SOCK WITH PADDING

Abstract

The present invention introduces a specialized sock which incorporates a multi-layered foam padding element sewn into the heel portion, specifically sized and configured to reduce blister formation in stiff footwear such as boots and loafers. The fabric composition includes specific percentages of cotton, spandex, nylon, and elastic yarn, providing an optimal balance of breathability, durability, and moisture control. The design maintains padding stability after repeated washing and extended wear. Constructed from a blend of moisture-wicking and breathable materials, the sock ensures a dry and cool foot environment. The design is machine washable and includes padding that remains stable during physical activities, offering a durable and effective solution for foot discomfort.

Claims

1. A sock with padding comprising: a multi-layered foam padding element sewn into a back of a heel portion on an inside surface of the sock; wherein the multi-layered foam padding element comprises: an inner foam material layer constructed from a foam-sponge material; and, an outer soft layer constructed from a breathable mesh fabric, wherein the outer soft layer is sewn such that it sits directly against the back of the heel of the wearer on the inside surface of the sock, wherein the multi-layered foam padding element provides a cushion, relief, and prevention of foot pain and skin conditions developed from friction; wherein the sock is constructed from a moisture-wicking, breathable, anti-sweat, and antimicrobial fabric.

2. The sock of claim 1, wherein the sock fabric is constructed from 73% cotton combed spinning yarn, 11% spandex, 11% nylon, and 5% elastic yarn, and the outer soft layer is constructed of 83.3% polyamide, 14.2% spandex, and 2.5% cotton.

3. The sock of claim 2, wherein the foam-sponge material comprises polyurethane foam.

4. The sock of claim 1, wherein the multi-layered foam padding element includes a shape selected from a shape group consisting of: a rectangular shape, a square shape, a diamond shape, a heart shape, a polygon shape, a curved shape, and a circular shape.

5. The sock of claim 1, wherein the multi-layered foam padding element has dimensions in a range of about 6.0-7.0 cm in height and about 7.5-8.5 cm in width, the dimensions being configured to cover a heel contact area sufficient to reduce blister formation. wherein the sock is constructed from a moisture-wicking, breathable, anti-sweat, and antimicrobial fabric.

7. The sock of claim 6, wherein the multi-layered foam padding element has dimensions in a range of about 6.0-7.0 cm in height and about 7.5-8.5 cm in width, the dimensions being configured to cover a heel contact area sufficient to reduce blister formation when wearing stiff leather footwear.

8. The sock of claim 6, wherein the sock fabric is constructed from 73% cotton combed spinning yarn, 11% spandex, 11% nylon, and 5% elastic yarn, and the outer soft layer is constructed of 83.3% polyamide, 14.2% spandex, and 2.5% cotton.

9. A method of manufacturing a sock with padding, the method comprising: cutting a moisture-wicking, breathable, anti-sweat, and antimicrobial fabric into a sock shape; sewing a multi-layered foam padding element into a back of a heel portion on an inside surface of the sock, the multi-layered foam padding element comprising a foam-sponge material and an outer soft breathable mesh layer; wherein the multi-layered foam padding element is dimensioned in a range of about 6.0-7.0 cm in height and about 7.5-8.5 cm in width and is specifically configured to provide blister relief when worn with stiff footwear.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0017] Other features and advantages of the present invention will become apparent when the following detailed description is read in conjunction with the accompanying drawings, in which:

[0018] FIG. 1 illustrates a rear perspective view of sock with foam padding according to an embodiment of the present invention;

[0019] FIG. 2 illustrates a rear view of the sock with foam padding according to an embodiment of the present invention;

[0020] FIG. 3 illustrates a rear view of an alternate sock with foam padding according to an embodiment of the present invention;

[0021] FIG. 4 illustrates a rear view of a second alternate sock with foam padding according to an embodiment of the present invention;

[0022] FIG. 5 illustrates a rear view of a third alternate sock with foam padding according to an embodiment of the present invention;

[0023] FIG. 6 illustrates a rear view of a fourth alternate sock with foam padding according to an embodiment of the present invention;

[0024] FIG. 7 illustrates a side cross-sectional view of the sock with foam padding according to an embodiment of the present invention; and

[0025] FIG. 8 illustrates a side cross-sectional view of the sock with foam padding according to an embodiment of the present invention; and

[0026] FIG. 9 illustrates a perspective side view cross-sectional view of the sock with foam padding according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the general principles of the present invention have been defined herein to specifically provide a sock with padding.

[0028] It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms a or an, as used herein, are defined as to mean at least one. The term plurality, as used herein, is defined as two or more. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). The term providing is defined herein in its broadest sense, e.g., bringing/coming into physical existence, making available, and/or supplying to someone or something, in whole or in multiple parts at once or over a period of time. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. The term foam-sponge refers to a porous, resilient material characterized by its cushioning properties. It is engineered to have specific density, porosity, and compressibility that make it suitable for use as padding in the sock. The foam-sponge is designed to offer optimal comfort and protection against friction and pressure points when sewn into the sock.

[0029] The present invention offers a revolutionary approach to foot comfort and health by introducing a sock with strategically placed foam padding. The use of high-quality, breathable, and moisture-wicking materials further enhances the user experience by keeping the feet cool and dry.

[0030] The at least one padding may be configured to exhibit a cushioning effect greater than that provided by other portions of the sock. The cushioning effect may reduce an extent of physical abrasion and/or irritation caused from indirect contact with an external object, such as a shoe worn by a user, on a skin of the user while wearing the sock.

[0031] In some embodiments, the at least one padding may include a foam sponge.

[0032] In some embodiments, the at least one padding may include one or more of a memory foam, an EVA foam, a gel insert, a silicone padding, and an air-filled chamber.

[0033] Further, in some embodiments, the at least one padding may include one or more of a gel-infused fabric, an elastane, a thermoplastic polyurethane (TPU), a latex foam, and a polyurethane (PU) foam.

[0034] In some embodiments, the at least one padding may include a combination of blended fibers, microfiber, bamboo fiber, and specialized foams like Poron.

[0035] In some embodiments, the at least one padding may include a medicinal substance such as, but not limited to, an antimicrobial agent, an antifungal agent, a skin-soothing compound, a wound-healing compound and a thermal agent. Accordingly, in some embodiments, the at least one padding may alleviate an existing skin condition of the user while wearing the sock and optionally a shoe.

[0036] In some embodiments, the at least one padding may include a pouch comprising an opening and a plurality of inserts. Accordingly, the at least one padding may be customizable according to a need and/or preference of a user. Further, in some embodiments, at least one of the plurality of inserts may include the medicinal substance.

[0037] In some embodiments, the at least one padding may include at least one protrusion configured to provide acupressure wherein the at least one protrusion is disposed on a bottom portion of the sock corresponding to at least one acupressure point on a sole of the user's foot corresponding to at least one ailment associated with the user. In some embodiments, the at least one ailment may be associated with the feet of the user. In some other embodiments, the at least one ailment may be associated with other bodily parts of the user.

[0038] In some embodiments, the at least one padding may include an interior surface configured to contact a skin of the user when wearing the sock and an exterior surface configured to contact an interior of a shoe when the user wears the shoe. Further, the interior surface may include an anti-skid material configured to maintain a relative position of the at least one padding on a corresponding designated area of the user's foot. Examples of the anti-skid material may include, but are not limited to, anti-skid stripes made of rubber and/or silicone, a nano-coating, water based adhesive dots, a Thermal Plastic Rubber (TPR) coating, a grip-enhancing pattern, a textured fabric, a silicone gripper and a rubberized pad and/or dot pattern. Further, the exterior surface may include a low friction material, such as, but not limited to, Nylon, polyester, spandex, microfiber, silk, satin, neoprene, bamboo fabric, Teflon coated fabric, and Gore-tex. Accordingly, the at least one padding may facilitate easy wearing and/or removal of the shoe while also ensuring that the padding remains proximal to the designated area in order to protect and/or provide comfort to the designated area.

[0039] FIG. 1 illustrates a perspective view of sock with foam padding 100 according to an embodiment of the present invention. Referring now to FIG. 1, the sock 100 is illustrated. In one embodiment, the sock 100 comprises a typical sock appearance and shape configured to be worn on the foot of a user. In one embodiment, the sock 101 is constructed from a moisture-wicking, breathable, anti-sweat, and antimicrobial fabric. In one embodiment, the fabric is a unique cotton blend that includes a mix of cotton combed spinning yarn, spandex, nylon, elastic, polyamide, and polyurethane.

[0040] In some embodiments, the sock 101 comprises foam padding 107 strategically sewn into the back of the heel portion. This padding is specifically engineered to mitigate the formation of friction blisters, particularly during physical activities or when wearing specialized footwear. The foam padding 107 is multi-layered, offering additional protection against abrasions and skin damage. In one embodiment, the foam padding forms an inner layer of the sock, and for illustrative purposes in the drawings, the foam padding is visible.

[0041] Referring to FIGS. 2-5, the foam padding 107 can take various shapes, sizes, and designs, including but not limited to rectangular, square, diamond, heart, curved shapes, circular shapes, polygons, and other custom shapes. The critical aspect is that the shape sufficiently covers the heel area to reduce friction between the user's foot and the shoe. In one embodiment, the foam padding has dimensions that are configured to have a length, a width, and a height that are specifically designed for optimal comfort. Specifically, in FIG. 2, the shape is rectangular with a flat bottom section 107b and a rounded top section 107a. In FIG. 3, the shape is rectangular with a flat top and bottom section 107a and 107b. In FIG. 4, the shape is rectangular with a rounded top and bottom section 107a and 107b. In FIG. 5, the shape is circular. In FIG. 6, the shape is an oval.

[0042] Best seen in FIG. 8, the foam padding 107 can be defined as an inner foam material 108 and a soft outer layer 109 encompassing the foam material. In one embodiment, the foam material 108 is constructed from a marine sponge, such as spongia. In other embodiments, the foam material 108 may be constructed from synthetic sponge material. In yet other embodiments, the foam material 108 is polyurethane foam, polyester foam, or poly laminate foam. In other embodiments, the foam material 108 is a gel. In some embodiments, the soft outer layer 109 is constructed of a breathable mesh fabric made of polyamide, spandex, and cotton. In other embodiments, the soft outer layer 109 is constructed from polyamide fiber.

[0043] Best seen in FIG. 9, this outer layer 109 sits directly against the back of the heel of the wearer, i.e. the foam padding 107 extrudes from the sock material. In other embodiments, such as seen in FIG. 8, the outer layer is configured to sit against the shoe (not illustrated) of the user.

[0044] Although the specific materials and compositions may vary, the following are few examples of sock 100 material construction. It should be noted that these are non-limiting examples. In one embodiment, the sock material is a cotton blend. In one embodiment, the cotton blend comprises cotton combed spinning yarn (73%), spandex (11%), nylon (11%), and elastic yarn (5%). These particular percentages were selected to achieve a balance of comfort, durability, elasticity, and moisture management that is not attainable with conventional blends. For example, the relatively high proportion of combed cotton spinning yarn provides softness, breathability, and moisture absorption, while still retaining structural integrity. The inclusion of approximately 11% spandex ensures stretch and conformability to the user's foot, reducing slippage and enhancing fit, which in turn minimizes blister formation. The 11% nylon further contributes abrasion resistance and durability, particularly at high-friction points, thereby extending the life of the sock compared to ordinary cotton socks. The 5% elastic yarn stabilizes the fabric structure and maintains compression characteristics, allowing the padding to remain in place even after repeated wash cycles. These ratios were determined through testing to yield a composition that uniquely balances comfort, resilience, and blister-prevention.

[0045] In some embodiments, the soft outer layer 108 is constructed of a breathable mesh fabric made of polyamide (83.3%), spandex (14.2%), and cotton (2.5%). This composition was selected to provide enhanced air permeability, flexibility, and a lightweight feel while maintaining sufficient tensile strength. The dominant polyamide content resists tearing and adds a smooth texture that reduces friction against the heel, while the higher spandex ratio relative to the cotton blend enhances multidirectional stretch. The small but meaningful cotton content improves moisture absorption and prevents an overly synthetic feel against the skin. These particular ratios therefore create a synergistic combination of softness, stretch, and cooling that is not provided by conventional single-fiber or different-ratio blends. Accordingly, the recited percentages provide both unexpected comfort benefits and improved durability in demanding environments such as athletic activity or use with stiff leather footwear or similar.

[0046] The particular material compositions and padding configurations disclosed herein were not arbitrarily selected, but were developed through iterative testing to address specific shortcomings of conventional sock constructions. For example, it was unexpectedly observed that a cotton blend of approximately 73% combed cotton spinning yarn, 11% spandex, 11% nylon, and 5% elastic yarn exhibited superior blister-prevention compared to blends with higher cotton or lower nylon content. The identified ratio provided a unique balance of breathability, moisture absorption, stretch, and abrasion resistance that maintained the structural integrity of the sock while allowing the padding to remain properly positioned during prolonged wear and repeated wash cycles. The padding element maintains integrity through repeated washing and drying cycles Similarly, the breathable mesh fabric composition of polyamide, spandex, and cotton in the recited percentages provided a synergistic effect in which air permeability, tensile strength, and skin comfort were all improved relative to conventional single-fiber or differently proportioned blends.

[0047] Unexpected results were further demonstrated during wear testing, where users reported a measurable reduction in heel slippage and blister formation when the disclosed compositions were used in combination with the multi-layered foam padding. The selected ratios also reduced compression set of the foam, allowing the padding to retain its cushioning properties over time. These benefits were particularly apparent in demanding environments such as stiff leather footwear, athletic shoes, and occupational footwear where extended standing or repetitive motion is common. By contrast, conventional cotton-dominant socks with generic padding rapidly lost shape and failed to provide equivalent relief. Accordingly, the disclosed fabric and padding compositions represent a non-obvious improvement that achieves technical advantages not attainable with prior sock designs.

[0048] In other embodiments, the soft outer layer is entirely polyamide fiber. It should be understood that compositions of the aforementioned materials may vary.

[0049] The manufacturing process of the sock is designed to ensure the highest quality and durability while maintaining comfort and functionality. The sock 100 is assembled using advanced knitting techniques that seamlessly integrate the foam padding into the fabric. In the initial phase, the specialized fabric cotton blend is knitted into the basic sock shape, which includes a variety of tube lengths depending on the size and type of the sock, such a crew, quarter length, ankle, or similar as is well known in the art. Following this, the foam padding 107 is precisely cut into the desired shapes and sizes as per the design specifications and desired locations. In a non-limited example, the foam padding 107 configured for the heel portion is approximately 6.5 cm in height, and 8 cm in width. It should be understood that the size may vary as needed, but is particularly configured for prevent blister prevention for still leather footwear as previously mentioned.

[0050] Next, these foam padding pieces are then sewn into the sock using high-tensile strength thread, ensuring that they remain securely in place even under strenuous conditions. The sewing process is carried out to ensure that the foam padding aligns perfectly with the targeted areas on the foot, such as the heel, sides, toe, arch, bottom of the foot locations, etc. After the sewing is complete, the sock undergoes a series of quality control tests, including stretch tests, moisture-wicking tests, and abrasion tests, to confirm its durability and effectiveness. The final product is then packaged and prepared for distribution.

[0051] The innovative design and advanced features of this sock 101 make it highly versatile, opening up a wide range of commercial applications. It is particularly well-suited for the athletic and sports industry, where foot comfort and protection are paramount. The sock could also find applications in the healthcare sector, offering relief to patients suffering from foot-related conditions like bunions, blisters, and arch pain. Additionally, its moisture-wicking and antimicrobial properties make it ideal for military and outdoor use, where long periods of physical activity and harsh conditions are common. The sock's all-encompassing comfort and protection features could also make it a sought-after product in the footwear and apparel markets, appealing to consumers looking for everyday comfort. Its unique blend of materials and strategic padding could even make it a candidate for specialized footwear in industries that require prolonged standing or walking, such as nursing, retail, and manufacturing.

[0052] Although the invention has been described in considerable detail in language specific to structural features, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features described. Rather, the specific features are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternative embodiments are contemplated, and can be made without departing from the spirit and scope of the invention.

[0053] It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, bottom, forward, reverse, clockwise, counterclockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, oblique, proximal, distal, parallel, perpendicular, transverse, longitudinal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction or orientation. Instead, they are used to reflect relative locations and/or directions/orientations between various portions of an object.

[0054] In addition, references to first, second, third, and etc. members throughout the disclosure (and in particular, claims) are not used to show a serial or numerical limitation but instead are used to distinguish or identify the various members of the group.