CN116685732B - Sports sock - Google Patents

Abstract

A knitted sock has a leg portion and an integrally knitted ankle strap extending around a perimeter of the leg portion and positioned at a lower end of the leg portion. The knitted sock also includes an integrally knitted tab located at a rear aspect of the ankle roll.

Description

Sports sock

Technical Field

Aspects herein relate to an athletic sock.

Background

Conventional athletic socks may be used for a variety of athletic activities. However, conventional athletic socks may lack features such as zoned cushioning, zoned grasping, zoned breathability and permeability, and fit features that make them suitable for certain activities such as running (including path long runs/hikes). Running (including path long run/hiking) presents many challenges such as uneven terrain that causes the foot to shift forward and backward within the shoe, for example, medial and lateral sides, debris (e.g., gravel) that may enter the space between the sock and the foot (especially for ankle socks), perspiration and temperature rise caused by exertion, and compact surfaces that may impact the joints and muscles of the wearer's foot.

Disclosure of Invention

The following clauses represent example aspects of the concepts contemplated herein. Any of the following clauses may be combined in a multi-subordinate manner to rely on one or more other clauses. Furthermore, any combination of subordinate clauses (clauses explicitly dependent on previous clauses) may be combined while remaining within the scope of aspects contemplated herein. The following clauses are examples and not limiting.

Clause 1. A knitted sock comprising: a collar having a peripheral edge surrounding an opening for receiving a foot of a wearer; a leg portion extending from the collar; a foot portion extending from the leg portion and terminating at a toe end; an integrally knit ankle roll extending around a perimeter of the knit sock and positioned at a lower end of the leg portion; and a tab located at a rear aspect of the ankle roll, the tab being integrally knit with the ankle roll.

Clause 2. The knitted sock of clause 1, wherein the inwardly facing surface of the flap is positioned adjacent the outwardly facing surface of the leg portion.

Clause 3 the knitted sock of any of clauses 1-2, wherein the ankle roll has an upper edge and a lower edge, the lower edge being integrally knit with the leg portion.

Clause 4. The knitted sock of clause 3, wherein the upper edge of the ankle strap is separated from the leg portion.

Clause 5. The knitted sock of any of clauses 3-4, wherein the flap comprises a flap base, a flap body extending from the flap base, and a top edge spaced from the flap base by the flap body, and wherein the flap base is integrally knit with the upper edge of the ankle roll.

Clause 6. The knitted sock of clause 5, wherein the top edge of the flap is separated from the leg portion.

Clause 7 the knitted sock of any of clauses 1-6, further comprising a heel portion positioned between the leg portion and the foot portion, the heel portion having an achilles section and a plantar section, wherein the achilles section is formed from a knitted structure having an alternating pattern comprising a first number of courses knitted with terry loops and a second number of courses knitted without terry loops.

Clause 8 the knit sock of clause 7, wherein the first number of courses and the second number of courses extend from the outside to the inside of the achilles tendon section.

Clause 9 the knitted sock of any of clauses 1-8, further comprising: a first plurality of integrally knit grip strips located on an outer side of the foot portion; and a second plurality of integrally knit grip strips on the medial side of the foot portion.

Clause 10 the knitted sock of any of clauses 1-9, further comprising: a third plurality of integrally knit grip strips located on a instep side of the toe end of the knit sock; and a fourth plurality of integrally knit grip strips located on a plantar side of the toe end of the knit sock.

Clause 11 the knitted sock of any of clauses 1-10, further comprising a heel portion positioned between the leg portion and the foot portion, the heel portion having an achilles tendon section and a plantar section, wherein the plantar section includes a fifth plurality of integrally knit grip strips extending from a lateral side to a medial side of the plantar section.

Clause 12, a knitted sock comprising: a tubular knitted body forming a leg portion and a foot portion extending from the leg portion and terminating at a toe end; an ankle roll extending around a perimeter of the tubular knitted body and positioned between the leg portion and the foot portion, the ankle roll being integrally knit with the tubular knitted body; and a flap located at a rear aspect of the ankle roll, an inwardly facing surface of the flap being positioned adjacent an outwardly facing surface of the leg portion.

Clause 13. The knitted sock of clause 12, wherein the ankle roll has an upper edge and a lower edge, and wherein the tab is integrally knit with the upper edge of the ankle roll.

Clause 14. The knitted sock of clause 13, wherein the lower edge of the ankle roll is integrally knit with the tubular knitted body, and wherein the upper edge of the ankle roll is separated from the leg portion.

Clause 15 the knitted sock of any of clauses 12-14, wherein the flap comprises a flap base, a flap body extending from the flap base, and a top edge spaced from the flap base by the flap body, wherein: the flap base is integrally knit with the ankle roll and each of the flap body and the top edge of the flap is separated from the leg portion.

Clause 16 the knitted sock of any of clauses 12-15, further comprising a heel portion positioned between the leg portion and the foot portion, the heel portion having an achilles section and a plantar section, wherein the achilles section is formed from a knitted structure having an alternating pattern comprising a first number of courses knitted with terry loops and a second number of courses knitted without terry loops.

Clause 17 the knitted sock of any of clauses 12-16, further comprising one or more integrally knitted grip strips knitted with yarns formed of filaments having diameters from about 25 nanometers to about 350 nanometers.

Clause 18. A method of knitting a sock, comprising: during a single knitting event: a knitted collar having a peripheral edge surrounding an opening for receiving a foot of a wearer; knitting a leg portion, the leg portion extending from the collar; knitting a foot portion extending from the leg portion and terminating at a toe end; knitting an ankle roll such that the ankle roll extends around a perimeter of the sock and is positioned at a lower end of the leg portion; and a knitted tab located at a rear aspect of the ankle roll such that an inwardly facing surface of the tab is positioned adjacent an outwardly facing surface of the leg portion.

Clause 19 the method of knitting a sock of clause 18, further comprising knitting one or more grip strips with yarns formed of filaments having diameters from about 25 nanometers to about 350 nanometers.

Clause 20 the method of knitting a sock of any of clauses 18-19, further comprising knitting a heel portion positioned between the leg portion and the foot portion, the heel portion being knitted with an achilles tendon section and a plantar tendon section, wherein the achilles tendon section comprises a knitted structure having an alternating pattern comprising a first number of courses knitted with terry loops and a second number of courses knitted without terry loops.

Drawings

Examples of aspects herein are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 illustrates a lateral view of an example knitted sock according to aspects herein;

FIG. 2 illustrates a medial side view of the example knitted sock of FIG. 1 in accordance with aspects hereof;

FIG. 3 illustrates a front view of the example knitted sock of FIG. 1 in accordance with aspects hereof;

FIG. 4 illustrates a bottom view of the example knitted sock of FIG. 1 in accordance with aspects hereof;

FIG. 5 illustrates a rear view of the example knitted sock of FIG. 1 in accordance with aspects hereof;

FIG. 6 illustrates a cross-section of an example knitted sock taken at cut line 6-6 of FIG. 1, in accordance with aspects hereof;

FIG. 7 illustrates a cross-section of an example knitted sock taken at cut line 7-7 of FIG. 3, in accordance with aspects hereof;

FIG. 8 illustrates a schematic knitting diagram of a knit structure at a heel portion of the example knit sock of FIG. 1, in accordance with aspects hereof;

FIG. 9 illustrates a schematic knitting diagram of a knit structure at a forefoot portion of the example knit sock of FIG. 1, in accordance with aspects hereof; and

Fig. 10 illustrates a flow chart of an example method of making the example knitted sock of fig. 1, in accordance with aspects herein.

Detailed Description

The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Furthermore, although the terms "step" and/or "block" may be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

Conventional athletic socks may be used for a variety of athletic activities. However, conventional athletic socks may lack features such as zoned cushioning, zoned grasping, zoned breathability and permeability, and fit features that make them suitable for certain activities such as running (including path long runs or hiking). Running (including path long runs or hiking) presents many challenges, such as uneven terrain that causes the foot to shift forward and backward within the shoe, for example, medial and lateral sides, debris (e.g., gravel) that may enter the space between the sock and the foot (especially for ankle socks), perspiration and temperature rise caused by exertion, and compact surfaces that may impact the joints and muscles of the wearer's foot.

Aspects herein relate to a knitted sock comprising different knitted structures and different yarn types, which facilitates its use in various athletic activities including, for example, running. In an example aspect, a knitted sock includes a leg portion. The knitted sock includes an integrally knitted ankle strap extending around the perimeter of the sock at the lower end of the leg portion of the sock. The ankle rolling strip provides 360 degree cushioning in the area adjacent the wearer's ankle corresponding to a typical collar. This may be useful when a wearer running on uneven terrain causes the foot to shift within the shoe. In an example aspect, the tab is located at a rear aspect of the ankle roll, wherein the tab is integrally knit with the ankle roll. The flap may provide enhanced cushioning along the achilles tendon of the wearer. Further, the tabs may help put on the sock and if the sock is displaced during wear, the tabs may provide the wearer with an easy way to adjust the positioning of the sock.

The knitted sock may include additional features that provide zoned cushioning and zoned breathability and/or permeability. For example, the heel portion of the sock may include an achilles tendon section adapted to be positioned adjacent to the wearer's achilles tendon during wear and a plantar section adapted to be positioned adjacent to the wearer's heel during wear. One or more of the achilles and plantar sections includes a knit structure having an alternating pattern of courses knitted with terry loops (to provide cushioning) and courses knitted without terry loops (to enhance breathability and permeability of the knit sock).

The knitted sock may optionally also have zoned gripping features. For example, integrally knitted grip strips knitted using grip yarns may be located at strategic locations to enhance grip where needed. Some example locations include the instep side and plantar side of the toe end of the sock. Designing the sock to include grip strips in this area can help prevent the toe area of the foot from shifting during wear. This is particularly useful when the wearer is running or hiking on a slope. Because conventional socks lack gripping strips in this area, this type of movement may cause the wearer's toe to slide forward and impact the toe end of the shoe, which may cause discomfort and/or bruising of the wearer's toenail. Integrally knit grip strips may also be positioned on the outside and inside of the foot portion of the sock. Positioning the grip strips on the medial and lateral sides of the foot portion of the sock can help minimize medial-to-lateral shifting that may occur when a wearer runs/walks on uneven terrain. In an example aspect, there may be no grip strip in the instep midfoot portion and the plantar midfoot portion of the sock. The lack of a grip strip on the midfoot portion of the instep of the sock may allow the wearer's skin to shift slightly during wear, which helps reduce tension or shear forces on the sensitive area. The lack of a grip strip on the plantar midfoot portion of the sock allows the sock to make some movement against the wearer's arch, which also reduces tension or shear forces to the sensitive area. An integrally knit grip strip may be positioned on the plantar section of the heel portion of the sock to help prevent heel shifting, especially when running or hiking in hilly terrain.

In an example aspect, the knitted sock may optionally include a knitted structure at the forefoot of the sock, wherein the knitted structure is adapted to be positioned adjacent to a ball of a foot of a wearer during wear. The knitted structure may provide cushioning, gripping, and breathability and/or permeability characteristics. In an example aspect, a knitted structure may include a repeating pattern having a first number of courses with body yarns and plating yarns knitted with terry loops in a basic stitch, and a subsequent second number of courses in which the body yarns float the first number of stitches and knit the second number of stitches; the second number of courses is integrally knit with the first number of courses. In further example aspects, the grip yarn may be used in a knitted structure (including in a loop). The floating body yarns increase stretch resistance and increase overall compression at the forefoot of the sock to provide a snug fit. Furthermore, floating the body yarn can increase the breathability and permeability of the knitted structure in the float areas because there are fewer stitches in the float areas, which reduces the overall yarn density in these areas. The use of loop loops provides cushioning for this high impact area of the wearer's foot. Furthermore, the use of gripping yarns in this area helps stabilize the forefoot within the shoe and thereby reduces displacement of the foot during movement.

The above features may be used in various combinations, including the use of all features, to provide such a knitted sock: which has zoned grasping, zoned cushioning, zoned breathability/permeability, and/or enhanced fit characteristics, making the knit sock suitable for athletic activities.

As used throughout this disclosure, the term "sock" means a knitted tubular structure having an open first end and a closed second end. The sock may be worn over the foot of a wearer. The term "inwardly facing surface" means a surface of the sock that is configured to face the skin surface of the wearer, and the term "outwardly facing surface" means a surface of the sock that faces away from the inwardly facing surface and faces towards the external environment. In an example aspect, the inwardly facing surface may comprise a technical back of the knitted tubular structure and the outwardly facing surface may comprise a technical front of the knitted tubular structure. In an example aspect, the knit sock described herein can include a middle stocking. The term "medial stocking" means a sock that includes leg portions that extend fully or partially over the calf region of the wearer. Socks may be described as having several portions, such as a collar, a leg portion, a heel portion, a foot portion, and a toe end. The collar has a peripheral edge defining an opening for receiving a foot of a wearer when the sock is donned. In one example, the collar may be positioned below the knee of the wearer when worn. The leg portion extends from the collar and is configured to fully or partially cover the calf/shank area of the wearer.

The foot portion extends from the leg portion and is configured to cover a foot of a wearer. The foot portion may in turn comprise: a instep side configured to cover an instep of a foot of a wearer; a medial side configured to cover a medial side of a foot of a wearer; a lateral side configured to cover a lateral side of a foot of a wearer; and a plantar side configured to cover a plantar aspect of a foot of a wearer. In an example aspect, the foot portion may be divided into: a toe end configured to cover a toe of a foot of a wearer; a forefoot portion configured to cover, for example, an area just behind the toe of the wearer, such as the ball of the foot; a midfoot portion configured to cover a middle portion of a foot of a wearer, including, for example, an arch region of the foot of the wearer; and a hindfoot portion configured to cover a rear portion of a foot of a wearer. The heel portion of the sock may include a plantar section that covers a plantar surface of the wearer's heel and an achilles tendon section configured to cover a lower portion of the wearer's achilles tendon. The different areas of the sock described above are intended to represent general areas or proximity locations for reference purposes discussed below and may not be limiting.

The relative terms such as upper, lower, upper, front, rear, etc., as used in describing the sock refer to a sock that is worn by a wearer when the wearer is in a standing position and facing forward.

As used herein, the term "course" refers to a predominantly horizontal row of stitches (in an upstanding textile article when knitted) produced by adjacent needles during the same knitting cycle. The courses may include one or more stitch types, such as knitting, holding, float, tuck, transfer, etc., as these terms are known in the knitting art. As used herein, the term "knit stitch" or "base knit stitch" refers to a base stitch type in which yarn is removed from the needle after pulling loops of yarn from the rear to the front of the textile by a previous stitch. Thus, the legs of the stitch appear on the technical face of the knitted textile and the top and bottom of the stitch appear on the technical back of the knitted textile. As used herein, a knitted stitch or base knitted stitch may include a loop stitch. As used herein, the term "wale" is a predominantly vertical column of knitted loops that are mutually nested or intertwined, typically created by the same needle in successive (but not necessarily all) courses or knitting cycles. The terms "horizontal" and "vertical" are relative to an upstanding textile article when knitted, with the head of the knitted loop facing the top of the textile article and the course knit being oriented first toward the bottom of the textile article.

As used herein, the term "float stitch" occurs when no new stitch is formed at the needle. Thus, the float yarns may extend across one or more adjacent wales. As used herein, the term "terry loop" refers to loops formed from knitting yarns that extend away from the technical face and/or technical back of the knitted textile, and the term is given its ordinary meaning in the knitting arts. In an exemplary aspect, the terry loops extend away from the technical back of the knit sock such that they face the skin surface of the wearer. As used herein, the term "plating" means a knit construction in which one or more body yarns and one or more plating yarns are knitted in the same knit stitch using, for example, a body yarn feeder and one or more plating yarn feeders. The term "stitch-bonding yarn" means a yarn that is incorporated into a knitted construction during a knitting cycle but does not knit the stitch-bonding yarn into loops.

Unless indicated otherwise, the body yarns used to knit the knit sock may include the following yarns: yarns comprising natural fibers/filaments, yarns comprising artificial fibers/filaments, or yarns comprising both natural fibers/filaments and artificial fibers/filaments. In one example aspect, the body yarn may include wool fibers/filaments twisted with polyester fibers/filaments. In an example aspect, the plating yarn can include an elastic yarn, such as a spandex yarn covered with nylon. Similarly, in an example aspect, the backing yarn may comprise an elastic yarn, such as a nylon covered yarnA yarn.

As used herein, the term "rolling bar" generally refers to such a knitted structure: which may include ribs and/or may be double knit for supporting or providing structure to specific areas of the sock. In a typical configuration, the rolling bar is generally positioned at the collar of the sock. In aspects contemplated herein, the sock may include a collar strap in addition to a strap positioned at the ankle region of the sock (referred to as an "ankle strap"), as further described herein.

As used herein, the term "integrally knit" may mean a textile in which yarn from one or more courses is intertwined with one or more courses of another area. For example, if the yarn from the ankle roll is intertwined with the yarn from the tubular body, the ankle roll may be integrally knit with the tubular body, such as a knit sock. In another example, if the yarn from the tab is intertwined with the yarn from the ankle roll, the tab may be integrally knit with the ankle roll.

Continuing, it is contemplated herein that the grip strips may be knitted with a yarn type having gripping characteristics, referred to herein as a "grip yarn". The term "grip yarn" as used in describing the yarn forming the grip strip refers to a yarn having a large number of filaments (e.g., 7000 or more) per individual yarn strand such that the grip yarn has a denier per filament of about 0.01 or less. In other words, the grip yarn may be formed from filaments having diameters from about 25 nanometers to about 350 nanometers. In an exemplary aspect, the grip yarns may be formed by an "islands-in-the-sea" process. An example filament that may be used to grip the yarn is produced by Di person Co., ltd (Teijin Limited) having headquarters located in Tokyo, japanThe high number of filaments provides a large surface-to-volume ratio for the yarn, which aids in the gripping function of the yarn. In other words, the large number of filaments within the yarn gives the yarn a higher coefficient of friction than more typical yarns, such as yarns, which combine, for example, 50 filaments to 500 filaments per yarn, which combine, for example, fewer filaments within a single yarn strand. As used herein, the term "elastic yarn" refers to the ability of a yarn to stretch from about 100% to about 200% of its original length and return to about its original length (e.g., within 5% to 10%) after removal of the stretching force.

All measurements provided herein were made while the sock was at standard ambient temperature and pressure (298.15K and 100 kPa) and the sock was in a resting state (e.g., unstretched state), unless otherwise indicated.

Fig. 1-5 depict lateral, medial, front, plantar, and rear views, respectively, of an example knitted sock 100 according to aspects herein. Sock 100 is depicted as if worn by a standing wearer with the wearer's heel lifted to better illustrate the different features of sock 100. Sock 100 generally includes a tubular body 101 having an open end and a closed end. With respect to fig. 1 (which depicts a lateral view of the knitted sock 100), the knitted sock 100 includes a collar 110, the collar 110 having a peripheral edge 111 defining an opening 112, the opening 112 for receiving a foot of a wearer. In some example aspects, the collar 110 may include a rolling bar as shown. The leg portion 114 extends downwardly from the collar 110. In an example aspect, the leg portion 114 can include a plurality of courses extending circumferentially around the leg portion 114.

The knitted sock 100 also includes an ankle roll 116 positioned at the lower end of the leg portion 114 and knitted integrally with the leg portion 114. Ankle rolling band 116 extends around the perimeter of knitted sock 100 and includes an upper edge 118 and a lower edge 120. In an exemplary aspect, the lower edge 120 is integrally knit with the leg portion 114, and the upper edge 118 is separated or separated from the leg portion 114 such that it includes a free edge. In an example aspect, ankle roller 116 may include a rib structure and/or may be double knit for additional cushioning, stability, and structure. Positioning the ankle roll 116 such that the ankle roll 116 extends around the wearer's ankle and between the collar of the shoe and the wearer's ankle when the knitted sock 100 is worn provides additional cushioning in this area, which may be useful when the foot is displaced medial and/or lateral and forward or rearward during wear.

A tab 122 is positioned at a rear aspect of ankle strap 116 and is integrally knit with ankle strap 116. In an example aspect, the flap 122 may be double knit for additional stability and cushioning. In an example aspect, the flap 122 may be knitted using a high dtex elastic yarn (such as a 156 dtex spandex yarn covered with nylon). In an example aspect, the tab 122 may not include plating or backing yarns. The use of high dtex elastic yarn provides structure for the flap 122 and provides stretch and recovery allowing the flap 122 to be more easily manipulated by the wearer.

In an example aspect, the airfoil 122 includes an airfoil base 124, an airfoil body 126 extending from the airfoil base 124, and a top edge 128 spaced apart from the airfoil base 124 by the airfoil body 126, wherein the top edge 128 is positioned above the airfoil base 124. In an example aspect, the top edge 128 of the airfoil 122 may be positioned from about 3cm to about 5cm above the airfoil base 124, from about 3.5cm to about 4.5cm above the airfoil base 124, or about 4cm above the airfoil base 124. As used herein, the term "about" means within ±10% of the indicated value. Configuring tab 122 to have this height ensures that top edge 128 is positioned such that it extends over the collar of a typical shoe, thereby enabling it to be easily grasped by the wearer when adjusting sock 100. In an example aspect, the flap base 124 may be integrally knit with the upper edge 118 of the ankle roll 116. The top edge 128 of the flap 122 may be separated or separated from the leg portion 114 of the knitted sock 100. As shown, the tab 122 tapers as the tab 122 extends from the tab base 124 to the top edge 128.

Below the ankle roll 116, the knitted sock 100 includes a heel portion 130. Heel portion 130 includes an achilles tendon section 132 and a plantar section 134, wherein achilles tendon section 132 is configured to cover the lower end of the wearer's achilles tendon and plantar section 134 is configured to cover the plantar portion of the wearer's heel region. In an exemplary aspect, and as further described with respect to fig. 8, achilles tendon section 132 has a knit structure comprising an alternating pattern of a first number of courses 136 and a second number of courses 138, the first number of courses 136 being knit with terry loops extending from an inward-facing surface of knit sock 100, the second number of courses 138 being knit without terry loops. A first number of courses 136 and a second number of courses 138 extend from the lateral side to the medial side of achilles tendon section 132.

The first number of courses 136 may include a greater number of courses than the second number of courses 138 such that a ratio of the first number of courses 136 to the second number of courses 138 may be about 2:1. In one example aspect, the first number of courses 136 may include from three courses to five courses or four courses, and the second number of courses 138 may include from one course to three courses or two courses.

In an example aspect, a first number of courses 136 may be knitted with one type of yarn and a second number of courses 138 may be knitted with a second type of yarn. For example, the first number of courses 136 may be knitted with yarns including natural fibers/filaments (such as wool), yarns including synthetic fibers/filaments (such as polyester), and/or yarns having a mixture of natural fibers/filaments and synthetic fibers/filaments. The second number of courses 138 may be knitted with an elastic yarn, such as a spandex yarn covered with polyester or nylon.

Alternate courses with courses of loop coils and courses without loop coils provide a desired degree of cushioning while still providing breathability and permeability characteristics. For example, the terry loops provide cushioning and the areas without terry loops provide breathability and permeability because they have a lower yarn density. The ratio of the first number of courses 136 to the second number of courses 138 may be adjusted as desired to provide more or less cushioning and/or more or less breathability/permeability characteristics. For example, the use of wool yarns in the first number of courses 136 may aid in cushioning characteristics due to inherent crimp of the wool fibers, and may also aid in moisture management due to the large moisture regain of wool (e.g., from about 13% to 18% under standard conditions), which allows the wool yarns to absorb moisture. The use of elastic yarns in the second number of courses 138 provides a snug fit around the achilles tendon region of the wearer.

The plantar section 134 of the heel portion 130 may include a similar knitting structure including an alternating pattern of a first number of courses 140 knitted with terry loops and a second number of courses 142 knitted without terry loops, as described for the achilles section 132. As such, the description of the pattern provided with respect to achilles tendon segment 132 also applies to plantar segment 134. A first number of courses 140 and a second number of courses 142 extend from the lateral side to the medial side of plantar section 134. In an example aspect, similar to the achilles tendon segment, the second number of knitted courses 142 may be knitted with an elastic yarn (such as a spandex yarn covered with polyester or nylon) to provide a snug fit. The first number of courses 140 may be knitted with a grip yarn, as explained further below.

The foot portion 144 extends from the heel portion 130 and the ankle roll 116 to a closed foot tip 146 of the knit sock 100. The leg portion 114 and the foot portion 144 combine to form the tubular body 101 of the stocking 100. The foot portion 144 includes a plurality of courses that extend around the perimeter of the knitted sock 100. As shown in the lateral view of fig. 1, the foot portion 144 can include a first plurality of grip strips 148, the first plurality of grip strips 148 being integrally knit with the knit sock 100 using a grip yarn. In an example aspect, the first plurality of grip strips 148 are generally positioned on the lateral side of the foot portion 144 of the knitted sock 100 such that they generally do not extend onto the instep side of the sock or the plantar side of the foot portion 144 of the sock 100. The first plurality of grip strips 148 can include loop stitches extending from an inward facing surface of the knitted sock 100. Forming the grip yarn into loop coils increases the exposed surface area of the grip yarn to provide a greater level of grip. The first plurality of grip strips 148 may help stabilize and prevent the foot of the wearer from shifting within the shoe, particularly over uneven terrain. As further described with respect to fig. 3 and 4, the toe end 146 of the knitted sock 100 may also include a grip strip.

Fig. 2 depicts a medial side view of the knitted sock 100 that includes many of the same features (indicated with the same reference numerals) as the lateral side view shown in fig. 1, but viewed from the opposite side of the knitted sock 100. As such, ankle strap 116 is shown extending circumferentially around knit sock 100, and tab 122 is shown extending partially around the inside of knit sock 100. Similarly, a first number of courses 136 and a second number of courses 138 of achilles section 132 are shown extending around the medial side of heel portion 130, and a first number of courses 140 and a second number of courses 142 of plantar section 134 are shown extending around the medial side of heel portion 130.

As shown in the medial view of fig. 2, the foot portion 144 can include a second plurality of grip strips 210, the second plurality of grip strips 210 being integrally knit with the knit sock 100 using a grip yarn. In an example aspect, the second plurality of grip strips 210 are generally positioned on the medial side of the foot portion 144 of the knitted sock 100 such that they generally do not extend to the instep side of the sock or the plantar side of the foot portion 144 of the sock 100. The second plurality of grip strips 210 can include loop stitches extending from the inward-facing surface of the knitted sock 100. Similar to the first plurality of grip strips 148, the second plurality of grip strips 210 may help stabilize and prevent medial and lateral displacement of the wearer's foot within the shoe, particularly on uneven terrain. By not extending first plurality of grip strips 148 and second plurality of grip strips 210 onto the instep side of sock 100 and the plantar side of at least the midfoot region of sock 100, the sensitive, thinner skin in that region may move more freely relative to the inward facing surface of knitted sock 100, which may reduce shear or tension in these regions and improve wearer comfort.

Fig. 3 depicts a front view of the knitted sock 100 illustrating many of the same features as shown in fig. 1 and 2. As shown in fig. 3, the first plurality of grip strips 148 and the second plurality of grip strips 210 do not extend onto the instep side (indicated by reference numeral 305) of the foot portion 144 of the knitted sock 100. In other words, the first plurality of grip strips 148 and the second plurality of grip strips 210 are not typically present on the instep side 305 of the knitted sock 100.

As shown in fig. 3, the toe end 146 includes a third plurality of gripping bars 310, the third plurality of gripping bars 310 being located on the instep side 305 of the sock and extending from the medial side to the lateral side of the toe end 146. The third plurality of grip strips 310 are integrally knit with the knit sock 100 using a grip yarn. In an example aspect, the third plurality of grip strips 310 includes loop coils formed from a grip yarn and extending from an inward facing surface of the knitted sock 100. The third plurality of grip strips 310 may help prevent the tips of the wearer from shifting forward, for example, during athletic activities, thereby reducing the chance of damage to the toenails of the wearer. Adjacent grip strips of the third plurality of grip strips 310 may be separated by courses such as those indicated by reference numeral 311 knitted using non-grip yarns such as the body yarns described above.

Fig. 4 depicts a bottom view of the knitted sock 100. The toe end 146 includes a fourth plurality of grip strips 410, the fourth plurality of grip strips 410 being located on the plantar side 405 of the knitted sock 100 and extending from the medial side to the lateral side of the toe end 146. The fourth plurality of grip strips 410 are integrally knit with the knit sock 100 using a grip yarn. In an example aspect, the fourth plurality of grip strips 410 includes loop coils formed from a grip yarn and extending from an inward facing surface of the knitted sock 100. The fourth plurality of grip strips 410 in combination with the third plurality of grip strips 310 helps reduce shifting of the wearer's toes during wear. Adjacent grip strips of the fourth plurality of grip strips 410 may be separated by courses such as those indicated by reference numeral 411 that are knitted using non-grip yarns such as the body yarns described above.

Fig. 4 also depicts the plantar section 134 of the heel portion 130. As described with respect to fig. 1, plantar section 134 includes a repeating pattern of a first number of courses 140 knitted with terry loops and a second number of courses 142 knitted without terry loops. In an example aspect, the first number of courses 140 is knitted with the grip yarn such that the first number of courses 140 forms a fifth plurality of grip strips 412. Positioning the fifth plurality of grip strips 412 on the plantar section 134 of the heel portion 130 helps lock the wearer's heel in place and prevents shifting, for example, during walking or running on uneven terrain.

Fig. 4 additionally depicts a knit structure, generally indicated by reference numeral 414, located on the plantar side 405 of the forefoot portion of the foot portion 144 directly behind the fourth plurality of grip strips 410 at the toe end 146. The knit structure 414 is positioned adjacent to the ball of the wearer's foot when the knit sock 100 is worn. As will be further described with respect to fig. 9, the knitting structure 414 may include a repeating pattern having a first number of courses 416 and a subsequent second number of courses 418, the first number of courses 416 having body yarns and plating yarns knitted with terry loops in basic knitting stitches, the body yarns floating the first number of stitches and knitting the second number of stitches in the second number of courses 418. The area of the knit structure 414 that includes floats is indicated by reference numeral 420. The floating body yarns increase stretch resistance and increase overall compression at that portion of the knit sock 100. The use of loop stitches in knit structure 414 provides cushioning for this high impact area of the wearer's foot. In addition, because the float zone 420 in the second number of courses 418 has a lower yarn density than, for example, a zone including knitting stitches without floats, the air permeability and permeability in the float zone 420 may be enhanced.

Fig. 5 depicts a rear view of the knitted sock 100. As shown, the tab 122 is positioned at a rear aspect of the knit sock 100 and extends from the outside to the inside of the knit sock 100. Such positioning allows the wearer to easily grasp the tab 122 to provide adjustment of the fit of the knit sock 100, particularly at the ankle region. Achilles tendon section 132 of heel portion 130 is depicted as having a repeating pattern of a first number of courses 136 including loop stitches and a second number of courses 138 not including loop stitches. The plantar section 134 of the heel portion 130 includes a repeating pattern of a first number of courses 140 knitted with terry loops and a second number of courses 142 knitted without terry loops, wherein the first number of courses 140 are knitted with grip yarns and form a fifth plurality of grip strips 412.

Fig. 6 is a cross-section of the knitted sock 100 taken at cut line 6-6 of fig. 1. Fig. 6 is provided to illustrate how the ankle rolling 116 is integrally knit with the knit sock 100 and the leg portion 114 of the knit sock 100. The lower edge 120 of ankle roller 116 is integrally knit with the lower end of leg portion 114, as indicated by the same shading pattern used throughout. Reference numeral 610 schematically depicts yarns intertwined with one or more yarns of the leg portion 114 and one or more yarns of the ankle roll 116. The upper edge 118 of the ankle strap 116 is spaced apart or separated from the leg portion 114, and the inwardly facing surface 612 of the ankle strap 116 is positioned adjacent to the leg portion 114 and/or faces the leg portion 114.

Fig. 7 is a cross-section of the knitted sock 100 taken at cut line 7-7 of fig. 3. Fig. 7 is provided to illustrate how tab 122 is integrally knit with ankle roll 116. The flap base 124 is integrally knit with the upper edge 118 of the ankle strap 116. Reference numeral 710 schematically depicts yarns intertwined with one or more yarns of ankle roller 116 and one or more yarns of tab 122. The top edge 128 of the flap 122 is separated or separated from the leg portion 114 and the inwardly facing surface 712 of the flap 122 is positioned adjacent to the leg portion 114 and/or faces the leg portion 114.

Fig. 8 is an enlarged schematic cross-sectional view illustrating a portion of the knitted structure that forms, for example, achilles tendon section 132 and/or plantar section 134 of heel portion 130. The knitted structure includes a first number of courses 136/140 knitted with terry loops (indicated by reference numeral 810) and a second number of courses 138/142 knitted without terry loops 810. Although not shown, the first number of courses 136/140 may include a greater number of courses than the second number of courses 138/142 such that the ratio of the first number of courses 136/140 to the second number of courses 138/142 may be about 2:1.

A first number of courses 136/140 are knitted with body yarn 805 and plating yarn 807. With respect to the first number of courses 136, the body yarn 805 may include yarns having natural fibers/filaments (such as wool), synthetic fibers/filaments (such as polyester), and/or a mixture of natural fibers and synthetic fibers/filaments. With respect to the first number of courses 140, the body yarn 805 may include a grip yarn. Plating yarn 807 in first number of courses 136 and first number of courses 140 may include an elastic yarn, such as a spandex yarn covered with polyester or nylon.

In some example aspects, a second number of courses 138/142 may be knitted with a different body yarn 812 than body yarn 805. For example, with respect to both the second number of courses 138 and the second number of courses 142, the body yarn 812 may include an elastic yarn, such as a spandex yarn covered with polyester or nylon. The same plating yarn 807 can be used for both the second number of courses 138 and the second number of courses 142.

Fig. 9 depicts a schematic knitting of a knit structure 414, the knit structure 414 being located on the plantar side 405 of the forefoot portion of the foot portion 144 directly behind the fourth plurality of grip strips 410 at the toe end 146. The knit structure 414 is positioned adjacent to the ball of the wearer's foot when the knit sock 100 is worn. It is contemplated herein that the knit structure 414 can be used in other locations on the knit sock 100.

The knit structure 414 includes a first number of courses 416 that are knit with basic knitting stitches using at least one body yarn 912 (shown cross-hatched) and one plating yarn 914 (shown hatched). In an example aspect, the body yarn 912 can include a grip yarn. Although loop stitches are not shown, it is contemplated herein that one or more of the body yarns 912 and plating yarns 914 in the first number of courses 416 may be knitted to form loop stitches on the technical back of the knit structure 414 to provide cushioning as known in the knitting arts. As shown, the first number of courses 416 may include two courses. In an example aspect, the first number of courses 416 may include more than two courses, such as three courses, four courses, and the like. Or the first number of courses 416 may include a fewer number of courses than shown, such as one course. The selection of the number of courses in the first number of courses 416 may be based on a desired final characteristic of the knit structure 414, such as increased or decreased cushioning.

Next, the knit structure 414 includes a second number of courses 418 with a repeating pattern of two basic knit stitches (such as knit stitches 918 and 920 knitted with the body yarn 912 and plating yarn 914) and subsequently two float stitches (such as float stitches 922 and 924 to form the float region 420). In this example aspect, the body yarn 912 floats over two wales while the plating yarn 914 continues to knit with the base knit stitch, followed by knitting two base knit stitches with the body yarn 912 and the plating yarn 914, followed by two float stitches, and so on. Floating at least the body yarn 912 increases the stretch resistance of the knit structure 414 (the knit structure 414 is more stretch resistant) because fewer yarns are available for stretching than the loops of knitting. This in turn increases the compression of the knit structure 414, which can create a tighter fit at the forefoot portion of the foot portion 144 and prevent shifting or rotation of the knit sock 100. Further, as yarn density at the float areas 420 decreases, air permeability and/or permeability in these areas may increase. Knitting plating 914 in float zone 420 increases the structural stability of knitted structure 414.

Although the second number of courses 418 is shown to include two courses, it is contemplated herein that the second number of courses 418 may include additional courses, such as three courses, four courses, and the like. It is also contemplated herein that second number of courses 418 may include the same number of courses as first number of courses 416, as shown in fig. 9. It is also contemplated herein that the second number of courses 418 may include a fewer number of courses than the first number of courses 416 or a greater number of courses than the first number of courses 416. The selection of the number of courses in the second number of courses 418 may be based on desired final characteristics of the knit structure 414, such as increased or decreased stretch resistance and/or breathability.

It is also contemplated herein that the body yarn 912 may extend over a fewer number of wales or a greater number of wales than shown. Stretch resistance and/or breathability may be reduced by extending the body yarn 912 over a fewer number of wales (e.g., one wale), and increased by extending the body yarn 912 over a greater number of wales (e.g., greater than two wales). It is additionally contemplated that the number of stitches (two in this example) of the float may be different from the number of basic knitting stitches immediately before and/or after the float. Any and all aspects and any variations thereof are contemplated as being within the various aspects herein.

Knitting structure 414 is a repeating pattern such that a first number of courses 416 are repeated as shown in figure 9. Thus, the repeating pattern includes a first number of courses having a primary stitch with terry loops and a second number of courses, wherein the body yarn knits the first number of stitches and then floats the second number of stitches.

Fig. 10 is a flow chart of an example method 1000 of manufacturing a knitted sock, such as knitted sock 100. The method 1000 is performed on a knitting machine (such as a circular knitting machine configured to knit socks) during a single knitting event. At step 1012, a collar, such as collar 110, is knitted, wherein the collar has a peripheral edge surrounding an opening for receiving a foot of a wearer. At step 1014, a leg portion, such as leg portion 114, is knitted, wherein the leg portion extends from the collar. At step 1018, an ankle roll, such as ankle roll 116, is knitted such that the ankle roll extends around the perimeter of the knitted sock and is positioned at the lower end of the leg portion. At step 1020, a flap, such as flap 122, is knitted at a rear aspect of the ankle roll. In an example aspect, the inwardly facing surface of the tab is positioned adjacent the outwardly facing surface of the leg portion.

Method 1000 may include additional steps, such as knitting a foot portion (e.g., foot portion 144) with the foot portion extending from the leg portion. Method 1000 may further include knitting one or more grip strips with yarns formed from filaments having diameters from about 25 nanometers to about 350 nanometers. Further, method 1000 can include knitting a heel portion, such as heel portion 130, where the heel portion is located between the leg portion and the foot portion. The heel portion is knitted with an achilles tendon section (such as achilles tendon section 132) and a plantar section (such as plantar section 134). One or more of the achilles and plantar sections may include a knit structure having an alternating pattern including a first number of courses knitted with terry loops (e.g., first number of courses 136 and 140) and a second number of courses not knitted with terry loops (e.g., second number of courses 138 and 142).

The above-described knitting steps may be performed in the order listed, but it is contemplated herein that the knitting steps may be performed in a different order. For example, the toe end of the knitted sock may be knitted first.

Aspects of the present disclosure have been described with an illustrative, but non-limiting, intent. Alternative aspects will become apparent to those skilled in the art without departing from the scope thereof. Alternative means of implementing the above-described improvements may be developed by the skilled person without departing from the scope of the present disclosure.

It should be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be performed in the particular order described.

Claims (17)

1. A knitted sock, comprising:

A collar having a peripheral edge surrounding an opening for receiving a foot of a wearer;

a leg portion extending from the collar;

a foot portion extending from the leg portion and terminating at a toe end;

An integral knit ankle roll extending around a perimeter of the knit sock and positioned at a lower end of the leg portion; and

A tab located at a rear of the ankle roll, the tab integrally knit with the ankle roll;

Wherein:

The ankle roll having an upper edge and a lower edge, the lower edge being integrally knit with the leg portion;

The upper edge of the ankle strap is spaced apart and spaced apart from the leg portion.

2. The knitted sock of claim 1, wherein an inwardly facing surface of the flap is positioned adjacent an outwardly facing surface of the leg portion.

3. The knitted sock of claim 1, wherein the flap includes a flap base, a flap body extending from the flap base, and a top edge spaced from the flap base by the flap body, and wherein the flap base is integrally knit with the upper edge of the ankle roll.

4. A knitted sock according to claim 3, wherein the top edge of the flap is separated from the leg portion.

5. The knitted sock of claim 1, further comprising a heel portion positioned between the leg portion and the foot portion, the heel portion having an achilles tendon section and a plantar tendon section, wherein at least the achilles tendon section is formed from a knitted structure having an alternating pattern including a first number of courses knitted with terry loops and a second number of courses knitted without terry loops.

6. The knitted sock of claim 5, wherein the first number of courses and the second number of courses extend from a lateral side to a medial side of the achilles tendon section.

7. The knitted sock of claim 1, further comprising:

A first plurality of integrally knit grip strips located on an outer side of the foot portion; and

A second plurality of integrally knit grip strips on the medial side of the foot portion.

8. The knitted sock of claim 7, further comprising:

a third plurality of integrally knit grip strips located on a instep side of the toe end of the knit sock; and

A fourth plurality of integrally knit grip strips located on a plantar side of the toe end of the knit sock.

9. The knitted sock of claim 8, further comprising a heel portion positioned between the leg portion and the foot portion, the heel portion having an achilles tendon section and a plantar section, wherein the plantar section includes a fifth plurality of integrally knit grip strips extending from a lateral side to a medial side of the plantar section.

10. A knitted sock, comprising:

A tubular knitted body forming a leg portion and a foot portion extending from the leg portion and terminating at a toe end;

An ankle roll extending around a perimeter of the tubular knitted body and positioned between the leg portion and the foot portion; the ankle roll is integrally knit with the tubular knit body and has an upper edge that is spaced apart and separated from the leg portion; and

A flap located at a rear of the ankle roll, an inwardly facing surface of the flap being positioned adjacent an outwardly facing surface of the leg portion;

Wherein the tab is integrally knit with the upper edge of the ankle roll.

11. The knitted sock of claim 10, wherein the ankle roll has a lower edge that is integrally knit with the tubular knitted body.

12. The knitted sock of claim 10, wherein the flap includes a flap base, a flap body extending from the flap base, and a top edge spaced from the flap base by the flap body, wherein:

the flap base is integrally knit with the ankle roll, and

Each of the tab body and the top edge of the tab is separated from the leg portion.

13. The knitted sock of claim 10, further comprising a heel portion positioned between the leg portion and the foot portion, the heel portion having an achilles tendon section and a plantar tendon section, wherein at least the achilles tendon section is formed from a knitted structure having an alternating pattern including a first number of courses knitted with terry loops and a second number of courses knitted without terry loops.

14. The knitted sock of claim 10, further comprising one or more integrally knitted grip strips knitted with yarns formed of filaments having a diameter from about 25 nanometers to about 350 nanometers.

15. A method of knitting a sock, comprising:

during a single knitting event:

A knitted collar having a peripheral edge surrounding an opening for receiving a foot of a wearer;

knitting a leg portion, the leg portion extending from the collar;

knitting a foot portion extending from the leg portion and terminating at a toe end;

Knitting an ankle roll such that the ankle roll extends around a perimeter of the sock and is positioned at a lower end of the leg portion; and

A knitted tab located at a rear of the ankle roll such that an inwardly facing surface of the tab is positioned adjacent an outwardly facing surface of the leg portion;

Wherein:

The ankle roll having an upper edge and a lower edge, the lower edge being integrally knit with the leg portion;

The upper edge of the ankle strap is spaced apart and spaced apart from the leg portion.

16. The method of knitting a sock of claim 15, further comprising knitting one or more grip strips with yarn formed from filaments having a diameter from about 25 nanometers to about 350 nanometers.

17. The method of knitting a sock of claim 15, further comprising knitting a heel portion between the leg portion and the foot portion, the heel portion being knitted with an achilles section and a plantar section, wherein at least the achilles section includes a knit structure having an alternating pattern including a first number of courses knitted with terry loops and a second number of courses knitted without terry loops.