inner layer, a middle layer, and an outer layer. In some embodiments, the inner layer may make contact with the user's foot when the multi-layered sock receives the user's foot. In some embodiments, the middle layer may be of varying thickness and may be encapsulated between the inner layer and the outer layer at various points corresponding to various locations of the user's foot. In many embodiments, the thickness of the middle layer may be greater in the heel region and/or in the toe region. By using multi-layered socks of the present invention, a user may benefit from support at key areas of the user's foot, promoting general foot health. For example, the multi-layered socks may utilize a sole having a middle layer of varying thickness corresponding to various locations of a user's foot thereby reducing foot motion and thus preventing formation of blisters, particularly during periods of physical activity. Multi-layered socks in accordance with embodiments of the invention are further discussed below.
Socks with Multiple Layers
[0046] Typically, socks include a single layer of material that provides an interface between a user's foot and the user's outside environment. Traditionally, conventional single layer socks are optimized to absorb perspiration from a user's foot (the foot is among the heaviest producers of sweat in the body) and/or to help keep a user's foot warm. In contrast, multi-layered socks in accordance with embodiments of the invention may be optimized for conventional features (e.g., sweat absorption, warmth, etc.) and additional features not typically considered in conventional single layer socks. For example, multi-layered socks may be optimized for protection and/or comfort of specific locations on a user's foot, as further described below.
[0047] A cross-sectional view of a multi-layered sock in accordance with an embodiment of the invention is illustrated in FIG. 1. The sock 100 may include a toe region 102, a midfoot region 104, heel region 106, and ankle region 108. The ankle region 108 may form an opening 110 for receiving a use's foot. For example, a user may insert their foot into the sock 100 using the opening 110 and sliding their foot into the sock 100 such that the user's toes rest in the toe region 102 and the user's heel rests in the heel region 106. Traditionally, the toe region 102 provides a front boundary of the sock 100 while the heel region 106 provides a rear boundary of the sock 100. Typically, the toe region 102, midfoot region 104, and heel region 106 form a hollow shape which can contain and protect a user's foot while providing a comfortable interface between the user's foot and a user's shoe or other environmental surfaces.
[0048] In reference to FIG. 1, the sock 100 may also include a sole 120 that may include an inner layer 112 and an outer layer 114. In many embodiments, the sole 120 may also include a middle layer 122. In various embodiments, the middle layer 122 may be an interface between an inner layer 112 and an outer layer 114. In many embodiments, the middle layer 122 may have a variable thickness so as to create cushions at key points along the sock 100 which correspond to one or more locations of a user's foot. For example, the middle layer 122 may include a ball cushion 116 that is configured to protect the ball of the user's foot. Further, the middle layer 122 may include a heel cushion 118 that is configured to protect the heel of the user's foot. Typically, a user's stride starts with the user's heel striking the ground, after which the user's weight rolls forward. The user's heel and the user's midfoot (or ball) are very important in the user's weight distribution as the user rolls their foot in the process of walking. A user may experience problems with their feet when their gait causes their foot to roll too far in any direction. When a user's foot rolls too far in any given direction, it causes parts of the user's foot to bear more weight than they normally would. The resulting problems to the user's foot can thereafter cause further health problems, including back pain. In some embodiments, the ball cushion 116 may be located between the toe region 102 and midfoot region 104. In some embodiments, the heel cushion 118 may be located in the heel region 106.
[0049] A bottom view of a pair of multi-layered socks in accordance with an embodiment of the invention is illustrated in FIG. 2. The pair of socks may include a left sock 200 and a right sock 210. The left sock 200 may include a left ball region 202 and a left heel region 216. The left sock 200 may also include a left inner layer 204 and a left middle layer. In several embodiments, the left middle layer may have a variable thickness. In many embodiments, the left middle layer may be thicker in particular areas corresponding to locations along a user's foot. For example, the left middle layer may have areas of greater thickness in the left ball region 202 and the left heel region 216 which may form a left ball cushion 206 and left heel cushion 208, respectively. Moreover, in several embodiments, the left sock 200 may include a left ball cushion 206 and/or a left heel cushion 208 utilizing elastomeric padding, as further described below. In many embodiments, the left ball cushion 206 may be configured to correspond to the portions of a user's ball bearing the user's weight distributing the weight across the user's foot. In some embodiments, the left cushion 206 may be wider at a location corresponding to an inside of a user's foot and more narrow at a location corresponding to an outside of a user's foot. In many embodiments, the left cushion 206 may have a uniform width.
[0050] The right sock 210 may include a right ball region 203 and a right heel region 217. The right sock 210 may also include a right inner layer 205 and a right middle layer. In several embodiments, the right middle layer may have a variable thickness. In many embodiments, the right middle layer may be thicker in particular areas corresponding to locations along a user's foot. For example, the right middle layer may have areas of greater thickness in the right ball region 203 and the right heel region 217 which may form a right ball cushion 212 and right heel cushion 214, respectively. Moreover, in several embodiments, the right sock 210 may include a right ball cushion 212 and/or a right heel cushion 214 utilizing elastomeric padding, as further described below. In many embodiments, the right ball cushion 212 may be configured to correspond to the portions of a user's ball bearing the user's weight distributing the weight across the user's foot. In some embodiments, the right cushion 207 may be wider at a location corresponding to an inside of a user's foot and more narrow at a location corresponding to an outside of a user's foot. In many embodiments, the right cushion 207 may have a uniform width.
[0051] A top view of a multi-layered sock in accordance with an embodiment of the invention is illustrated in FIG. 3. In many embodiments, the sock 300 may include an ankle region 302. In various embodiments, the ankle region 302 may include an opening 304 which a user may use to position their foot into the sock 300. In many embodiments the sock 300 may contain an outer layer 306 which contacts the outside environment of the sock 300.
[0052] A cross-sectional view of a multi-layered sock's multiple layers in accordance with an embodiment of the invention is illustrated in FIG. 4. In many embodiments, a multi-layered sock may include a plurality of layers. For example, the plurality of layers can include an inner layer 400, a middle layer 402, and an outer layer 404. In many embodiments, the inner layer 400 and outer layer 404 may be constructed using various materials such as, but not limited to, cotton, wool, etc. In several embodiments, the middle layer 402 may be constructed using an elastomeric material (may also be referred to as an elastomeric padding). The elastomeric padding may create a specific geometric pattern which allows the elastomeric padding to fit naturally to the shape of the sock. In many embodiments, the elastomeric padding may include a specific grid pattern that allows for air and moisture transfer while providing localized support in key pressure point areas, as further described below. In some embodiments, the middle layer 402 may have varying thickness so as to accommodate key areas corresponding to particular locations along a user's foot, as further described below. In some embodiments, the thickness of the middle layer 402 may have a maximum thickness of 2.00 mm. In some embodiments, the elastomeric padding may have a hardness between Shore 00-0 and Shore A-40. In some embodiments, the elastomeric padding may have a maximum density of 4.50 g/cc. In some embodiments, the elastomeric padding may have a compressive strength between 5 MPa and 35 MPa. In some embodiments, the elastomeric padding may have a maximum water absorption of 3 percent. In some embodiments, the elastomeric padding may have a maximum modulus of rigidity (20 C) of 1.00 MPa.
[0053] Although specific multi-layered socks for providing improved general foot health are discussed above with respect to FIGS. 1-4, any of a variety of multi-layered socks including a variety of layer thicknesses, cushions, and/or materials as appropriate to the requirements of a specific application can be utilized in accordance with embodiments of the invention. Middle layer configurations of multi-layered socks in accordance with embodiments of the invention are discussed further below.
Middle Layer Configurations of Multi-Layered Socks
[0054] As described above, multi-layered socks may be optimized for protection and/or comfort of specific locations on a user's foot. In many embodiments, multi-layered socks may include a middle layer with variable thickness so as to create cushions at key points of the sock which may correspond to various locations along a user's foot. For example, the middle layer may include a ball cushion that is configured to provide extra support and/or movement reduction to the ball of the user's foot. Further, the middle layer may include a heel cushion that provides protection and/or support to a heel of the user's foot. Although specific examples of locations along a user's foot are provided (e.g., the ball and heel), the middle layer may have regions of increased thickness in any location on the multi-layered sock as appropriate to the requirements of a specific application. For example, the regions of increased thickness in the middle layer can include elastomeric padding.
[0055] A cross-sectional view of another multi-layered sock in accordance with an embodiment of the invention is illustrated in FIG. 5. In several embodiments, the multi-layered sock 500 may include an outer layer 512 that interfaces (e.g., is in contact) with the outside environment. For example, when the multi-layered sock 500 receives a user's foot through opening 510, the outer layer 512 may interface with the outer environment including, but not limited to, a ground surface, the inside of a user's shoe, etc. In many embodiments, the multi-layered sock 500 may also include an inner layer 514 that interfaces with the user's foot. For example, when the multi-layered sock 500 receives a user's foot, the inner layer 514 may interface directly with the skin of the user's foot. In several embodiments, a middle layer 522 may have an increased thickness in the toe region 502 and the heel region 506. For example, elastomeric padding may be utilized in the toe region 502 and the heel region 506 resulting in a ball cushion 516 and a heel cushion 518, respectively. In some embodiments, the outer layer 512 may surround the inner layer 514 so that the middle layer 522 including the ball and heel cushions 516, 518 are entirely encapsulated.
[0056] In some embodiments, the cushion or cushions in the middle layer are flexible in at least one direction (e.g., vertically, laterally, etc.). The cushion or cushions in the middle layer may have similar or different flexibility. For example, the ball cushion and the heel cushion may have same, similar, or different flexibilities. These flexibilities may depend on the desired support of the user or the activity the user is engaged in. Additionally, the cushion or cushions in the middle layer, when encapsulated between the inner layer and the outer layer, may be fixed in place between the inner layer 514 and outer layer 512. This fixed position may allow for consistent support at those specified locations. Further, the thickness of the middle layer may differ between various regions. For example, in some embodiments, there may be a greater thickness in the heel cushion 518 than in the ball cushion for 516, and thus the thickness of the middle layer may vary. Further, the middle layer may also have cushion (and thus increased thickness) in various regions including, but not limited to, in the midfoot region 504 or the ankle region 508.
[0057] In reference to FIG. 5, in several embodiments, during the construction process, the outer layer 512 may be folded over the inner layer 514 and middle layer cushions 516, 518, as further described below. In several embodiments, the inner layer 514 and the outer layer 512 meet at the toe stitch 520. The toe stitch 520 allows for the creation of a seam that closes the toe region of the sock 502 in a way that does not cause discomfort for the user. For example, the toe stitch 520 may be located at a position corresponding to knuckles of a user's toes. The precise location of the toe stitch may vary with the method of knitting the sock 500.
[0058] The extent to which the outer layer may cover the inner layer may vary in different embodiments. The need for the outer layer to cover the entirety of the inner layer may depend on the type of physical activity the user is engaged in. For less strenuous activities, multiple layers in all regions of the sock may not be necessary. However, having multiple layers may provide additional moisture wicking properties in the respective regions that have multiple layers. Other benefits of multiple layers may include blister reduction and increased padding that may provide comfort to the user's foot. A cross-sectional view of a multi-layered sock with a single-layered ankle region in accordance with an embodiment of the invention is illustrated in FIG. 6. In some embodiments of the invention, the outer layer 614 of the sock 600 may not fully cover the inner layer 612. The length of the outer layer 614 may vary depending on the intended activity of the user. In various embodiments, the outer layer 614 may or may not be covering the inner layer 612 near the ankle region 608. In other embodiments, the outer layer 614 may cover the entirety of the inner layer 612.
[0059] To provide support or comfort or other benefit to a user's foot during strenuous activity, in various embodiments, the outer layer 614 may cover the entirety of the inner layer 612 and middle layer cushions 616, 618 to reduce friction when the user's foot comes into contact with an outer surface. The amount of the inner layer 612 covered by the outer layer 614 may vary between embodiments. For example, some embodiments may only have multiple layers (e.g., the inner layer 612 and the outer layer 614) on the sole of the sock (e.g., toe region 602, midfoot region 604, and heel region 606) and a single layer on the top of the sock and near the ankle region. The single layer may be either an inner layer 612 or an outer layer 614. Other embodiments may have multiple layers around the entirety of the sock. The presence of multiple layers in the various regions may be according to a user's preference or according to ease of manufacturing.
[0060] The number and locations of middle layer cushions utilizing elastomeric padding may also vary depending on the support required by the activity of the user. A cross-sectional view of a multi-layered sock with a single-layered ankle region and three middle-layer cushions in accordance with an embodiment of the invention is illustrated in FIG. 7. The sock 700 may have a middle layer with an increased thickness in the heel area 706 and ankle area 708, creating an extended heel cushion 718 that provides support and/or comfort for the user's foot in both the heel area 706 and the ankle area 708. This extended heel cushion 718 can offer support and prevent blisters in the heel area 706 and/or the ankle area 708, providing extra protection against motion-related discomfort. This may be particularly useful in circumstances where the user's external environment is in direct contact with a user's heel area such as, but not limited to a hiking boot, ski boot, or other environment contacting the user's heel.
[0061] In further reference to FIG. 7, the middle layer may have an increased thickness near the first metatarsal, resulting in a first metatarsal cushion 726, providing extra support to the first metatarsal and reducing foot movement in this area to reduce blister formation in the toe region 702. This particular location may be advantageous during strenuous activity such as, but not limited to, running or hiking that can often result in blisters on the first metatarsal. The shape, size, and location of this and all other middle layer cushions may vary depending on the aid required for particular activities. The shape, size, and location of the cushions may vary as needed to provide support. Additionally, the extent to which the outer layer 714 covers inner layer 712 may vary, as further described above.
[0062] In some embodiments, other middle layer cushions may be added to improve support in key areas and/or reduce movement and/or associated blisters. A bottom view of an inner layer and middle layer of a multi-layered sock with middle-layer cushions in accordance with an embodiment of the invention is illustrated in FIG. 8. In this view, the outer layer is removed to show a left inner layer 804 and a right inner layer 805 and various possible middle layer cushion configurations. For example, the right and left multi-layered socks 810, 800 may include first metatarsal cushions 822, 818, respectively. The right and left multi-layered socks 810, 800 may also include fifth metatarsal cushions 824, 820, respectively. Further, the right and left multi-layered socks 810, 800 may include ball cushions 812, 806, respectively. In addition, the right and left multi-layered socks 810, 800 may include heel cushions 814, 808, respectively. Although FIG. 8 illustrates the right and left multi-layered socks 810, 800 including the various cushions, in some embodiments, the right or left multi-layered sock 810, 800 may not include one or more of the cushions.
[0063] In reference to FIG. 8, the middle layer cushions may have a foot-specific shape depending on whether the sock is a sock designed for a user's left foot (e.g., the left multi-layered sock 800) or a sock designed for a user's right foot (e.g., the right multi-layered sock 810). In some embodiments, the middle layer may have an elastomeric padding creating greater thickness in areas within the toe regions 802, 803, creating a first metatarsal cushion 822, 818. In some embodiments, the elastomeric padding may cause thickness of the middle layer to create ball cushions 812, 806. In some embodiments, the middle layer may have an elastomeric padding creating greater thickness in the toe regions 802, 803 such that fifth metatarsal cushions 824, 820 are present. The fifth metatarsal cushions 824, 820 of the middle layer may provide further support to the toe areas 802, 803. In some embodiments, the middle layer may have an elastomeric padding creating thickness in the heel regions 816, 817 so as to create heel cushions 814, 808. In many embodiments, the precise shape of the cushions in the middle layer may vary. Additionally, the thickness of the cushions in the middle layer may vary. For example, the middle layer heel cushion may have a greater thickness than the middle layer ball cushion or the middle layer metatarsal cushions. Any combination of these or other cushions in the middle layer may be utilized in accordance with embodiments of the invention.
[0064] In addition, in some embodiments, middle layers may have cushions that are not right foot and left foot specific. These embodiments may allow the user to easily match up a pair of socks without needing to consider left and right orientations. Such embodiments may also provide for more efficient manufacturing. A bottom view of an inner layer 904 and middle layer of a multi-layered sock where the right and left socks have similarly shaped middle-layer cushions in accordance with an embodiment of the invention is illustrated in FIG. 9. In some embodiments, the shape of the middle layer ball cushion 906 in the toe region 902 of sock 900 may be symmetric. Further, in the heel region 910, the shape of the heel cushion 908 of the middle layer may be symmetric. In many embodiments, the shape of the various cushions such as, but not limited to the ball cushion 906 and the heel cushion 908 may be the same whether the sock is a left sock or a right sock. As described above, the symmetric nature of the cushion paddings may allow for such embodiments. In various embodiments, the middle layer may have a thickness utilizing elastomeric padding such that other middle layer cushions may be present. In some embodiments, the middle layer may have greater thickness in only one region, creating a cushion in only one area. For example, the middle layer may only have a thickness in the ball region of the foot, creating a ball cushion. In some embodiments, the shape of the middle layer cushions may differ from those depicted in the figure. The shape of the middle layer cushions may differ depending on the activity of the user.
[0065] Additional cushions in the ankle region may provide additional support and movement reduction during activities that involve shoes with ankle protection. Such physical activity may include activities such as, but not limited to, hiking, skiing, or basketball. A cross-sectional view of a multi-layered sock with ankle cushions in accordance with an embodiment of the invention is illustrated in FIG. 10. The sock 1000 may have middle layer ankle cushions 1022 in the ankle region 1008. There may be one or more ankle cushion(s) 1022. The ankle cushion 1022 may help reduce blister formation that may occur at the ankle region when the user's ankle is in contact with an external surface. In several embodiments, the outer layer 1012 may fully encapsulate the ankle middle layer cushion(s) 1022 by covering the inner layer 1014. The middle layer being encapsulated may allow for greater comfort for the user. The middle layer being encapsulated may also increase the durability of the middle layer cushions by keeping the middle layer cushions 1018, 1016 from being exposed to an external environment.
[0066] Although specific multi-layered socks with middle layer configurations for providing improved general foot health are discussed above with respect to FIGS. 5-10, any of a variety of multi-layered socks with various configurations including various number of cushions at various locations as appropriate to the requirements of a specific application can be utilized in accordance with embodiments of the invention. Processes for constructing multi-layered socks in accordance with embodiments of the invention are discussed further below.
Processes for Constructing Multi-layered Socks
[0067] Traditionally, a sock may be formed by knitting a hollow tubular shape with a closed end and an open end. As further described below, multi-layered socks may be constructed by knitting a tube with two open ends, folding the tube back over itself, and knitting one open end closed.
[0068] A process for constructing multi-layered socks in accordance with an embodiment of the invention are shown in FIGS. 11a-d. In reference to FIG. 11a, a tube 1100 may be knit of various material, such as, not limited to cotton, wool, etc. The tube 1100 may include a first opening 1110 and a second opening 1124. In many embodiments, the tube 1100 may also include a folding line 1122. In various embodiments, the tube 1100 may include a first half 1112 on one side of the folding line 1122 and a second half 1114 on another side of the folding line 1122. In several embodiments, the second half 1114 may include a middle layer 1126. In many embodiments, the middle layer 1126 may include one or more elastomeric padding causing varying thickness, as further described above. In various embodiments, the middle layer 1126 may have elastomeric padding causing greater thickness corresponding to particular locations on a user's foot. In several embodiments, the middle layer 1126 may have a varying thickness forming a heel cushion 1118 and a ball cushion 1116.
[0069] In reference to FIG. 11b, the first half 1112 can be folded over the second half 1114 at the folding line 1122. In many embodiments, the second opening 1124 is stretched and pulled backwards over the first half 1114 in a direction 1136. In various embodiments, the first half 1112 may form an outer layer 1134 when folded across the folding line 1122 over the first half 1114 and the ball cushion 1116 and the heel cushion 1118. In several embodiments, the first half 1112 may form an inner layer when the outer layer 1134 is pulled over the first half 1112 across the folding line 1122. In various embodiments, the tube 1130 may contain a toe hole 1132 after the second half 1112 is folded back over folding line 1122 to create an outer layer 1134.
[0070] In further reference to FIG. 11b, the folding line 1122 may be located at a variety of positions along the tube 1100. In some embodiments, the folding line 1122 may be positioned to divide the tube 1100 into a first half 1112 and a second half 1114 of equivalent lengths. In some embodiments, the folding line 1122 may be positioned to divide the tube 1100 into a first half 1112 with a different length than the second half 1114. Positioning the folding line 1122 at various positions along the tube 1100 allows for the multi-layered sock to have an outer layer 1134 extending to a variety of points along the sock. For example, a folding line 1122 dividing the first half 1112 and second half 1114 into equal lengths could support a construction of a multi-layered sock with coextensive inner and outer layers. A folding line 1122 dividing the first half 1112 and second half 1114 into different lengths could support a construction utilizing an outer layer covering a user's foot but not ankles.
[0071] In reference to FIG. 11c, an unfinished sock 1160 may be formed after folding a first half 1112 at a folding line 1122 over a second half 1114, a ball cushion 1116, and a heel cushion 1118. In many embodiments, the unfinished sock 1160 may have a toe hole 1162 located alone the folding line 1122 after the first half 1112 has been folded at the folding line 1122 over the second half 1114. In many embodiments, the second opening 1124 may be in line with the first opening 1110.
[0072] In reference to FIG. 11d the sock 1190 may include a stitch 1192 closing a toe hole 1162. In several embodiments, the stitching 1192 may create a toe region 1194 which may be used to contain a user's toes. In many embodiments, the second opening 1124 and the first opening 1110 may be stitched together. In several embodiments, the second opening 1124 and the first opening 1110 may, when stitched together, create hole which a user may use to place a foot into the sock 1190.
[0073] Although specific processes for constructing multi-layered socks are discussed above with respect to FIGS. 11a-11d, any of a variety of construction methods as appropriate to the requirements of a specific application can be utilized in accordance with embodiments of the invention. Additional processes for constructing multi-layered socks in accordance with embodiments of the invention are discussed further below.
Additional Processes for Constructing Multi-layered Socks
[0074] Various methods may be utilized for constructing multi-layered socks. In particular, construction methods may be optimized for ease of manufacture. Some methods may involve using a loom to knit a single continuous fabric tube of which the first portion of the fabric tube becomes an inner layer and a second portion of the fabric tube constitutes an outer layer. By manufacturing a single continuous tube, as opposed to two separate tubes, sewing time is reduced, producing a sock with a lower cost of manufacturing. Additionally, such manufacturing processes may also have a shorter knitting time than another traditional method of knitting multiple individual sock layers and then sewing the sock layers together after each sock layer has been knit. In multi-layered socks that are not fabric material, this method of knitting a single circular tube for the inner layer and outer layer may be paired with an additional process of applying a physically distinct middle layer. This method of separately adding a middle layer to the single continuous fabric tube may also be utilized if the middle layer does or does not consist in part or in entirety of a fabric material.
[0075] Additionally, there may be multiple different types of fabric knit into the single continuous fabric tube. Each type of fabric may have a different or similar function. Various fabrics may have wicking properties and/or provide padding and/or support to a user's foot. As discussed above, the middle layer may consist of an elastomeric material. The middle layer may also be a washable material, providing for convenient washing of the sock with multiple layers. The middle layer thickness may vary, and subsequently the middle layer may be applied as a single continuous layer with varying thicknesses. The middle layer may also be attached as multiple individual cushions with varying thicknesses.
[0076] A flow chart illustrating a process for constructing a multi-layered sock in accordance with an embodiment of the invention is illustrated in FIG. 12. The process 1200 may include knitting (1202) a circular tube comprising a first portion and a second portion. The process 1200 may also include attaching (1204) a middle layer to the first portion of the circular tube, as further described below. Alternatively, the middle layer may be attached to the second portion of the circular tube or some combination of the first portion of the circular tube and the second portion of the circular tube. This attachment may occur after the circular tube is knit or as the circular tube is being knit. The middle layer may be attached by one of several methods or of multiple different methods. Some of these methods are discussed below. The process 1200 may also include folding (1206) the second portion of the circular tube back over the first portion 1206 relative to a fold line.
[0077] The distance that the second portion is folded back over the first portion may correspond to the amount of the sock that will have multiple layers. For example, if the sock is not intended to have multiple layers around the ankle region, the second portion will be folded over the first portion relative to the fold line, so as to only cover the heel region. The process 1200 may also include, once the second portion is folded over the first portion to the desired amount, closing (1208) the tube at the toe region. This may be done as a stitch in the toe region, so as to close the toe end of the sock. The stitch may be placed so that it does not interfere with the end of a user's toes. The second layer may also be fixed to the first layer where the second end of the sock has been folded back.
[0078] As described above, a middle layer may be attached (1204) to the circular tube in constructing multi-layered socks. The application of the middle layer to the circular tube may be performed in several ways. A flow chart illustrating another process for creating a multi-layered sock by applying a screen print to a knitted circular tube in accordance with an embodiment of the invention is illustrated in FIG. 13. The process 1300 may include knitting (1302) a circular tube consisting of a first portion and a second portion. The first portion may be the inner layer and the second portion may be the outer layer. Alternatively, the first portion may be the outer layer and the second portion may be the inner layer of the multiple layered sock. The application of the middle layer may be performed by applying (1304) a middle layer to the first portion of the circular tube by applying a viscous gel through a screen print. The middle layer applied may be one continuous layer or may be of varying thicknesses resulting in individual middle layer cushions in key regions of the sock. In some embodiments, the second portion may be folded (1306) over the first portion as described above. In some embodiments, the circular tube is closed (1308) at the toe region. As discussed above, this may be completed by stitching the first portion and the second portion together at the toe region.
[0079] Alternatively, or in addition, other methods of applying a middle layer to a continuous knit tube may be utilized. A flow chart illustrating another process for creating a multi-layered sock by securing a middle layer to a knitted circular tube with an adhesive in accordance with an embodiment of the invention is illustrated in FIG. 14. In some embodiments, the process 1400 may include knitting (1402) a circular tube consisting of a first portion and a second portion. The middle layer may be applied (1404) to the first portion by securing the separate middle layer to the first portion with an adhesive. The middle layer applied may be one continuous layer or may be of varying thicknesses resulting in individual middle layer cushions in key regions of the sock. In some embodiments, this may result in individual cushions being applied to the knitted circular tube. In some embodiments, the second portion may be folded (1406) over the first portion as described above. In some embodiments, the circular tube is closed (1408) at the toe region. As discussed above, this may be completed by stitching the first portion and the second portion together at the toe region.
[0080] In some embodiments of the invention, the middle layer is not attached after the circular tube is knit, but rather is interwoven during the sock construction process. This may provide for quicker manufacturing and reduced manufacturing costs. This may also provide comfort to the user as such a sock may be less bulky. The sock produced by this manufacturing process may also have less mass. It also may be folded easier, providing for easier transport of the invention. A flow chart illustrating another process for creating a multi-layered sock where a second portion of a circular tube is made with material different than that of a first portion in accordance with an embodiment of the invention is illustrated in FIG. 15. In the process 1500, a circular tube is knit (1502) consisting of a first portion and a second portion, wherein the first portion is made of a first material and the second portion is made of a second material. The second material may be a combination of multiple types of materials, with different materials being knit at certain locations to provide for support and/or comfort at those locations. The locations that have materials that may provide support and/or comfort may be similar to those described above, such as the ball area, the heel area, and/or the ankle area. The material in these locations may be an elastomeric yarn, which may be spliced in as the circular tube is knit. In the locations having elastomeric yarn, the elastomeric yarn may act as support for a user's foot. In various embodiments, the second portion of the circular tube is folded (1504) over the first portion of the circular tube as described above. In many embodiments, the tube is closed (1506) at the toe region as described above.
[0081] Although specific processes for constructing multi-layered socks are discussed above with respect to FIGS. 12-15, any of a variety of construction methods as appropriate to the requirements of a specific application can be utilized in accordance with embodiments of the invention. While the above description contains many specific embodiments of the invention, these should not be construed as limitations on the scope of the invention, but rather as an example of one embodiment thereof. It is therefore to be understood that the present invention may be practiced otherwise than specifically described, without departing from the scope and spirit of the present invention. Thus, embodiments of the present invention should be considered in all respects as illustrative and not restrictive.
