WO2018220485A1 - Sock with double-layer foot portion and bottom toe seam - Google Patents

Sock with double-layer foot portion and bottom toe seam Download PDF

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Publication number
WO2018220485A1
WO2018220485A1 PCT/IB2018/053702 IB2018053702W WO2018220485A1 WO 2018220485 A1 WO2018220485 A1 WO 2018220485A1 IB 2018053702 W IB2018053702 W IB 2018053702W WO 2018220485 A1 WO2018220485 A1 WO 2018220485A1
Authority
WO
WIPO (PCT)
Prior art keywords
foot
layer
sock
tubular outer
outer layer
Prior art date
Application number
PCT/IB2018/053702
Other languages
French (fr)
Inventor
Steven K. Roe
Original Assignee
Wigwam Mills, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Wigwam Mills, Inc. filed Critical Wigwam Mills, Inc.
Publication of WO2018220485A1 publication Critical patent/WO2018220485A1/en

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Classifications

    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41B—SHIRTS; UNDERWEAR; BABY LINEN; HANDKERCHIEFS
    • A41B11/00—Hosiery; Panti-hose
    • A41B11/005—Hosiery made essentially of a multi-ply construction
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41B—SHIRTS; UNDERWEAR; BABY LINEN; HANDKERCHIEFS
    • A41B11/00—Hosiery; Panti-hose
    • A41B11/01—Seams
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/10—Patterned fabrics or articles
    • D04B1/102—Patterned fabrics or articles with stitch pattern
    • D04B1/108—Gussets, e.g. pouches or heel or toe portions
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/22—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting goods of particular configuration
    • D04B1/24—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting goods of particular configuration wearing apparel
    • D04B1/26—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting goods of particular configuration wearing apparel stockings
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41B—SHIRTS; UNDERWEAR; BABY LINEN; HANDKERCHIEFS
    • A41B2500/00—Materials for shirts, underwear, baby linen or handkerchiefs not provided for in other groups of this subclass
    • A41B2500/10—Knitted
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/023—Fabric with at least two, predominantly unlinked, knitted or woven plies interlaced with each other at spaced locations or linked to a common internal co-extensive yarn system
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2501/00—Wearing apparel
    • D10B2501/06—Details of garments
    • D10B2501/061—Piped openings (pockets)

Definitions

  • the present disclosure relates generally to socks having double layer portions and/or a seam under the toes of a wearer, and more particularly to socks having two layers in select portions of the sock and/or a seam positioned under the toes of a wearer and methods for making the same.
  • Double layer socks provide additional cushioning of the foot when the wearer is engaged in activities such as running, hiking and the like. Such socks also may be made to be particularly effective at absorbing perspiration. Double layer socks allow for movement between the layers, thereby reducing the movement between the inner layer and the wearer's foot, resulting in a more comfortable fit.
  • Single, as well as double, layer socks are generally knit as a sock blank with a cuff or welt surrounding an opening at the leg portion and an opening at the toe portion. The toe opening of a machine knit sock is then closed.
  • Existing double layer socks typically have two separate layers that are stitched together at the toe and leg opening.
  • conventional socks are formed by knitting the hem or welt first, followed by the leg, heel, foot, and then toe. After the toe is knit, a seam is formed to attach the opposite sides of the toe pocket to each other, closing the toe.
  • the heel and toe of the sock are typically knit by using the same half of the total needles in the cylinder in the knitting machine. As such, the heel and toe are conventionally formed on the same side of the sock, and the sock is closed with a seam.
  • the toe seam is on the top of the foot, running across the top of the toes of the wearer.
  • Embodiments of the invention described herein provide improved socks and methods for making the same.
  • the inventor has identified that having two separate layers that are attached at the ends of the socks can lead to too much movement of the layers with respect to each other, causing discomfort for the wearer, and that having a toe seam positioned over the top of a wearer's toes may cause the seam to rub the tops of the toes, again causing discomfort for the wearer.
  • socks formed in accordance with the embodiments described herein include double layers in select portions of the sock and/or a seam positioned under the toes to improve wearer comfort.
  • embodiments of the invention provide a double layer sock formed on a circular knitting machine from at least two yarns.
  • the double layer sock comprises a tubular outer layer and an inner layer.
  • the tubular outer layer is knit of at least one yarn and has wales and courses.
  • the tubular outer layer also includes a foot portion and a leg portion merging substantially at the ankle of a wearer, and the foot portion defines a foot bottom portion and an upper instep portion.
  • the inner layer is knit of at least one other yarn and has wales and courses.
  • the inner layer also comprises a plurality of edges that define a perimeter of the inner layer.
  • the inner layer is substantially aligned with the foot bottom portion of the tubular outer layer, and one of the yarns extends between the inner layer and the tubular outer layer to connect the inner layer and the tubular outer layer around the perimeter of the inner layer and at spaced apart wales and courses.
  • a region of the double layer sock corresponding to the upper instep portion of the tubular outer layer is single-layered, and a region of the double layer sock corresponding to the foot bottom portion of the tubular outer layer is double- layered.
  • the yarn extending between the inner layer and the tubular outer layer may be knit into both layers.
  • the yarn extending between the inner layer and the tubular outer layer may be knit into both layers.
  • the yarn extending between the inner layer and the tubular outer layer may be knit predominately in one layer and may be knit for connection purposes only in the other layer. In further embodiments, the yarn extending between the inner layer and the tubular outer layer may be knit predominately in the inner layer and may be knit for connection purposes only in the tubular outer layer as tuck stitch loops.
  • the foot portion of the tubular outer layer may further comprise a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and at least one of the heel portion or the toe portion may be made via reciprocated knitting.
  • at least one of the heel portion or the toe portion may comprise terry loops.
  • a portion of the inner layer may be substantially aligned with part of the leg portion of the tubular outer layer proximate the heel portion.
  • a method of knitting a double layer sock on a circular knitting machine includes knitting at least one yarn into courses and wales to form a tubular outer layer of the sock, the tubular outer layer having a foot portion and a leg portion merging substantially at the ankle of a wearer, and the foot portion defines a foot bottom portion and an upper instep portion.
  • the method further includes knitting at least one other yarn into courses and wales to form an inner layer of the sock such that the inner layer is knit concurrently with at least a portion of the tubular outer layer, and the inner layer comprises a plurality of edges that define a perimeter of the inner layer.
  • the method further includes connecting the inner layer and the tubular outer layer together around the perimeter of the inner layer and at spaced apart wales and courses by causing one of the yarns to extend between the inner layer and the tubular outer layer concurrently with the knitting of the tubular outer layer and the inner layer.
  • the inner layer is substantially aligned with the foot bottom portion of the tubular outer layer.
  • the yarn extending between the inner layer and the tubular outer layer may be knit into both layers.
  • the yarn extending between the inner layer and the tubular outer layer may be knit into both layers.
  • the yarn extending between the inner layer and the tubular outer layer may be knit predominately in one layer and may be knit for connection purposes only in the other layer. In further embodiments, the yarn extending between the inner layer and the tubular outer layer may be knit predominately in the inner layer and may be knit for connection purposes only in the tubular outer layer as tuck stitch loops.
  • the inner layer may be knit on dial needles of the circular knitting machine, and the tubular outer layer may be knit on cylinder needles of the circular knitting machine.
  • the foot portion of the tubular outer layer may further comprise a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and at least one of the heel portion or the toe portion may be made via reciprocated knitting.
  • at least one of the heel portion or the toe portion may comprise terry loops.
  • a portion of the inner layer may be substantially aligned with part of the leg portion of the tubular outer layer proximate the heel portion.
  • a sock formed on a circular knitting machine from at least one yarn includes a tubular body and a toe seam.
  • the tubular body includes a foot portion and a leg portion merging substantially at the ankle of a wearer such that the foot portion defines a foot bottom portion and an upper instep portion and further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion.
  • the toe seam is positioned within the toe portion proximate the foot bottom portion such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer.
  • At least one of the toe portion or the heel portion may be made via reciprocated knitting.
  • at least one of the heel portion or the toe portion may comprise terry loops.
  • at least a portion of the sock may be double-layered.
  • a method of knitting a sock comprising a tubular body having a foot portion and a leg portion on a circular knitting machine such that the foot portion defines a foot bottom portion and an upper instep portion.
  • the method includes knitting at least one yarn into courses and wales to form the leg portion, reciprocating at least one yarn into courses and wales to form a heel portion at a first end of the foot portion, knitting at least one yarn into courses and wales to form the foot bottom portion and the upper instep portion adjacent to the heel portion, reciprocating at least one yarn into courses and wales on the opposite side of the sock as the heel portion to form a toe portion adjacent the foot bottom portion at a second end of the foot portion, and closing the toe portion with a toe seam positioned within the toe portion proximate the foot bottom portion, such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer.
  • FIG. 1 is a perspective view of a double layer sock according to an example embodiment of the invention
  • FIG. 2 is a perspective view of a double layer sock according to an example embodiment of the invention as it appears having a portion cut away;
  • FIG. 3 is an enlarged fragmentary perspective view of the knit structure of a double layer sock according to an example embodiment of the invention.
  • FIG. 4 is a schematic block diagram illustrating a method of knitting a double layer sock according to an example embodiment of the invention
  • FIG. 5 is a perspective view of a sock having a seam under the toes according to an example embodiment of the invention.
  • FIG. 6 is a schematic block diagram illustrating a method of knitting a sock according to an example embodiment of the invention.
  • Double layer socks provide additional cushioning of the foot as compared to single layer socks when the wearer is engaged in activities such as running, hiking and the like. Such socks also may be made to be particularly effective at absorbing perspiration. Double layer socks provide for movement between the layers, thereby reducing the movement between the inner layer and the wearer's foot, resulting in a more comfortable fit.
  • Single, as well as double, layer socks are generally knit as a sock blank with a cuff or welt surrounding an opening at the leg portion and an opening at the toe portion. The toe opening of a machine knit sock is then closed.
  • conventional double layer socks provide improved comfort over single layer socks
  • conventional double layer socks typically have two separate and distinct layers that are stitched to each other at the corresponding toe and leg openings. Because the layers are separately formed and are only attached at the toe and leg opening, conventional double layer socks are prone to exhibiting movement of one layer with respect to the other. This movement may cause chafing, blisters, and other painful conditions for the wearer.
  • having double layers throughout most of the sock may improve perspiration absorption
  • having two layers covering most or all of the foot may cause the foot to overheat and/or may limit the airflow around the foot, causing further discomfort to the wearer.
  • both conventional double and single layer socks are generally formed by knitting the hem or welt first, followed by the leg, the heel, the foot, and then the toe.
  • the heel of the sock is typically knit using the set of needles (half of the total needles) in the cylinder of the knitting machine as used for knitting the toe.
  • the heel and toe are located on the same side of the sock, and the toe opening of the sock is closed with a seam.
  • socks having a conventional toe seam may rub the tops of the wearer's toes, creating friction on the top of the wearer's foot. In this regard, this friction may cause chafing, blisters, and other discomfort to the wearer.
  • embodiments of the invention provide improved double layer socks, methods for knitting double layer socks, socks having toe seams under the toes, and methods for knitting socks having seams under the toes.
  • FIG. 1 a double layer sock 10 is illustrated according to an example embodiment of the invention.
  • Portions of the sock 10 are knit of a double layer construction. Such portions are characterized by two layers being connected together at spaced apart locations during the knitting thereof.
  • the sock 10 has a foot portion 12 extending from a toe portion 14 to a heel portion 16, and a leg portion 18 extending from the heel portion 16 of the foot portion 12 to a top opening (e.g., a cuff 22) at its upper end.
  • the foot portion 12 also defines a foot bottom portion 13 and an upper instep portion 15.
  • the sock 10 includes an inner layer 24 and a tubular outer layer 26.
  • the tubular outer layer 26 may include the foot portion 12 and the leg portion 18 merging substantially at the ankle of a wearer when the sock is worn.
  • the inner layer 24 is not formed as a tubular inner layer that generally corresponds with the size and/or shape of the tubular outer layer, the inner layer 24 according to the embodiment of the invention has a plurality of edges defining a perimeter of the inner layer 24.
  • the inner layer 24 may be substantially aligned with the foot bottom portion 13 of the tubular outer layer 26, such that the edges 25 of the inner layer 24 generally correspond with the boundary defining the foot bottom portion B, as shown in FIG. 2.
  • a region of the double layer sock 10 corresponding to the upper instep portion 15 of the tubular outer layer 26 may be single-layered, and a region of the double layer sock 10 corresponding to the foot bottom portion 13 of the tubular outer layer 26 may be double-layered.
  • the inner layer 24 may also be substantially aligned with at least part of the leg portion 18 of the tubular outer layer 26 proximate the heel portion 16.
  • a second inner layer may be knit having different edges (e.g., edges that do not coincide with the edges 25 of the depicted inner layer 24 of FIG.
  • this second inner layer may be disposed such that it underlies at least part of the leg portion 18 of the tubular outer layer 26 proximately the heel portion 16.
  • multiple distinct (e.g., spaced apart) region of the sock 10 may be double-layered, while multiple other distinct (e.g., spaced apart) regions of the sock 10 may be single-layered.
  • the heel portion 16, the toe portion 14, and/or the cuff 22 are single-layered.
  • the inner layer 24 may be integrally connected to the tubular outer layer 26, or vice versa, around the perimeter of the inner layer 24 and at spaced apart locations during the knitting thereof.
  • the yarn extending between the inner layer 24 and the tubular outer layer 26 may be knit into both layers.
  • the yarn extending between the inner layer 24 and the tubular outer layer 26 may be knit predominately in one layer and may be knit for connection purposes into the other layer.
  • the yarn extending between the inner layer 24 and the tubular outer layer 26 may be knit predominately in the inner layer 24 (e.g., may be one of the yarns forming the inner layer) and may be knit for connection purposes only into the tubular outer layer 26.
  • this connection may be provided by tuck stitch loops 30 (as shown in FIG. 3), which are formed in selected courses and wales of the inner layer 24 and tubular outer layer 26.
  • the sock 10 may be knit on a conventional circular knitting machine having a cylinder and dial capable of knitting socks.
  • a conventional circular knitting machine having a cylinder and dial capable of knitting socks.
  • Two examples of such machines 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® 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 tubular outer layer 26 of the sock 10 may be knit on the cylinder needles while the inner layer 24 may be concurrently knit on the dial needles.
  • adjustments in the weight of the foot bottom of the sock 10 may be made separately from adjustments in the weight of the sock body by disposing the inner layer in certain locations.
  • the resulting sock 10 may have a heavier weight foot bottom and a lighter weight instep.
  • the main yarn feed of the knitting machine (not shown) may feed a first yarn to the cylinder needles to form stitch loops 26a arranged in courses and wales w 2 -w 9 .
  • the tubular outer layer 26 may be knit in any desired stitch pattern.
  • the secondary yarn feed of the knitting machine (not shown) may feed a second yarn to the dial needles to form stitch loops 24a arranged in courses and wales W1-W4.
  • the dial needles may be used to form stitch loops 24a in the inner layer 24 as compared to the cylinder needles forming stitch loops 26a in the tubular outer layer 26.
  • the feeders may need to be removed and re-engaged for each course of the sock 10.
  • the needle selection for the secondary yarn feed may only incorporate high butt needles by keeping the secondary feed dial knit cam at half height, while the short needles knit only at the main yarn feed.
  • the inner layer 24 is limited to covering only a portion of the sock 10, the yarn may be cut off at the end of each course of the inner layer 24. As a result, additional needles at tuck height may come into action before and after the inner layer 24 is knit to secure the tail of the yarn to the tubular outer layer 26 to prevent raveling.
  • the heel portion 16 and the toe portion 14 may be made via reciprocated knitting.
  • Reciprocated knitting may refer to the process of selecting opposite needles to remain in the active race and removing the remaining needles to the inactive race during knitting.
  • the swing of the cylinder changes to match the active needles, such that the reciprocated portions (e.g., the heel portion 16 and the toe portion 14) are knit back- and- forth rather than in the conventional circular manner.
  • the inner layer 24 and tubular outer layer 26 may be connected together by tuck stitches 30.
  • 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 so that the yarn is captured by the cylinder needles and knit into the tubular outer layer 26 along with a stitch loop of the yarn from the main yarn feed to connect the two layers 24, 26 together.
  • the spacing between the locations of the connecting stitch loops 30 and the type of connections may vary, as will be understood by one of ordinary skill in the art in light of this disclosure.
  • the toe may be closed, such as by a LIN-TOE® device or seaming machine.
  • FIG. 4 a schematic block diagram is shown illustrating a method 40 of knitting a double layer sock according to an example embodiment of the invention.
  • the method 40 may include knitting at least one yarn into courses and wales to form a tubular outer layer of the sock, the tubular outer layer having a foot portion and a leg portion merging substantially at the ankle of a wearer, wherein the foot portion defines a foot bottom portion and an upper instep portion at block 41.
  • the method may further include knitting at least one other yarn into courses and wales to form an inner layer of the sock, wherein the inner layer is knit concurrently with at least a portion of the tubular outer layer, and the inner layer comprises a plurality of edges, wherein the edges define a perimeter of the inner layer at block 42.
  • the method may further include connecting the inner layer and the tubular outer layer together around the perimeter of the inner layer and at spaced apart wales and courses by causing one of the yarns to extend between the inner layer and the tubular outer layer concurrently with the knitting of the tubular outer layer and the inner layer at block 43.
  • each layer 24, 26 may be different.
  • double layer socks may be knit using various types of yarn in various weights. The selection of natural or synthetic yarn, textures, and patterns may depend on the anticipated use to which the socks may be put.
  • the foot bottom portion 13 of the foot portion 12 may be reinforced or made thicker by selecting a higher weight yarn for the inner layer 24 and/or the corresponding portion of the tubular outer layer 26.
  • the foot portion 12, such as the heel portion 16 or the toe portion 14 of the foot portion 12 may be formed using terry loops knit therein.
  • both layers 24, 26 may be the same.
  • Further embodiments of the present invention may include a sock having a toe seam positioned under the toes of a wearer.
  • the sock 50 has a foot portion 52 extending from a toe portion 54 to a heel portion 56, and a leg portion 58 extending from the heel portion 56 of the foot portion 52 to a top opening (e.g., the cuff 59) at its upper end.
  • the foot portion 52 and the leg portion 58 may merge substantially at the ankle of a wearer.
  • the foot portion 52 may also define a foot bottom portion 53 and an upper instep portion 55.
  • the sock 50 may include a toe seam 57 positioned within the toe portion 54 proximate the foot bottom portion 53 such that, when the sock 10 is donned by a wearer, the toe seam 57 is disposed under the toes of the wearer.
  • the sock 50 may be knit using various types of yarn in various weights. The selection of natural or synthetic yarn, textures, and patterns may depend on the anticipated use to which the socks may be put.
  • the foot bottom portion 53 of the foot portion 52 may be reinforced or made thicker by selecting a higher weight yarn of the inner layer 24 and/or the corresponding portion of the tubular outer layer 26.
  • the foot portion 52 such as the heel portion 56 or the toe portion 54 of the foot portion 52, may be formed using terry loops knit therein.
  • at least a portion (e.g., the foot bottom portion 53, part of the leg portion 58, and/or the like) of the sock 50 may be double-layered.
  • the sock 50 may be formed by knitting the heel portion 56 using the opposite half of the needles than that conventionally used so that the heel portion 56 may be knit on the opposite side of the tubular body 52.
  • the cylinder of the circular knitting machine may be reciprocated 180 degrees out of synchronization with normal operation, and the opposite needles may then be selected into the inactive race to allow for reciprocation of the opposite needles in the knitting process.
  • the heel is formed on the same side of the sock as the toe, such that the toe seam is positioned along the bottom of the wearer' s toes when the sock is worn.
  • FIG. 6 a schematic block diagram is shown illustrating a method 60 of knitting a sock according to an example embodiment of the invention.
  • the method 60 may include knitting at least one yarn into courses and wales to form a leg portion at operation 61, reciprocating at least one yarn into courses and wales to form a heel portion at a first end of the foot portion at block 62, and knitting at least one yarn into courses and wales to form a foot bottom portion and an upper instep portion adjacent to the heel portion at block 63.
  • At least one yarn may be reciprocated into courses and wales on the opposite side of the sock with respect to the heel portion to form a toe portion adjacent the foot bottom portion at a second end of the foot portion at block 64, and the toe portion may be closed with a toe seam positioned within the toe portion proximate the foot bottom portion as shown in FIG. 5, such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer at block 65.
  • the toe portion may be closed by a LINT-TOE® device or seaming machine, as previously discussed.
  • the toe seam 57 is not moved to the bottom of the sock 50 during knitting according to embodiments of the invention.
  • the heel portion 56 of the sock 50 is knit such that it is positioned on the opposite side of the sock 50 as compared to a conventional sock.
  • the toe portion 54 is upside-down, which causes the toe seam 57 to be positioned on the bottom of the sock 50, under the toes of the wearer.

Abstract

A double layer sock and a sock having a seam under the toes of a wearer are described. The sock includes a tubular outer layer and an inner layer. The tubular outer layer includes a foot portion and a leg portion. The foot portion defines a foot bottom portion and an upper instep portion. The inner layer includes a number of edges that define a perimeter and is substantially aligned with the foot bottom portion of the tubular outer layer. One of the yarns extends between the inner layer and the tubular outer layer to connect the inner layer and the tubular outer layer around the perimeter of the inner layer and at spaced apart wales and courses. A region of the double layer sock corresponding to the upper instep portion is single-layered while a region of the double layer sock corresponding to the foot bottom portion is double-layered.

Description

SOCK WITH DOUBLE-LAYER FOOT PORTION AND BOTTOM TOE SEAM
FIELD OF THE INVENTION
[0001] The present disclosure relates generally to socks having double layer portions and/or a seam under the toes of a wearer, and more particularly to socks having two layers in select portions of the sock and/or a seam positioned under the toes of a wearer and methods for making the same.
BACKGROUND
[0002] Double layer socks provide additional cushioning of the foot when the wearer is engaged in activities such as running, hiking and the like. Such socks also may be made to be particularly effective at absorbing perspiration. Double layer socks allow for movement between the layers, thereby reducing the movement between the inner layer and the wearer's foot, resulting in a more comfortable fit. Single, as well as double, layer socks are generally knit as a sock blank with a cuff or welt surrounding an opening at the leg portion and an opening at the toe portion. The toe opening of a machine knit sock is then closed. Existing double layer socks typically have two separate layers that are stitched together at the toe and leg opening.
[0003] Moreover, conventional socks are formed by knitting the hem or welt first, followed by the leg, heel, foot, and then toe. After the toe is knit, a seam is formed to attach the opposite sides of the toe pocket to each other, closing the toe. The heel and toe of the sock are typically knit by using the same half of the total needles in the cylinder in the knitting machine. As such, the heel and toe are conventionally formed on the same side of the sock, and the sock is closed with a seam. When a wearer dons the sock such that the heel is in the proper position on the wearer's foot, the toe seam is on the top of the foot, running across the top of the toes of the wearer.
[0004] The inventor has identified a number of deficiencies and problems associated with the conventional socks and associated methods described above. Through applied effort, ingenuity, and innovation, many of these identified problems have been solved by developing solutions that are included in embodiments of the present invention, many examples of which are described in detail herein. BRIEF SUMMARY
[0005] Embodiments of the invention described herein provide improved socks and methods for making the same. In particular, the inventor has identified that having two separate layers that are attached at the ends of the socks can lead to too much movement of the layers with respect to each other, causing discomfort for the wearer, and that having a toe seam positioned over the top of a wearer's toes may cause the seam to rub the tops of the toes, again causing discomfort for the wearer. Accordingly, socks formed in accordance with the embodiments described herein include double layers in select portions of the sock and/or a seam positioned under the toes to improve wearer comfort.
[0006] Accordingly, embodiments of the invention provide a double layer sock formed on a circular knitting machine from at least two yarns. The double layer sock comprises a tubular outer layer and an inner layer. The tubular outer layer is knit of at least one yarn and has wales and courses. The tubular outer layer also includes a foot portion and a leg portion merging substantially at the ankle of a wearer, and the foot portion defines a foot bottom portion and an upper instep portion. The inner layer is knit of at least one other yarn and has wales and courses. The inner layer also comprises a plurality of edges that define a perimeter of the inner layer. The inner layer is substantially aligned with the foot bottom portion of the tubular outer layer, and one of the yarns extends between the inner layer and the tubular outer layer to connect the inner layer and the tubular outer layer around the perimeter of the inner layer and at spaced apart wales and courses. As a result, a region of the double layer sock corresponding to the upper instep portion of the tubular outer layer is single-layered, and a region of the double layer sock corresponding to the foot bottom portion of the tubular outer layer is double- layered.
[0007] According to certain embodiments, the yarn extending between the inner layer and the tubular outer layer may be knit into both layers. In particular, in some
embodiments, the yarn extending between the inner layer and the tubular outer layer may be knit predominately in one layer and may be knit for connection purposes only in the other layer. In further embodiments, the yarn extending between the inner layer and the tubular outer layer may be knit predominately in the inner layer and may be knit for connection purposes only in the tubular outer layer as tuck stitch loops.
[0008] According to certain embodiments, the foot portion of the tubular outer layer may further comprise a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and at least one of the heel portion or the toe portion may be made via reciprocated knitting. In some embodiments, at least one of the heel portion or the toe portion may comprise terry loops. In further embodiments, a portion of the inner layer may be substantially aligned with part of the leg portion of the tubular outer layer proximate the heel portion.
[0009] In another aspect, a method of knitting a double layer sock on a circular knitting machine is provided. The method includes knitting at least one yarn into courses and wales to form a tubular outer layer of the sock, the tubular outer layer having a foot portion and a leg portion merging substantially at the ankle of a wearer, and the foot portion defines a foot bottom portion and an upper instep portion. The method further includes knitting at least one other yarn into courses and wales to form an inner layer of the sock such that the inner layer is knit concurrently with at least a portion of the tubular outer layer, and the inner layer comprises a plurality of edges that define a perimeter of the inner layer. The method further includes connecting the inner layer and the tubular outer layer together around the perimeter of the inner layer and at spaced apart wales and courses by causing one of the yarns to extend between the inner layer and the tubular outer layer concurrently with the knitting of the tubular outer layer and the inner layer. The inner layer is substantially aligned with the foot bottom portion of the tubular outer layer. As a result, a region of the double layer sock corresponding to the upper instep portion of the tubular outer layer is single-layered, and a region of the double layer sock
corresponding to the foot bottom portion of the tubular outer layer is double-layered.
[0010] According to certain embodiments, the yarn extending between the inner layer and the tubular outer layer may be knit into both layers. In particular, in some
embodiments, the yarn extending between the inner layer and the tubular outer layer may be knit predominately in one layer and may be knit for connection purposes only in the other layer. In further embodiments, the yarn extending between the inner layer and the tubular outer layer may be knit predominately in the inner layer and may be knit for connection purposes only in the tubular outer layer as tuck stitch loops.
[0011] According to certain embodiments, the inner layer may be knit on dial needles of the circular knitting machine, and the tubular outer layer may be knit on cylinder needles of the circular knitting machine.
[0012] According to certain embodiments, the foot portion of the tubular outer layer may further comprise a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and at least one of the heel portion or the toe portion may be made via reciprocated knitting. In some embodiments, at least one of the heel portion or the toe portion may comprise terry loops. In further embodiments, a portion of the inner layer may be substantially aligned with part of the leg portion of the tubular outer layer proximate the heel portion.
[0013] In yet another aspect, a sock formed on a circular knitting machine from at least one yarn is provided. The sock includes a tubular body and a toe seam. The tubular body includes a foot portion and a leg portion merging substantially at the ankle of a wearer such that the foot portion defines a foot bottom portion and an upper instep portion and further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion. The toe seam is positioned within the toe portion proximate the foot bottom portion such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer.
[0014] According to certain embodiments, at least one of the toe portion or the heel portion may be made via reciprocated knitting. In some embodiments, at least one of the heel portion or the toe portion may comprise terry loops. In further embodiments, at least a portion of the sock may be double-layered.
[0015] In yet another aspect, a method of knitting a sock comprising a tubular body having a foot portion and a leg portion on a circular knitting machine such that the foot portion defines a foot bottom portion and an upper instep portion is provided. The method includes knitting at least one yarn into courses and wales to form the leg portion, reciprocating at least one yarn into courses and wales to form a heel portion at a first end of the foot portion, knitting at least one yarn into courses and wales to form the foot bottom portion and the upper instep portion adjacent to the heel portion, reciprocating at least one yarn into courses and wales on the opposite side of the sock as the heel portion to form a toe portion adjacent the foot bottom portion at a second end of the foot portion, and closing the toe portion with a toe seam positioned within the toe portion proximate the foot bottom portion, such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0016] 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: [0017] FIG. 1 is a perspective view of a double layer sock according to an example embodiment of the invention;
[0018] FIG. 2 is a perspective view of a double layer sock according to an example embodiment of the invention as it appears having a portion cut away;
[0019] FIG. 3 is an enlarged fragmentary perspective view of the knit structure of a double layer sock according to an example embodiment of the invention;
[0020] FIG. 4 is a schematic block diagram illustrating a method of knitting a double layer sock according to an example embodiment of the invention;
[0021] FIG. 5 is a perspective view of a sock having a seam under the toes according to an example embodiment of the invention; and
[0022] FIG. 6 is a schematic block diagram illustrating a method of knitting a sock according to an example embodiment of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0023] 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.
[0024] Conventional double layer socks provide additional cushioning of the foot as compared to single layer socks when the wearer is engaged in activities such as running, hiking and the like. Such socks also may be made to be particularly effective at absorbing perspiration. Double layer socks provide for movement between the layers, thereby reducing the movement between the inner layer and the wearer's foot, resulting in a more comfortable fit. Single, as well as double, layer socks are generally knit as a sock blank with a cuff or welt surrounding an opening at the leg portion and an opening at the toe portion. The toe opening of a machine knit sock is then closed.
[0025] While conventional double layer socks provide improved comfort over single layer socks, conventional double layer socks typically have two separate and distinct layers that are stitched to each other at the corresponding toe and leg openings. Because the layers are separately formed and are only attached at the toe and leg opening, conventional double layer socks are prone to exhibiting movement of one layer with respect to the other. This movement may cause chafing, blisters, and other painful conditions for the wearer. In addition, while having double layers throughout most of the sock may improve perspiration absorption, having two layers covering most or all of the foot may cause the foot to overheat and/or may limit the airflow around the foot, causing further discomfort to the wearer.
[0026] Moreover, both conventional double and single layer socks are generally formed by knitting the hem or welt first, followed by the leg, the heel, the foot, and then the toe. The heel of the sock is typically knit using the set of needles (half of the total needles) in the cylinder of the knitting machine as used for knitting the toe. As a result, the heel and toe are located on the same side of the sock, and the toe opening of the sock is closed with a seam. When a wearer dons the sock such that the heel is in the proper position on the wearer's foot, the toe seam is disposed on the top of the foot, running across the top of the toes of the wearer. [0027] As such, socks having a conventional toe seam may rub the tops of the wearer's toes, creating friction on the top of the wearer's foot. In this regard, this friction may cause chafing, blisters, and other discomfort to the wearer.
[0028] Through applied effort, ingenuity, and innovation, many of these identified problems have been solved by the inventor. Accordingly, embodiments of the invention provide improved double layer socks, methods for knitting double layer socks, socks having toe seams under the toes, and methods for knitting socks having seams under the toes.
[0029] Turning now to FIG. 1, a double layer sock 10 is illustrated according to an example embodiment of the invention. Portions of the sock 10 are knit of a double layer construction. Such portions are characterized by two layers being connected together at spaced apart locations during the knitting thereof. Turning to the sock in more detail, the sock 10 has a foot portion 12 extending from a toe portion 14 to a heel portion 16, and a leg portion 18 extending from the heel portion 16 of the foot portion 12 to a top opening (e.g., a cuff 22) at its upper end. The foot portion 12 also defines a foot bottom portion 13 and an upper instep portion 15.
[0030] As shown in FIG. 2, the sock 10 includes an inner layer 24 and a tubular outer layer 26. The tubular outer layer 26 may include the foot portion 12 and the leg portion 18 merging substantially at the ankle of a wearer when the sock is worn. Because the inner layer 24 is not formed as a tubular inner layer that generally corresponds with the size and/or shape of the tubular outer layer, the inner layer 24 according to the embodiment of the invention has a plurality of edges defining a perimeter of the inner layer 24. In some embodiments, for example, the inner layer 24 may be substantially aligned with the foot bottom portion 13 of the tubular outer layer 26, such that the edges 25 of the inner layer 24 generally correspond with the boundary defining the foot bottom portion B, as shown in FIG. 2. In this regard, a region of the double layer sock 10 corresponding to the upper instep portion 15 of the tubular outer layer 26 may be single-layered, and a region of the double layer sock 10 corresponding to the foot bottom portion 13 of the tubular outer layer 26 may be double-layered. In further embodiments, for instance, the inner layer 24 may also be substantially aligned with at least part of the leg portion 18 of the tubular outer layer 26 proximate the heel portion 16. For example, a second inner layer may be knit having different edges (e.g., edges that do not coincide with the edges 25 of the depicted inner layer 24 of FIG. 2), and this second inner layer may be disposed such that it underlies at least part of the leg portion 18 of the tubular outer layer 26 proximately the heel portion 16. As such, in some cases, multiple distinct (e.g., spaced apart) region of the sock 10 may be double-layered, while multiple other distinct (e.g., spaced apart) regions of the sock 10 may be single-layered. In certain embodiments, the heel portion 16, the toe portion 14, and/or the cuff 22 (if included) are single-layered.
[0031] In the double-layered portions of the sock 10, the inner layer 24 may be integrally connected to the tubular outer layer 26, or vice versa, around the perimeter of the inner layer 24 and at spaced apart locations during the knitting thereof. In certain embodiments, for example, the yarn extending between the inner layer 24 and the tubular outer layer 26 may be knit into both layers. In some embodiments, for instance, the yarn extending between the inner layer 24 and the tubular outer layer 26 may be knit predominately in one layer and may be knit for connection purposes into the other layer. In further embodiments, for example, the yarn extending between the inner layer 24 and the tubular outer layer 26 may be knit predominately in the inner layer 24 (e.g., may be one of the yarns forming the inner layer) and may be knit for connection purposes only into the tubular outer layer 26. In some embodiments, this connection may be provided by tuck stitch loops 30 (as shown in FIG. 3), which are formed in selected courses and wales of the inner layer 24 and tubular outer layer 26.
[0032] In accordance with certain embodiments, the sock 10 may be knit on a conventional circular knitting machine having a cylinder and dial capable of knitting socks. Two examples of such machines 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® 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.
[0033] According to certain embodiments, the tubular outer layer 26 of the sock 10 may be knit on the cylinder needles while the inner layer 24 may be concurrently knit on the dial needles. In this regard, adjustments in the weight of the foot bottom of the sock 10 may be made separately from adjustments in the weight of the sock body by disposing the inner layer in certain locations. As such, the resulting sock 10 may have a heavier weight foot bottom and a lighter weight instep. As shown in FIG. 3, the main yarn feed of the knitting machine (not shown) may feed a first yarn to the cylinder needles to form stitch loops 26a arranged in courses and wales w2 -w9. For illustration only, the stitch pattern shown in FIG. 3 is a plain or jersey stitch pattern, but one of ordinary skill in the art in light of the disclosure would understand that the tubular outer layer 26 may be knit in any desired stitch pattern. The secondary yarn feed of the knitting machine (not shown) may feed a second yarn to the dial needles to form stitch loops 24a arranged in courses and wales W1-W4. As shown in FIG. 3, the dial needles may be used to form stitch loops 24a in the inner layer 24 as compared to the cylinder needles forming stitch loops 26a in the tubular outer layer 26. In this regard, because the inner layer 24 is knit over only half of each course, the feeders may need to be removed and re-engaged for each course of the sock 10. Similarly, the needle selection for the secondary yarn feed may only incorporate high butt needles by keeping the secondary feed dial knit cam at half height, while the short needles knit only at the main yarn feed. Moreover, because the inner layer 24 is limited to covering only a portion of the sock 10, the yarn may be cut off at the end of each course of the inner layer 24. As a result, additional needles at tuck height may come into action before and after the inner layer 24 is knit to secure the tail of the yarn to the tubular outer layer 26 to prevent raveling.
[0034] In some embodiments, the heel portion 16 and the toe portion 14 may be made via reciprocated knitting. Reciprocated knitting, according to certain embodiments, may refer to the process of selecting opposite needles to remain in the active race and removing the remaining needles to the inactive race during knitting. In general, because the opposite needles are reciprocating, the swing of the cylinder changes to match the active needles, such that the reciprocated portions (e.g., the heel portion 16 and the toe portion 14) are knit back- and- forth rather than in the conventional circular manner.
[0035] At spaced locations, such as in alternate courses of the tubular outer layer 26 and the inner layer 24, e.g., in every fourth wale w4 and w8 of the tubular outer layer 26, the inner layer 24 and tubular outer layer 26 may be connected together by tuck stitches 30. To form the tuck stitches, 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 so that the yarn is captured by the cylinder needles and knit into the tubular outer layer 26 along with a stitch loop of the yarn from the main yarn feed to connect the two layers 24, 26 together. The spacing between the locations of the connecting stitch loops 30 and the type of connections may vary, as will be understood by one of ordinary skill in the art in light of this disclosure. After the sock blank has been knit, the toe may be closed, such as by a LIN-TOE® device or seaming machine.
[0036] In FIG. 4, for example, a schematic block diagram is shown illustrating a method 40 of knitting a double layer sock according to an example embodiment of the invention. As shown in FIG. 4, the method 40 may include knitting at least one yarn into courses and wales to form a tubular outer layer of the sock, the tubular outer layer having a foot portion and a leg portion merging substantially at the ankle of a wearer, wherein the foot portion defines a foot bottom portion and an upper instep portion at block 41. The method may further include knitting at least one other yarn into courses and wales to form an inner layer of the sock, wherein the inner layer is knit concurrently with at least a portion of the tubular outer layer, and the inner layer comprises a plurality of edges, wherein the edges define a perimeter of the inner layer at block 42. The method may further include connecting the inner layer and the tubular outer layer together around the perimeter of the inner layer and at spaced apart wales and courses by causing one of the yarns to extend between the inner layer and the tubular outer layer concurrently with the knitting of the tubular outer layer and the inner layer at block 43.
[0037] In some embodiments, each layer 24, 26 may be different. As will be understood by one of ordinary skill in the art in light of this disclosure, double layer socks may be knit using various types of yarn in various weights. The selection of natural or synthetic yarn, textures, and patterns may depend on the anticipated use to which the socks may be put. For example, the foot bottom portion 13 of the foot portion 12 may be reinforced or made thicker by selecting a higher weight yarn for the inner layer 24 and/or the corresponding portion of the tubular outer layer 26. As another example, the foot portion 12, such as the heel portion 16 or the toe portion 14 of the foot portion 12, may be formed using terry loops knit therein. However, in other embodiments, both layers 24, 26 may be the same.
[0038] Further embodiments of the present invention may include a sock having a toe seam positioned under the toes of a wearer.
[0039] Turning now to FIG. 5, for example, a sock 50 having a seam 57 under the toes is illustrated according to an example embodiment of the invention. As shown in FIG. 5, the sock 50 has a foot portion 52 extending from a toe portion 54 to a heel portion 56, and a leg portion 58 extending from the heel portion 56 of the foot portion 52 to a top opening (e.g., the cuff 59) at its upper end. The foot portion 52 and the leg portion 58 may merge substantially at the ankle of a wearer. The foot portion 52 may also define a foot bottom portion 53 and an upper instep portion 55. In addition, the sock 50 may include a toe seam 57 positioned within the toe portion 54 proximate the foot bottom portion 53 such that, when the sock 10 is donned by a wearer, the toe seam 57 is disposed under the toes of the wearer. [0040] According to certain embodiments, the sock 50 may be knit using various types of yarn in various weights. The selection of natural or synthetic yarn, textures, and patterns may depend on the anticipated use to which the socks may be put. For example, the foot bottom portion 53 of the foot portion 52 may be reinforced or made thicker by selecting a higher weight yarn of the inner layer 24 and/or the corresponding portion of the tubular outer layer 26. As another example, the foot portion 52, such as the heel portion 56 or the toe portion 54 of the foot portion 52, may be formed using terry loops knit therein. In further embodiments, at least a portion (e.g., the foot bottom portion 53, part of the leg portion 58, and/or the like) of the sock 50 may be double-layered.
[0041] The sock 50 may be formed by knitting the heel portion 56 using the opposite half of the needles than that conventionally used so that the heel portion 56 may be knit on the opposite side of the tubular body 52. In particular, the cylinder of the circular knitting machine may be reciprocated 180 degrees out of synchronization with normal operation, and the opposite needles may then be selected into the inactive race to allow for reciprocation of the opposite needles in the knitting process. As a result, the heel is formed on the same side of the sock as the toe, such that the toe seam is positioned along the bottom of the wearer' s toes when the sock is worn.
[0042] In FIG. 6, for example, a schematic block diagram is shown illustrating a method 60 of knitting a sock according to an example embodiment of the invention. As shown in FIG. 6, the method 60 may include knitting at least one yarn into courses and wales to form a leg portion at operation 61, reciprocating at least one yarn into courses and wales to form a heel portion at a first end of the foot portion at block 62, and knitting at least one yarn into courses and wales to form a foot bottom portion and an upper instep portion adjacent to the heel portion at block 63. At least one yarn may be reciprocated into courses and wales on the opposite side of the sock with respect to the heel portion to form a toe portion adjacent the foot bottom portion at a second end of the foot portion at block 64, and the toe portion may be closed with a toe seam positioned within the toe portion proximate the foot bottom portion as shown in FIG. 5, such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer at block 65. The toe portion may be closed by a LINT-TOE® device or seaming machine, as previously discussed. The toe seam 57, however, is not moved to the bottom of the sock 50 during knitting according to embodiments of the invention. Instead, the heel portion 56 of the sock 50 is knit such that it is positioned on the opposite side of the sock 50 as compared to a conventional sock. In this regard, when the heel portion 56 is placed correctly on the foot of a wearer, the toe portion 54 is upside-down, which causes the toe seam 57 to be positioned on the bottom of the sock 50, under the toes of the wearer.
[0043] 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. 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

THAT WHICH IS CLAIMED:
1. A double layer sock formed on a circular knitting machine from at least two
yarns, the double layer sock comprising:
a tubular outer layer knit of at least one yarn and having wales and courses, the tubular outer layer having a foot portion and a leg portion merging substantially at the ankle of a wearer, wherein the foot portion defines a foot bottom portion and an upper instep portion; and
an inner layer knit of at least one other yarn and having wales and courses, wherein the inner layer comprises a plurality of edges, wherein the edges define a perimeter of the inner layer,
wherein the inner layer is substantially aligned with the foot bottom portion of the tubular outer layer,
wherein one of the yarns extends between the inner layer and the tubular outer layer to connect the inner layer and the tubular outer layer around the perimeter of the inner layer and at spaced apart wales and courses,
wherein a region of the double layer sock corresponding to the upper instep portion of the tubular outer layer is single-layered, and a region of the double layer sock corresponding to the foot bottom portion of the tubular outer layer is double- layered.
2. The double layer sock according to claim 1, wherein the yarn extending between the inner layer and the tubular outer layer is knit into both layers.
3. The double layer sock according to claim 2, wherein the yarn extending between the inner layer and the tubular outer layer is knit predominately in one layer and is knit for connection purposes only in the other layer.
4. The double layer sock according to claim 3, wherein the yarn extending between the inner layer and the tubular outer layer is knit predominately in the inner layer and is knit for connection purposes only in the tubular outer layer as tuck stitch loops.
The double layer sock according to claim 1, wherein the foot portion of the tubular outer layer further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and at least one of the heel portion or the toe portion is made via reciprocated knitting.
The double layer sock according to claim 5, wherein at least one of the heel portion or the toe portion comprises terry loops.
The double layer sock according to claim 1, wherein the foot portion of the tubular outer layer further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and a portion of the inner layer is substantially aligned with part of the leg portion of the tubular outer layer proximate the heel portion.
A method of knitting a double layer sock on a circular knitting machine, the method comprising:
knitting at least one yarn into courses and wales to form a tubular outer layer of the sock, the tubular outer layer having a foot portion and a leg portion merging substantially at the ankle of a wearer, wherein the foot portion defines a foot bottom portion and an upper instep portion;
knitting at least one other yarn into courses and wales to form an inner layer of the sock, wherein the inner layer is knit concurrently with at least a portion of the tubular outer layer, and the inner layer comprises a plurality of edges, wherein the edges define a perimeter of the inner layer; and
connecting the inner layer and the tubular outer layer together around the perimeter of the inner layer and at spaced apart wales and courses by causing one of the yarns to extend between the inner layer and the tubular outer layer concurrently with the knitting of the tubular outer layer and the inner layer,
wherein the inner layer is substantially aligned with the foot bottom portion of the tubular outer layer, and
wherein a region of the double layer sock corresponding to the upper instep portion of the tubular outer layer is single-layered, and a region of the double layer sock corresponding to the foot bottom portion of the tubular outer layer is double- layered.
9. The method according to claim 8, wherein the yarn extending between the inner layer and the tubular outer layer is knit into both layers.
10. The method according to claim 9, wherein the yarn extending between the inner layer and the tubular outer layer is knit predominately in one layer and is knit for connection purposes only in the other layer.
11. The method according to claim 10, wherein the yarn extending between the inner layer and the tubular outer layer is knit predominately in the inner layer and knit for connection purposes only in the tubular outer layer as tuck stitch loops.
12. The method according to claim 8, wherein the inner layer is knit on dial needles of the circular knitting machine, and the tubular outer layer is knit on cylinder needles of the circular knitting machine.
13. The method according to claim 8, wherein the foot portion of the tubular outer layer further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and at least one of the heel portion or the toe portion is made via reciprocated knitting.
14. The method according to claim 13, wherein at least one of the heel portion or the toe portion comprises terry loops.
15. The method according to claim 8, wherein the foot portion of the tubular outer layer further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and a portion of the inner layer is substantially aligned with part of the leg portion of the tubular outer layer proximate the heel portion.
16. A sock formed on a circular knitting machine from at least one yarn, the sock comprising:
a tubular body having a foot portion and a leg portion merging substantially at the ankle of a wearer, wherein the foot portion defines a foot bottom portion and an upper instep portion and further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion; and a toe seam positioned within the toe portion proximate the foot bottom portion, such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer.
17. The sock according to claim 16, wherein at least one of the toe portion or the heel portion is made via reciprocated knitting.
18. The sock according to claim 16, wherein at least one of the heel portion or the toe portion comprises terry loops.
19. The sock according to claim 16, wherein at least a portion of the sock is double- layered.
20. A method of knitting a sock comprising a tubular body having a foot portion and a leg portion on a circular knitting machine, the foot portion defining a foot bottom portion and an upper instep portion, the method comprising:
knitting at least one yarn into courses and wales to form the leg portion; reciprocating at least one yarn into courses and wales to form a heel portion at a first end of the foot portion;
knitting at least one yarn into courses and wales to form the foot bottom portion and the upper instep portion adjacent to the heel portion;
reciprocating at least one yarn into courses and wales on the opposite side of the sock as the heel portion to form a toe portion adjacent the foot bottom portion at a second end of the foot portion; and closing the toe portion with a toe seam positioned within the toe portion proximate the foot bottom portion, such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer.
PCT/IB2018/053702 2017-05-31 2018-05-24 Sock with double-layer foot portion and bottom toe seam WO2018220485A1 (en)

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US11583009B2 (en) 2018-12-28 2023-02-21 Nike, Inc. Sock with lateral toe seam
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