US20160340811A1

US20160340811A1 - Fabric and method for manufacturing sock

Info

Publication number: US20160340811A1
Application number: US14/714,859
Authority: US
Inventors: Steven K. Roe
Original assignee: Wigwam Mills Inc
Current assignee: Wigwam Mills Inc
Priority date: 2015-05-18
Filing date: 2015-05-18
Publication date: 2016-11-24

Abstract

Fabrics, socks, and methods are described in which conductive traces are integrally knit into fabric for making a sock. In some cases, certain stitches are selected for knitting conductive yarn in addition to or in place of the main body yarn of the sock. The conductive yarn creates a conductive trace in a wale-wise and/or a course-wise direction, with the conductive trace extending from a first connection point (such as a sensor pad) to a second connection point (such as an electrical contact for connecting a device). The conductive trace is designed to transmit an electrical signal between the first and second connection points, such that data collected at the first connection point may be transmitted via the pathway provided by the conductive trace to the second connection point and the connected device, where the data can be analyzed and/or displayed to the wearer.

Description

BACKGROUND

The present disclosure relates in general to a weft knit fabrics and associated methods for making a sock. In particular, the fabrics and methods described herein incorporate at least one conductive yarn that is structured and positioned to serve as a conductive trace, such as for facilitating the sensing of various data regarding the wearer of the sock.
In the information age, the need to gather data regarding various aspects of a person's life and daily activities is continually growing. In the area of health, sports, and fitness, athletes and individuals who are engaging in recreational exercise and other physical activities may, for example, be interested to collect data regarding their physical condition before, during, and after they engage in the activity.

BRIEF SUMMARY

Embodiments of the invention described herein provide improved fabrics and methods of manufacturing fabrics for socks that can be worn by a person engaging in an activity, where the fabric is knit to incorporate electrically conductive traces that can transmit electrical signals from a collection point (e.g., a sensor) where data regarding the condition of the person engaging in the activity is detected or measured. In this way, the wearer need not be troubled with wearing extraneous data collection equipment or applying sensors to his or her body prior to exercising, but rather can put on a pair of socks (which he or she would likely wear regardless of the collection of data) that have such sensors and pathways for transmitting the collected data integrally formed with the sock fabric.
Fabrics, socks, and methods are thus described herein in which conductive traces are integrally knit into the fabric for making a sock. In some embodiments, certain stitches are selected for knitting conductive yarn in addition to or in place of the main body yarn of the sock. For example, certain needles of a knitting machine may be programmed to receive conductive yarn, whereas other needles may be programmed to receive nonconductive yarns in one course of fabric. Consecutive courses of fabric may use the same or slightly shifted stitches in the course to direct the conductive traces in the desired pathway between connection points, as described herein. The conductive yarns in consecutive courses, as a whole, thereby produce an electrical circuit knit into the sock.
Accordingly, in some embodiments, a weft knit fabric is provided that includes at least one non-conductive yarn and at least one conductive yarn that is weft knit with the at least one non-conductive yarn by selectively incorporating the conductive yarn at predefined locations for at least one stitch over a plurality of adjacent courses or wales to form a fabric having a plurality of wales and courses. The at least one conductive yarn defines a conductive trace in at least one of a wale-wise or a course-wise direction, respectively, of the fabric. The conductive trace extends from a first connection point to a second connection point and is configured to transmit an electrical signal between the first and second connection points.
In some cases, the first connection point may comprise a device selected from the group consisting of a temperature sensor, a humidity sensor, a pressure sensor, and a heart rate monitor. The second connection point may include an electrical contact that is configured to allow a device to be connected to the conductive trace and to receive the electrical signal from the first connection point. The conductive trace may, in some cases, comprise a plurality of adjacent wales.
In some embodiments, the at least one non-conductive yarn may comprise a first non-conductive yarn and a second non-conductive yarn, and the second non-conductive yarn may be selectively replaced with the at least one conductive yarn at predetermined locations to define the conductive trace. The at least one conductive yarn may define a plurality of conductive traces along respective wales, where each conductive trace is isolated from other conductive traces. In some cases, consecutive courses may include stitches of the conductive yarn of a respective conductive trace that are shifted with respect to adjacent courses.
The at least one non-conductive yarn may define an inner layer having wales and courses and an outer layer having wales and courses, wherein the inner and outer layers are connected together at spaced apart wales and courses by one of the non-conductive yarns extending between the layers, and wherein the at least one conductive yarn is knit between the inner and outer layers, such that each conductive trace formed by the conductive yarn is isolated from at least an inner surface of the fabric. The conductive yarn may, in some cases, form at least part of the outer layer.
In other embodiments, a double layer sock is provided, where the double layer sock is formed on a circular knitting machine from a first non-conductive yarn, a second non-conductive yarn, and at least one conductive yarn. The sock may include a tubular inner layer and a tubular outer layer surrounding the inner layer. The tubular inner layer may have at least a foot portion knit of at least a first non-conductive yarn and may have wales and courses, and the tubular outer layer may be knit of at least a second non-conductive yarn and a conductive yarn and may also have wales and courses. The outer layer may have at least a foot portion aligning with the foot portion of the inner layer. The inner and outer layers may be connected together at spaced apart wales and courses by one of the first or second non-conductive yarns extending between the layers. The at least one conductive yarn may define a conductive trace in a course-wise direction. The conductive trace may extend from a first connection point to a second connection point and may be configured to transmit an electrical signal between the first and second connection points, such that each conductive trace formed by the conductive yarn is isolated from at least an inner surface of the sock.
In some cases, the second course of the outer layer may include the second non-conductive yarn and the conductive yarn. The first non-conductive yarn may extend between the layers, may be knit predominantly in the inner layer, and may be knit only for connection purposes in the outer layer, and the conductive yarn may be weft knit between the inner and outer layers. The first non-conductive yarn extending between the inner and outer layers may be knit in the outer layer as tuck stitch loops. In some cases, at least one of the first connection points may form part of the inner layer.
In still other embodiments, a method of knitting a sock on a circular knitting machine is provided, in which a first non-conductive yarn is knit into courses and wales. A second non-conductive yarn may also be knit into courses and wales, and a conductive yarn may be selectively incorporated at predefined locations for at least one stitch over a plurality of adjacent courses or wales. The at least one conductive yarn may define a conductive trace in at least one of a wale-wise or a course-wise direction, respectively. Furthermore, the conductive trace may extend from a first connection point to a second connection point and may be configured to transmit an electrical signal between the first and second connection points.
In some cases, selectively incorporating the conductive yarn may comprise selectively replacing the second non-conductive yarn of the outer layer with the conductive yarn at the predefined locations. Knitting the first non-conductive yarn may comprise knitting the first non-conductive yarn into courses and wales to form an inner layer of the sock, and knitting the second non-conductive yarn may comprise knitting the second non-conductive yarn into courses and wales to form an outer layer of the sock in surrounding relation to said inner layer. Selectively incorporating the conductive yarn may comprise plating the conductive yarn between the inner and outer layers by selecting at least one stitch in a plurality of adjacent courses to receive the at least one conductive yarn. The method may further comprise connecting the inner and outer layers together at spaced apart wales and courses by causing one of the at least one first or second non-conductive yarns to extend between the inner and outer layers, such that each conductive trace formed by the conductive yarn is isolated from at least an inner surface of the fabric.
In some cases, selectively incorporating the conductive yarn may comprise replacing the second non-conductive yarn of the second course of the outer layer with the conductive yarn. Additionally or alternatively, selectively incorporating the conductive yarn may comprise adding the conductive yarn to the second course of the outer layer, such that the second course of the outer layer includes the second non-conductive yarn and the conductive yarn.
In some embodiments, the method may further comprise attaching at least one of the first connection points to the inner layer and connecting the at least one first connection point to a corresponding conductive trace.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIGS. 1A and 1B show perspective views of a sock with integrally knit conductive traces according to an example embodiment;

FIG. 2 is a simplified schematic view of an example knit structure incorporating non-conductive and conductive yarns according to an example embodiment;

FIG. 3 is a simplified schematic view of an example knit structure for a double layer sock including an inner layer and an outer layer and incorporating conductive yarns between the inner and outer layers according to an example embodiment; and

FIG. 4 illustrates a double layer sock incorporating non-conductive and conductive yarns according to an example embodiment.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements Like numbers refer to like elements throughout.
As noted above, individuals engaged in physical activity, such as walking, running, jogging, aerobic exercise, weight training, cycling, or any other sport or physical activity, as well as individuals with certain medical conditions who are undertaking physical activity, may have the need or the desire to monitor certain parameters regarding their physical response to the activity. Information such as regarding the person's body temperature, perspiration level, heart rate, blood pressure, and so on may, for example, help the person determine whether the level of activity in which they are engaged is adequate for their desired purposes (e.g., whether they are pushing themselves far enough) and, in some cases, can alert the wearer in the event the activity becomes too taxing or they begin to have a negative physical response to the activity (e.g., if the activity becomes too strenuous or lasts too long).
In one case, for example, a wearer, who is training for a certain athletic event, may have a goal of elevating his or her heart rate to a certain level for a certain period of time. On the other hand, in another case, the wearer may be an elderly person or a person with a certain medical condition who, although required to exercise, may be prohibited from exceeding a certain threshold of intensity of physical activity or duration of physical activity based on the physical response such activity might elicit. Thus, the fabrics, garments, and methods disclosed herein may have applications for both personal performance and medical products.
Conventional methods of monitoring physical parameters, such as heart rate, body temperature, blood pressure, etc., involve applying external sensors and monitoring devices to a person's skin, such as through the use of wired sensors with adhesive patches, pulse monitoring devices that are part of exercise equipment (e.g., a treadmill), or other devices that must be secured to the wearer's body using adhesives, clips, ties, elastic bands, etc. Such devices and monitoring accessories can thus be difficult, and at the very least cumbersome, to correctly position and secure on the wearer's body, and the size, location, method of attachment, etc. of such devices may end up negatively affecting or hindering the person's activity. Moreover, incorrect positioning or securement of conventional devices to the wearer's body may result in inaccurate data collection, providing poor information to the wearer.
Accordingly, embodiments of the invention described herein provide a fabric and method of manufacturing a fabric for a sock that can be worn by a user, where the sock fabric is knitted to include conductive yarns that form conductive traces to allow electrical signals carrying data regarding the physical parameters of the wearer to be transmitted between connection points on the sock. For example, one or more connection points may collect data such as body temperature, applied pressure, humidity level, blood pressure, heart rate (pulse), and other data, such as through the use of sensors, whereas other connection points may transmit the collected data to a remote location (e.g., an external processor, network server, cloud server, etc.) for processing, storage, reporting, display, etc.
In some embodiments, for example, a sock may be constructed of conductive and non-conductive traces, as described in greater detail below, with connection points having sensors at locations on the sock corresponding to the bottom of the wearer's foot. For example, three pressure sensors may be provided on the sock corresponding to points on the bottom of the wearer's foot to monitor the wearer's actual steps and the pressure at those points. By monitoring the pressure at certain points on the wearer's foot, the wearer's actual steps and the way the foot is landing with each stride can be analyzed via the pressure data, and the wearer may be able to determine ways to change his or her stride to improve his or her performance.
Turning now to FIG. 1, a sock 10 made of fabric structured and manufactured according to embodiments of the present invention is shown. The sock 10 can be made of a single layer weft knit fabric or may, in some cases, incorporate a double layer construction, as described in greater detail below. In particular, the weft knit fabric may include at least one non-conductive yarn 20 and at least one conductive yarn 25 that is weft knit with the at least one non-conductive yarn to form a fabric having a plurality of wales w and courses c. The at least one conductive yarn may be knit with the non-conductive yarn in such a manner as to define a conductive trace 30 along at least a portion of one of the plurality of wales w, such as in a wale-wise direction (e.g., as shown in FIG. 2). Additionally or alternatively, the at least one conductive yarn may be knit with the non-conductive yarn in such a manner as to define a conductive trace 30 along at least a portion of one of the plurality of courses c, such as in the course-wise direction (e.g., as shown in FIG. 3). Thus, in some embodiments, the conductive trace 30 may run in both wales and courses. The conductive trace 30 may extend from a first connection point 35 to a second connection point 40 (e.g., under the ankle band of the sock 10). The second connection point 40 may, for example, be configured to transmit the data collected at the first connection point 35 to a remote location (e.g., a location not on the sock itself, such as for processing, display, etc.). Thus, the conductive trace 30 may be configured to transmit an electric signal between the first and second connection points.
In some embodiments, the first connection point 35 may comprise a device such as a temperature sensor, a humidity sensor, a pressure sensor, and/or a heart rate monitor. In some cases, for example, a single first connection point 35 may be provided that includes a sensor that is capable of detecting a single parameter (e.g., a temperature sensor for detecting a body temperature of the wearer). In other cases, the single first connection point 35 may include a sensor that is capable of detecting multiple parameters, such as body temperature, blood pressure, humidity, and/or heart rate.
In still other cases, multiple first connection points 35 may be provided. Each first connection point 35 may be connected to a corresponding second connection point 40 via corresponding conductive traces 30. Accordingly, conductive traces 30 must be knit in such a manner that the conductive yarn 25 of one trace 30 is isolated from (e.g., has no electrical contact with) the conductive yarn of another trace. The second connection point 40 may, in some cases, be a transmitter or other electrical terminus that is configured to wirelessly transmit the electrical signal that is conducted from the first connection point 35 via the conductive trace 30 to a remote location, as noted above. In other cases, the second connection point 40 may include an electrical contact that is configured to allow a device, such as a hard-wired, Bluetooth®, or wireless device (e.g., a smart phone) to be connected.
With reference to FIG. 2, in some embodiments, for example, non-conductive and conductive yarns 20, 25 may be weft knit to form a single-layer fabric 45. In this regard, the fabric 45 may include a first non-conductive yarn 20 a that is continuously knit and a second non-conductive yarn 20 b that is selectively replaced with the conductive yarn 25 at predetermined locations to create one or more conductive traces 30 in a wale-wise direction of the fabric. For example, in some embodiments, a sock may be knit on a circular knitting machine by knitting the first non-conductive yarn 20 a to form courses and wales and knitting the second non-conductive yarn with the first non-conductive yarn to form the courses and wales. The second non-conductive yarn 20 b may be replaced with a conductive yarn 25 at predefined locations for at least one stitch over a plurality of adjacent courses, such that conductive stitches in adjacent (e.g., contacting) courses define a conductive trace 30 in a wale-wise direction of the fabric, as illustrated.
In some cases, the conductive trace 30 may comprise a plurality of adjacent wales w. In the depicted embodiment of FIG. 2, for example, the conductive trace 30 includes 2 stiches in each course c, where the stiches are aligned longitudinally such that a conductive trace 30 is formed that includes 2 wales w extending in a vertical direction (e.g., aligned vertically). In other cases, however, more than 2 stitches in each consecutive course c may be conductive, and the conductive trace 30 may thus include more than 2 wales, depending on the application. In still other cases, consecutive courses c may include stitches of conductive yarn 25 of a respective conductive trace 30, where the stitches are shifted with respect to adjacent courses. For example, using 5 stitches and shifting one needle over for each subsequent course, in any given course 4 conductive stitches will remain in contact with 4 conductive stiches in the adjacent course above and below the given course. As long as at least one conductive stitch touches a conductive stitch of the previous course, the conductive trace 30 will allow the electrical signal to propagate to the subsequent course, thereby forming an electrical pathway. Thus, by shifting stiches over, one course at a time, a conductive trace 30 can be moved across the fabric at an angle to provide for slanted or angled pathways such as those shown in FIGS. 1A and 1B.
In some embodiments, the sock may be made of a single layer fabric, as described above. In other embodiments, however, the sock may include, at least in part, a double layer fabric construction.
For example, with reference to FIGS. 3 and 4, in some cases the one or more non-conductive yarns 20 a, 20 b may define an inner layer 50 having wales w and courses c and an outer layer 55 having wales and courses. The inner and outer layers 50, 55 may be connected together at spaced apart wales and courses by one of the non-conductive yarns 20 a extending between the respective layers. The at least one conductive yarn 25 may be knit between the inner and outer layers 50, 55, such that each conductive trace 30 formed by the conductive yarn is isolated from an inner surface 60 of the fabric and from an outer surface 65 of the fabric. For example, the conductive traces 30 may be plated between the inner and outer layers 50, 55 and may be protected from contact with objects contacting the inner layer 60 (e.g., the wearer's skin) as well as objects contacting the outer layer 65 (e.g., the wearer's shoe) and may thus not be exposed on either side of the fabric.
Accordingly, in some embodiments, a double layer sock 100 may be formed on a circular knitting machine from at least one non-conductive yarn 20 a, 20 b and at least one conductive yarn 25. Each layer 50 and 55 may extend through a foot portion 110 of the sock 100 and through at least a portion of leg portion 120. In some embodiments, the yarns forming the inner layer 50 and the outer layer 55 may be knit together as a single layer (e.g., using a construction shown in FIG. 2) to form at least a cuff 130, a heel pocket 140, and toe pocket 150. In other embodiments, however, only the foot portion 110 of the sock may be formed using the double layer construction of FIG. 3. The double layer construction may be used in the foot portion 110, for example, to shield the conductive traces 30 in that area from direct contact with the wearer's skin in areas corresponding to the bottom of the wearer's feet, where the sensors at the respective connection points may be more susceptible to short circuiting when in contact with the conductive surface of the wearer's skin under an applied pressure (as may be experienced by the bottoms of the wearer's feet).
In the double layer regions, the inner layer 50 may be connected to the outer layer 55, or vice versa, at spaced locations during knitting thereof. This connection may, for example, be provided by tuck stitches 160 that are in selected courses and wales of the inner layer 50 and outer layer 55, as shown in FIG. 3.
In some embodiments, the sock 100 may be knit on a conventional circular knitting machine having a cylinder and dial capable of knitting socks, two examples of which are a 4-inch diameter 156 needle cylinder circular hosiery knitting machine with a cooperating dial having needles therein and with or without a LIN toe closing device, and a 4-inch diameter 112 needle cylinder circular knitting machine with a cooperating dial and a LIN toe device. Such knitting machines are conventionally provided with two yarn feeds that supply yarns to the cylinder and dial needles at spaced apart locations around the circular knitting machine.
The outer layer 55 of the sock 100 may be knit on the cylinder needles while the inner layer 50 may be knit on the dial needles. The main yarn feed of the knitting machine (not shown) may, for example, feed a second non-conductive yarn 20 b to the cylinder needles to form stitch loops 75 arranged in courses c1, c2 and wales w1-w10, shown in FIG. 3. For illustration only, the stitch pattern illustrated in FIG. 3 is a plain or jersey stitch pattern, but it would be understood that the outer layer 55 may be knit in any desired stitch pattern.
The secondary yarn feed of the knitting machine (not shown) may feed a first non-conductive yarn 20 a to the dial needles to form stitch loops 70 arranged in courses c1, c2 and wales w1-w5. As shown in FIG. 3, the dial needles may be used to form stitch loops 70 in the inner layer 50 while the cylinder needles may be used to form the stitch loops 75 in outer layer 55.
At spaced locations, such as in alternate courses c2 of the outer layer 55 and c2 of the inner layer 50 and such as in every fourth wale w4 and w8 of the outer layer 55, the inner layer 50 and outer layer 55 may be connected together by tuck stitches 130. To form such tuck stitches 130, for example, the cylinder needles forming such wales in those courses may be raised to the tuck position as they approach the secondary yarn feed of the knitting machine (feeding the first non-conductive yarn 20 a) so that the first non-conductive yarn 20 a is captured by the cylinder needles and knit into the outer layer 55 along with a stitch loop of the second non-conductive yarn 20 b from the main yarn feed to connect the two layers 50, 55 together. The spacing between the locations of the connecting stitch loops 130 and the type of connections may vary without departing from embodiments of the present invention.
The conductive yarn 25 may be incorporated into the sock 100 in different ways. In one embodiment, for example, the conductive yarn 25 may be fed by the main yarn feed of the knitting machine (not shown) along with the second course c2 of the second non-conductive yarn 20 b to the cylinder needles, but on an inner side of the outer layer 55, as shown in FIG. 3 (e.g., behind the second non-conductive yarn 20 b when viewed from an outer surface of the sock). In other embodiments, however, the conductive yarn 25 may replace the second course c2 of the second non-conductive yarn 20 b, such that one of the outer body yarns is replaced with conductive yarns as needed for the application (e.g., to form the desired number and position of the conductive traces 30). After the sock blank has been knit, the toe may be closed, such as by a LIN Toe device or seaming machine, with a toe closure seam 170, shown in FIG. 4.
Accordingly, in some embodiments, a double layer sock 100 is provided that is formed on a circular knitting machine from a first non-conductive yarn 20 a, a second non-conductive yarn 20 b, and a conductive yarn 25, as shown in FIGS. 3 and 4. The sock 100 may include a tubular inner layer 50 having a foot portion 110 and a leg portion 120 merging substantially at the ankle of a wearer knit of at least the first non-conductive yarn 20 a and having wales and courses, as described above. The sock 100 may further include a tubular outer layer 55 surrounding the inner layer 50 knit of at least the second non-conductive yarn 20 b and the conductive yarn 25 and having wales and courses. The outer layer 55 may also have a foot portion 110 and a leg portion 120 merging substantially at the ankle of the wearer and aligning with the foot portion and the leg portion, respectively of the inner layer 50.
The inner and outer layers 50, 55 may be connected together at spaced apart wales and courses by the first non-conductive yarns 20 a extending between the layers. The conductive yarn 25 may, for example, be knit with the second non-conductive yarns 20 b, such as in one of the courses cl, c2 of the outer layer 55, to define a conductive trace in a course-wise direction. For example, in some embodiments, the second course c2 of the outer layer 55 may include the second non-conductive yarn 20 b and the conductive yarn 25, as shown in FIG. 3. In other cases, however, the second non-conductive yarn 20 b of the second course c2 of the outer layer 55 may be replaced in some locations with the conductive yarn 25, as shown in FIG. 2. In this way, a conductive trace defined by connected (e.g., contacting) locations of the conductive yarn 25 may be knit into the sock such that the trace extends from a first connection point to a second connection point and is configured to transmit an electrical signal between the first and second connection points, as described above with respect to FIGS. 1 and 2. Moreover, by virtue of the double layer design, each conductive trace formed by the conductive yarn 25 may be isolated from at least the inner surface 60 of the sock 100 in those portions of the sock in which the double layer construction is used, and in some cases may be isolated from the outer surface 65 of the sock as well.
As described above, the first non-conductive yarn 20 a and may extend between the layers 50, 55, may be knit predominantly in the inner layer 50, and may be knit only for connection purposes in the outer layer 55. The conductive yarn 25 may thus be weft knit between the inner and outer layers 50, 55. In some embodiments, the first non-conductive yarn 20 a extending between the inner and outer layers 50, 55 may be knit in the outer layer 55 as tuck stitch loops. Additionally or alternatively, at least one of the first connection points 35 (shown in FIG. 1), such as a sensor, may form part of the inner layer 50. For example, the first connection point 35 (e.g., a sensor pad) may be sewn on the inner surface 60 of the inner layer 50 with conductive thread.
In socks that include regions having a single layer construction (e.g., shown in FIG. 2) and a double layer construction (e.g., shown in FIG. 3), the conductive yarn 25 may have tails (e.g., free ends) resulting from switching needles during knitting, etc. The tails may, in some cases, be the free ends of the conductive yarn 25 used in a single layer portion of the sock, and the tails may thus be disposed proximate a transition between the single layer portion and a double layer portion of the sock. In such cases, the tails may be placed between the inner and outer layers 50, 55 of the double layer portion to avoid unintended conductivity via the tails.
Accordingly a method of knitting a sock on a circular knitting machine is provided according to embodiments described above. With respect to a single layer sock for example, a first non-conductive yarn 20 a may be knit to form courses and wales, and a second non-conductive yarn 20 b may be knit with the first non-conductive yarn to form the courses and wales. The second non-conductive yarn 20 b may be selectively replaced with a conductive yarn 25 at predefined locations for at least one stitch over a plurality of adjacent courses. In this way, conductive stitches in adjacent courses may define a conductive trace in a wale-wise direction, and the conductive trace may thus extend from a first connection point to a second connection point, as described above, such that the conductive trace can transmit an electrical signal between the first and second connection points.
In some embodiments, the method of knitting the sock may be modified, at least in some regions of the sock, to provide a double layer sock construction. In such cases, the first non-conductive yarn 20 a may be knit to form courses and wales of an inner layer 50 of the sock, and the second non-conductive yarn 20 b may be knit to form courses and wales of an outer layer 55 of the sock. The conductive yarn 25 may be plated between the inner and outer layers 50, 55 by selecting at least one stitch in a plurality of consecutive courses c to receive the conductive yarn 25. The inner and outer layers 50, 55 may be connected together, as described above with respect to FIGS. 3 and 4, at spaced apart wales and courses by causing the first non-conductive yarn 20 a to extend between the inner and outer layers 50, 55. In this way, each conductive trace formed by the conductive yarn may be isolated from at least an inner surface 60 of the fabric.
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, although the fabric described herein is described as being used to make socks, in other embodiments other types of garments may be made using embodiments of the fabrics and methods described. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

What is claimed is:

1. A weft knit fabric comprising:

at least one non-conductive yarn; and

at least one conductive yarn that is weft knit with the at least one non-conductive yarn by selectively incorporating the conductive yarn at predefined locations for at least one stitch over a plurality of adjacent courses or wales to form a fabric having a plurality of wales and courses,

wherein the at least one conductive yarn defines a conductive trace in at least one of a wale-wise or a course-wise direction, respectively, of the fabric,

wherein the conductive trace extends from a first connection point to a second connection point and is configured to transmit an electrical signal between the first and second connection points.

2. The weft knit fabric of claim 1, wherein the first connection point comprises a device selected from the group consisting of a temperature sensor, a humidity sensor, a pressure sensor, and a heart rate monitor.

3. The weft knit fabric of claim 1, wherein the second connection point includes an electrical contact configured to allow a device to be connected to the conductive trace and to receive the electrical signal from the first connection point.

4. The weft knit fabric of claim 1, wherein the conductive trace comprises a plurality of adjacent wales.

5. The weft knit fabric of claim 3, wherein the at least one non-conductive yarn comprises a first non-conductive yarn and a second non-conductive yarn, wherein the second non-conductive yarn is selectively replaced with the at least one conductive yarn at predetermined locations to define the conductive trace.

6. The weft knit fabric of claim 1, wherein the at least one conductive yarn defines a plurality of conductive traces along respective wales, wherein each conductive trace is isolated from other conductive traces.

7. The weft knit fabric of claim 1, wherein consecutive courses include stitches of the conductive yarn of a respective conductive trace that are shifted with respect to adjacent courses.

8. The weft knit fabric of claim 1, wherein the at least one non-conductive yarn defines an inner layer having wales and courses and an outer layer having wales and courses, wherein the inner and outer layers are connected together at spaced apart wales and courses by one of the non-conductive yarns extending between the layers, and wherein the at least one conductive yarn is knit between the inner and outer layers, such that each conductive trace formed by the conductive yarn is isolated from at least an inner surface of the fabric.

9. The weft knit fabric of claim 8, wherein the conductive yarn forms at least part of the outer layer.

10. A double layer sock formed on a circular knitting machine from a first non-conductive yarn, a second non-conductive yarn, and at least one conductive yarn, the sock comprising:

a tubular inner layer having at least a foot portion knit of at least a first non-conductive yarn and having wales and courses; and

a tubular outer layer surrounding the inner layer knit of at least a second non-conductive yarn and a conductive yarn and having wales and courses, wherein the outer layer has at least a foot portion aligning with the foot portion of the inner layer,

wherein the inner and outer layers are connected together at spaced apart wales and courses by one of the first or second non-conductive yarns extending between the layers,

wherein the at least one conductive yarn defines a conductive trace in a course-wise direction,

wherein the conductive trace extends from a first connection point to a second connection point and is configured to transmit an electrical signal between the first and second connection points, such that each conductive trace formed by the conductive yarn is isolated from at least an inner surface of the sock.

11. The sock of claim 10, wherein the second course of the outer layer includes the second non-conductive yarn and the conductive yarn.

12. The sock of claim 10, wherein the first non-conductive yarn extends between the layers, is knit predominantly in the inner layer, and is knit only for connection purposes in the outer layer, and wherein the conductive yarn is weft knit between the inner and outer layers.

13. The sock of claim 12, wherein the first non-conductive yarn extending between the inner and outer layers is knit in the outer layer as tuck stitch loops.

14. The sock of claim 10, wherein at least one of the first connection points forms part of the inner layer.

15. A method of knitting a sock on a circular knitting machine comprising:

knitting a first non-conductive yarn into courses and wales;

knitting a second non-conductive yarn into courses and wales; and

selectively incorporating a conductive yarn at predefined locations for at least one stitch over a plurality of adjacent courses or wales,

wherein the at least one conductive yarn defines a conductive trace in at least one of a wale-wise or a course-wise direction, respectively,

16. The method of claim 15, wherein selectively incorporating the conductive yarn comprises selectively replacing the second non-conductive yarn of the outer layer with the conductive yarn at the predefined locations.

17. The method of claim 15, wherein

knitting the first non-conductive yarn comprises knitting the first non-conductive yarn into courses and wales to form an inner layer of the sock;

knitting the second non-conductive yarn comprises knitting the second non-conductive yarn into courses and wales to form an outer layer of the sock in surrounding relation to said inner layer;

selectively incorporating the conductive yarn comprises plating the conductive yarn between the inner and outer layers by selecting at least one stitch in a plurality of adjacent courses to receive the at least one conductive yarn; and

the method further comprising connecting the inner and outer layers together at spaced apart wales and courses by causing one of the at least one first or second non-conductive yarns to extend between the inner and outer layers, such that each conductive trace formed by the conductive yarn is isolated from at least an inner surface of the fabric.

18. The method of claim 17, wherein selectively incorporating the conductive yarn comprises replacing the second non-conductive yarn of the second course of the outer layer with the conductive yarn.

19. The method of claim 17, wherein selectively incorporating the conductive yarn comprises adding the conductive yarn to the second course of the outer layer, such that the second course of the outer layer includes the second non-conductive yarn and the conductive yarn.

20. The method of claim 15 further comprising attaching at least one of the first connection points to the inner layer and connecting the at least one first connection point to a corresponding conductive trace.