WO2012032458A2

WO2012032458A2 - Socks, and method and system for making socks

Info

Publication number: WO2012032458A2
Application number: PCT/IB2011/053877
Authority: WO
Inventors: Avi Cohen
Original assignee: Delta Galil Industries Ltd.
Priority date: 2010-09-07
Filing date: 2011-09-05
Publication date: 2012-03-15
Also published as: WO2012032458A3

Abstract

The present invention includes socks, as well as a method and a system for manufacturing socks. For example, a sock includes: a toe area; a foot area; and a taped seam to connect the toe area with the foot area. For example, a method for manufacturing a sock includes: producing a toe area of the sock; producing a foot area of the sock; and applying a taped seam connecting the toe area with the foot area.

Description

SOCKS, AND METHOD AND SYSTEM FOR MAKING SOCKS

FIELD

[001 ] The present invention is related to the field of knitting.

BACKGROUND

[002] A sock is a knitted garment used for enclosing and covering the human foot, and often also the lower part of the leg. Socks are usually aimed at isolating the foot from the outside temperature, absorbing moisture and sweat, and mitigating friction between the foot and the shoe.

[003] Socks are often made of cotton, wool, polyester, nylon or other materials. Socks come in many colors and patterns, although the complexity and structure of the patterns is usually limited by the manufacturing techniques in use today.

SUMMARY

[004] The present invention may include a sock or a pair of socks, as well as a method and a system for producing socks.

[005] In accordance with the present invention, for example, a sock may include: a toe area; a foot area; and a taped seam to connect the toe area with the foot area. The taped seam may be located over a stitched permanent seam. The taped seam may be located over a stitched temporary seam. The taped seam may be located over a stitched partially-dissolved seam. The taped seam may be located on a top part of the sock. The taped seam may be located on a bottom part of the sock. The taped seam may be located on an external side of the sock. The taped seam may be located on an internal side of the sock. The taped seam may include one or more patterned features.

[006] In accordance with the present invention, a system for manufacturing a sock may include: a toe area production unit to produce a toe area of the sock; a foot area production unit to produce a foot area of the sock; and a taping unit to apply a taped seam connecting the toe area with the foot area. The system may include an initial seam generator to create, prior to application of the taped seam, a stitched seam connecting the toe area with the foot area. The taping unit may apply the taped seam over the stitched seam. The system may include an initial seam remover to remove the stitched seam subsequent to application of the taped seam. The initial seam remover may dissolve the stitched seam by utilizing one or more heating operations. The stitched seam may include an at least partially dissolving stitched seam.

[007] In accordance with the present invention, a method for manufacturing a sock may include: producing a toe area of the sock; producing a foot area of the sock; and applying a taped seam connecting the toe area with the foot area. The method may include: prior to applying the taped seam, creating a stitched seam connecting the toe area with the foot area. Optionally, applying the taped seam may include applying over the stitched seam. The method may include: removing the stitched seam subsequent to application of the taped seam; for example, by dissolving the stitched seam by utilizing one or more heating operations. The stitched seam may include an at least partially dissolving stitched seam.

[008] The present invention may provide other and/or additional benefits and/or advantages.

BRIEF DESCRIPTION OF THE DRAWINGS

[009] For simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity of presentation. Furthermore, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. The figures are listed below.

[0010] Fig. 1A is a schematic top-view illustration of a sock in accordance with the present invention;

[001 1] Fig. IB, which is a schematic side-view illustration of the sock in accordance with the present invention;

[0012] Fig. 2 is a schematic bottom- view illustration of another sock in accordance with the present invention;

[0013] Figs. 3A-3C are schematic top-view illustrations of a sock during three phases of a demonstrative sock manufacturing process, in accordance with the present invention;

[0014] Fig. 4 is a schematic flow-chart of a method of manufacturing socks, in accordance with the present invention; [0015] Fig. 5 is a schematic flow-chart of another method of manufacturing socks, in accordance with the present invention; and

[0016] Fig. 6 is a schematic block-diagram illustration of a system for manufacturing socks, in accordance with the present invention.

DETAILED DESCRIPTION

[0017] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of some embodiments. However, it will be understood by persons of ordinary skill in the art that some embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, units and/or circuits have not been described in detail so as not to obscure the discussion.

[0018] Applicants have realized conventional socks include a seam, typically around or at the toe area, and that the seam may be uncomfortable for some sock consumers. Applicants have realized that there exists a long-felt need in the socks industry as well as among sock consumers, for socks that include a comfortable seam or an alternate method of closing or connecting fabric at the toe area.

[0019] At an overview, the present invention may include a sock including a taped seam, or a sock in which the toe area may include or may be surrounded by a taped seam. The taped seam may be produced, for example, by taping, adhering, bonding and/or gluing two adjacent ends of fabric to each other. In a process of manufacturing a sock, a knitting machine may knit or produce a tubular cloth item intended to be a sock; may sew together adjacent ends of the tube to produce a toe area of the sock having an initial or temporary seam; and may tape the adjacent ends to produce a taped seam of the sock. Optionally, the initial or temporary seam may be unraveled or removed, subsequent to the taping.

[0020] Reference is made to Fig. 1A, which is a schematic top-view illustration of a sock 100 in accordance with the present invention; as well as to Fig. IB, which is a schematic side-view illustration of sock 100 in accordance with the present invention. Sock 100 may include multiple areas or regions, for example, a toe area 101 , a heel area 102, and a foot area 103 (which may also be referred to herein as a "residual area" or a "body area"). In accordance with the present invention, a taped seam 104 may connect toe area 101 to foot area 103. [0021] Taped seam 104 may be manufactured, for example, by utilizing silicone gel(s) which may turns into solid upon heating; by utilizing solid and/or liquid thermo-plastic material(s) which may be heated or cooled to produce a strip; by utilizing a ribbon of fabric which may be heated to adheres together two fabric ends or edges; by utilizing ultrasonic welding or soldering, or by other suitable methods of fabric bonding or gluing.

[0022] Optionally, taped seam 104 may one or more features or embedded characteristics, for example, anti-slip bumps or protrusions, friction bumps or protrusions, smooth and friction-free region(s), or other suitable features which may be achieved by utilizing particular material(s) and/or particular knitting techniques.

[0023] The length and/or width of taped seam may vary, and may not necessarily be at the proportions which are depicted for demonstrative purposes in Fig. 1 A. For example, taped seam 104 may have a length which may be substantially equal to the entire width of toe area 101 or the entire width of foot area 103. Alternatively, taped seam 104 may have a length which may be smaller than the entire width of toe area 101 or of foot area 103, for example, approximately 75 percent or approximately 50 percent of the width of toe area 101. Similarly, the width of taped seam 104 may vary, for example, in the range of approximately 1 millimeter to approximately 12 millimeters. Other suitable sizes, dimensions or proportions may be used.

[0024] Optionally, taped seam 104 may further include a graphical component 105, which may be, for example, a logo, a textual item, an image, a pattern, a branded item, an ornamental or decorative image, or the like. Optionally, graphical component 105 or patterned feature may have additional or other functionality; for example, taped seam 104 in a left sock may have graphical component 105 indicating the letter "L", whereas taped seam 104 in a right sock may have graphical component 104 having graphical component 105 indicating the letter "R". Similarly, color coding may be used, or different patterns may be used, or other indications may be used (e.g., gender indication, size indication, or the like) in conjunction with taped seam 104.

[0025] Taped seam 104 may be on an internal side of sock 100, or on an external side of sock 100. Optionally, two taped seems 104 may be used, on both the internal and external sides of sock 100.

[0026] As demonstrated in Fig. IB, a transitional element 106 which may optionally be utilized for transition between toe area 101 and foot area 103, which may optionally be manufactured separately of each other. Transition element 106 may be visible, or may be substantially invisible or at the same color of both toe area 101 and foot area 103. Other transition elements may optionally be used, for example, to transit between heel area 102 and foot area 103.

[0027] Reference is made to Fig. 2, which is a schematic bottom-view illustration of a sock 200 in accordance with the present invention. Sock 200 may be generally similar to sock 100 of Fig. 1A, and may similarly include toe area 101, heel area 102, foot area 103, and taped seam 104. However, whereas taped seam 104 of Fig. 1A may be located at the top part of sock 100, taped seam 104 of Fig. 2 may be located at the bottom part of sock 100.

[0028] Other suitable implementations may be used in accordance with the present invention; for example, taped seam 104 may be locate at both the bottom and top parts of sock 100; on a right side, and/or on a left side, of sock 100; on one or more sides or regions of sock 100; or the like.

[0029] Reference is made to Figs. 3A-3C, which are schematic top-view illustrations of sock 100 during three phases 301-303 of a demonstrative manufacturing process, in accordance with the present invention.

[0030] In phase 301 , a seam 1 10 may be stitched in sock 100, to connect toe area 101 with foot area 103. Seam 1 10 (which may be referred to herein as "stitched seam"), may be stitched, sewn, or otherwise link in a hand-made or manual process, in a process of manual linking or classic linking or hand-linking, or semi-automatically or automatically by using a sewing machine or other suitable machine. Optionally, seam 110 may be an initial seam or temporary seam or preliminary seam, adapted to temporarily hold together toe area 101 and foot area 103. Seam 110 may be formed of fibers or thread(s). Optionally, seam 110 may be a dissolving seam or a partially-dissolving seam, formed of material(s) that, upon heating or cooling, may dissolve (in whole or in part) or evaporate or melt or become embedded within surrounding materials.

[0031] In phase 302, taped seam 104 may be applied to sock 100, to connect toe area 101 with foot area 103. Optionally, taped seam 104 may be located over or on top of seam 110, or in proximity to seam 1 10, or generally in parallel to seam 110.

[0032] In phase 303, optionally, taped seam 104 may be maintained in sock 100, whereas seam 110 may be removed from sock 100, by one or more suitable methods, for example, dissolving, reaction to heating or cooling, unraveling, or the like.

[0033] Alternatively, phase 303 may demonstrate a single-step process of directly applying taped seam 104 to sock 100, without initially utilizing seam 1 10. [0034] Reference is made to Fig. 4, which is a schematic flow-chart of a method of manufacturing socks, in accordance with the present invention. The method may include, for example, taping together a toe area and a foot area (block 410), or otherwise connecting the toe area and the foot area by utilizing a taped seam or by applying a taped seam.

[0035] Reference is made to Fig. 5, which is a schematic flow-chart of another method of manufacturing socks, in accordance with the present invention. The method may include, for example, sewing or stitch an initial seam to connect a toe area and a foot area (block 510); applying a taped seam (or taping) over or above, or in proximity to, the initial seam (block 520); and optionally, removing (or dissolving) the initial seam (block 530).

[0036] The methods of Fig. 4 and/or Fig. 5 may utilize other and/or additional operations, or may be used such that other areas of the sock may be similarly connected or manufactured.

[0037] Reference is made to Fig. 6, which is a schematic block-diagram illustration of a system 600 for manufacturing socks, in accordance with the present invention. System 600 may include, for example, a toe area production unit 601 , a heel area production unit 602, a foot area production unit 603, a taping unit 604, an initial seam generator 610, an initial seam remover 611 , a control unit 621 , and a control interface 622.

[0038] Toe area production unit 601 may include a sewing machine or a knitting machine, having one or more needles (which, optionally, may be selectively operated or controlled by control unit 621), and may be able to produce toe area 101 by sewing or knitting.

[0039] Heel area production unit 602 may include a sewing machine or a knitting machine, having one or more needles (which, optionally, may be selectively operated or controlled by control unit 621), and may be able to produce heel area 102 by sewing or knitting.

[0040] Foot area production unit 603 may include a sewing machine or a knitting machine, having one or more needles (which, optionally, may be selectively operated or controlled by control unit 621), and may be able to produce foot area 103 by sewing or knitting.

[0041] Optionally, production units 601 , 602 and/or 603 may be implemented using a single production unit or machine, or using two or more separate units or modules.

[0042] Taping unit 604 may be or may include a tape applicator able to dispense and/or apply tape in order to create taped seam 104, for example, to connect toe area 101 with foot area 103.

Optionally, taping unit 604 may be able to add to taped seam 104 a logo, a pattern, or other feature(s), prior to the taping, during the taping operation, or subsequent to the taping. [0043] Initial seam generator 610 may include a knitting unit, sewing unit, or one or more needles able to create or form the optional initial seam 110, prior to the forming of taped seam 104.

[0044] Initial seam remover 611 may include a module or unit able to remove or dissolve initial seam 110, for example, subsequent to the taping of taped seam 104. Initial seam remover 611 may include, for example, a heating unit able to generate and/or emanate heat, a cooling unit able to generate and/or emanate cold air, or other suitable units able to cause initial seam 610 to dissolve or otherwise modify its characteristic(s).

[0045] Control unit 621 may include, for example, a computer, a computerized device, controller(s), circuit(s), or other suitable combination of hardware and/or software. Control unit 621 may be able to control or modify the operation of one or more other units of system 600; may be able to activate and/or deactivate one or more other units of system 600; may be able ensure that a particular unit of system 600 operates only before or after one or more other units of system 600; or the like.

[0046] Control interface 622 may include an interface able to receive user commands with regard to the sock production process. The user commands may include, for example, commands to begin or end the process; commands indicating to system 600 whether or not to utilize initial seam 110; commands indicating to system 600 whether or not to remove or dissolve initial seam 1 10; commands indicating to system 600 at which area(s) to apply taped seam 104; commands indicating to system 600 whether taped seam 104 is intended to be on the external side of sock 100 or on the internal side of sock 100; commands indicating to system 600 whether or not to apply a logo or pattern onto taped seam 104; or other suitable commands.

[0047] The present invention may be used to produce a sock, or a pair of socks, intended to be worn by a man, a woman, a child, an animal, or the like. Some aspects of the present invention may be applied to other types of clothes or clothing articles, for example, leggings, calf-warmers, tights, gloves, or other garments.

[0048] Functions, operations, components and/or features described herein with reference to one or more embodiments, may be combined with, or may be utilized in combination with, one or more other functions, operations, components and/or features described herein with reference to one or more other embodiments, or vice versa. [0049] While certain features of some embodiments of the present invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents may occur to those skilled in the art. Accordingly, the following claims are intended to cover all such modifications, substitutions, changes, and equivalents.

Claims

CLAIMS What is claimed is:

1. A sock comprising:

a toe area;

a foot area; and

a taped seam to connect the toe area with the foot area.

2. The sock of claim 1 , wherein the taped seam is located over a stitched permanent seam.

3. The sock of claim 1 , wherein the taped seam is located over a stitched temporary seam.

4. The sock of claim 1 , wherein the taped seam is located over a stitched partially-dissolved seam.

5. The sock of claim 1 , wherein the taped seam is located on a top part of the sock.

6. The sock of claim 1 , wherein the taped seam is located on a bottom part of the sock.

7. The sock of claim 1, wherein the taped seam is located on an external side of the sock.

8. The sock of claim 1, wherein the taped seam is located on an internal side of the sock.

9. The sock of claim 1, wherein the taped seam comprises one or more patterned features.

10. A system for manufacturing a sock, the system comprising:

a toe area production unit to produce a toe area of the sock;

a foot area production unit to produce a foot area of the sock; and

a taping unit to apply a taped seam connecting the toe area with the foot area.

11. The system of claim 10, further comprising:

an initial seam generator to create, prior to application of the taped seam, a stitched seam connecting the toe area with the foot area.

12. The system of claim 1 1, wherein the taping unit is to apply the taped seam over the stitched seam.

13. The system of claim 12, further comprising:

an initial seam remover to remove the stitched seam subsequent to application of the taped seam.

14. The system of claim 13, wherein the initial seam remover is to dissolve the stitched seam by utilizing one or more heating operations.

15. The system of claim 11, wherein the stitched seam comprises an at least partially dissolving stitched seam.

16. A method for manufacturing a sock, the method comprising:

producing a toe area of the sock;

producing a foot area of the sock; and

applying a taped seam connecting the toe area with the foot area.

17. The method of claim 16, further comprising:

prior to applying the taped seam, creating a stitched seam connecting the toe area with the foot area.

18. The method of claim 17, wherein applying the taped seam comprises applying over the stitched seam.

19. The method of claim 18, further comprising:

removing the stitched seam subsequent to application of the taped seam.

20. The method of claim 19, wherein the removing comprises dissolving the stitched seam by utilizing one or more heating operations.

21. The method of claim 17, wherein the stitched seam comprises an at least partially dissolving stitched seam.