Sock

Abstract

A knitted sock has an inner layer 2 comprising a toe end 4 and an outer layer 3 comprising a toe end 7. The inner and outer toe ends are aligned and joined wale stitch to wale stitch to form a composite toe end, which is closed to provide a flat toe seam 10. The layered sock is manufactured complete in a single process being knit continuously from the inner toe end to the outer toe end. It comprises reciprocated heel and toe portions. The foot portion of the inner layer is knit from a yarn with properties such as a low coefficient of friction and / or antifungal / antibacterial properties. The low friction fiber is a fluoropolymer such as polytetrafluroethylene. The outer layer may comprise a cushion structure.

Description

[0001] The invention relates to socks and in particular to socks having more than one layer or ply.[0002] Socks with more than one layer in theory provide improved properties of durability, performance and comfort for a user. However, there are serious drawbacks with available layered socks. Conventional double layer socks are closed at the toe by sewing the toe of the inner layer closed and then sewing the toe of the outer layer closed with the result that the inner layer and outer layer are not connected. This leads to bunching, twisting and other causes of discomfort to the wearer. Alternatively, the inner and outer toes are closed together by manually aligning the knitting wales of the two layers to avoid the undesired twisting. However, this increases the amount of manual operator time and results in a bulky seam which can cause wearer discomfort. In particular, such socks are wholly unsuitable for use by people with ailments which place them at high risk of recurring serious f...

AI Technical Summary

Benefits of technology

[0069] In one embodiment the leg portion of the outer layer is of relaxed construction.

[0140] The single process manufacture of the double sock allows the knitting of the inner sock in single, unplated, yarns. This allows maximum flexibility in the yarn composition and structure of the two sock layers while at the same time minimises the overall bulk and weight of the double layer structure a problem with most existing double layer socks manufactured using conventional methods.

[0141] Knitting of a foot portion of an inner sock in a 1.times.1 stitch, unplated construction from a low friction fiber creates a smoothly constructed, low friction fiber interface to both the foot and the inner surface of the outer sock.

[0143] In particular, the invention provides a double layer sock in which the foot portion of the inner layer sock comprises an unplated, low friction fluoropolymer yarn such as the PTFE fiber Teflon (from DuPont). The outer layer sock may be of a cotton, plated with Nylon / lycra construction with the foot area comprised of the heel, toe and sole being made with a sandwich terry fabric. Both the outer sock structure and the material used to make the outer sock can be changed to meet varied performance requirements. For example, cotton could be substituted by wool or a wool variant such as smartwool to make a sock with better thermal properties for winter conditions. Similarly, the structure of the outer sock could be varied, for example by changing the area size and location of terry cushion to provide cushion protection over a greater or lesser area of the foot and / or leg.

Problems solved by technology

However, there are serious drawbacks with available layered socks.

This leads to bunching, twisting and other causes of discomfort to the wearer.

However, this increases the amount of manual operator time and results in a bulky seam which can cause wearer discomfort.

In particular, such socks are wholly unsuitable for use by people with ailments which place them at high risk of recurring serious foot complaints and complications.

This gives an overall weight, bulkiness and constrictiveness which makes such layered socks wholly unsuitable for use by people with ailments which place them at higher risk callus and blister formation, and other types of skin breakdown can lead to of recurring serious foot complaints and complications.

The lower the elasticity of the yarn the greater will be the robbing back dynamic which is virtually impossible to control accurately in a production setting.

Callus formation, blisters and other types of skin breakdown can lead to ulceration, which if not healed, can result in amputation in people afflicted with certain autoimmune diseases and disorders such as diabetes, eczemza, lupus; collagen and skin inflammatory disorders; circulatory problems, geriatric needs, obesity and other ailments or conditions which place them at a higher risk of recurring foot complications caused by even moderate friction and pressure levels, even in properly fitted footwear.

It is a chronic life-long condition which, if not carefully managed, can lead to various serious short and long-term complications.

The progressive effect of nerve disease and vascular disease on the lower extremities leave patients with Type 2 diabetes at risk of developing serious foot complications which can lead to amputation.

However, none of the available socks adequately address the problem.

These conditions place diabetics and others with reduced circulatory ability or skin disorders at risk of serious foot complications.

The combination of perspiration, a warm enclosed environment and the presence of bacteria results in the unpleasant smell commonly referred to as foot odour.

The problem is exacerbated by non-breathable shoe component materials, particularly foot-wear such as trainers or sneakers.

Shoes which are not allowed to dry out between wear can absorb foot odour and will host odour causing bacteria and fungi.

It is a most uncomfortable condition with the most common symptoms being intense itching combined with cracked and peeling skin between the toes but can infect any part of the foot and toe nails.

The infected skin has a white and soggy appearance and can become inflamed and bleeding can occur in severe cases.

Both shoes and hosiery may retain fungal spores, making effective treatment more difficult.

Bacteria may thrive as a secondary infection which worsens the symptoms of the condition and makes it more difficult to cure.

However there is growing consumer concern about the safety of the chemical agents used in the treatment of these products and most treated yarns have the added weakness of reduced effectiveness after repeat washing.

However, none of the available socks optimally apply the yarn in the prevention of foot odour and athletes foot.

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