Multi-Layered Socks With Elastomeric Padding

The present invention generally relates to socks and more specifically to socks with multiple layers to provide support to a user's foot.

A sock is an article of clothing that is worn on an individual's (may also be referred to as a “user”) feet, with the sock often covering the ankle or a portion of the individual's calf. Socks have multiple uses, with one of the primary uses including absorbing perspiration to provide comfort to the user. The foot is one of the heaviest producers of sweat in the body, with the ability to produce over 0.25 US pints (0.12 liters) of perspiration per day. Part of a sock's functionality is moisture wicking, as the material helps absorb sweat produced, drawing it to areas where air can aid in evaporating the perspiration. A thin sock worn in warmer temperatures may help keep feet cool by facilitating the removal of excess perspiration. Alternatively, socks can also perform a warming function in cold environments, increasing foot temperature when made of fabrics such as cotton or wool.

Socks can be made from a variety of materials which may depend on the intended use of the user. Sock materials may include cotton, wool, nylon, acrylic, polyester, silk, bamboo, linen, or blends of those or other further materials. Some of these materials may be preferred for their ability to provide warmth and comfort to an individual.

The various embodiments of the present multi-layered socks with elastomeric padding (may also be referred to as “multi-layered socks”) contain several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the present embodiments, their more prominent features will now be discussed below. After considering this discussion, and particularly after reading the section entitled “Detailed Description,” one will understand how the features of the present embodiments provide the advantages described here.

One aspect of the present embodiments includes the realization that in current socks other than the present embodiments, a user may develop blisters. For example, in socks with a single layer of material, a user's foot may move around more while wearing the sock. This extra motion may subject the user to greater frictional forces, which may further result in the development of blisters. The present embodiments solve this problem by providing additional layers of material and cushions which reduce the motion a user experiences while wearing a sock. The present embodiments thus advantageously enable multi-layered socks to reduce frictional forces and blister formation. The present embodiments provide these advantages and enhancements, as described below.

In a first aspect, a sock for reducing foot movement is provided, the sock comprising: a toe region that is positioned at a first end of the sock for receiving at least one toe of a user's foot; a mid-foot region comprising a first side connected to the toe region and a second side connected to a heel region, wherein the first side is positioned opposite the second side; the heel region positioned for receiving a heel of a user's foot; an ankle region connected to the heel region, wherein the ankle region comprises an opening; a sole positioned from the toe region through the mid-foot region to the heel region, the sole comprising an inner layer, a middle layer, and an outer layer, wherein: the inner layer makes contact with the user's foot when the sock receives the user's foot; the middle layer is attached to the inner layer and is encapsulated between the inner layer and the outer layer, wherein: the middle layer of the sole varies in thickness; a thickness of the middle layer of the sole is greater in the heel region and the toe region; and wherein the sock forms a hollow tubular shape that is closed at the toe region and open at the ankle region.

In an embodiment of the first aspect, the middle layer of the sole is concentrated in the toe region in areas corresponding to first and fifth metatarsals of the user's foot.

In another embodiment of the first aspect, the middle layer of the sole comprises an elastomeric material.

In another embodiment of the first aspect, the elastomeric material has a geometric grid pattern that allows for adequate air and moisture transfer while providing localized support.

In another embodiment of the first aspect, the inner layer comprises a blend of all natural fibers.

In another embodiment of the first aspect, the inner layer comprises a blend of all synthetic fibers.

In another embodiment of the first aspect, the inner layer comprises a combination blend of synthetic and natural fibers including cellulosic fibers.

In another embodiment of the first aspect, the elastomeric material has a Shore hardness between 00-0 and A-40.

In another embodiment of the first aspect, the elastomeric material has a water absorption rate no greater than 3.00%.

In another embodiment of the first aspect, the elastomeric material has a thickness not to exceed 2.00 mm.

In a second aspect, a method for fabricating a movement-reducing cushioned sock, the method comprising: knitting an inner layer of material of a tubular structure; applying a middle layer of material to an exterior surface of the inner layer; and attaching an outer layer of material to the middle layer such that the middle layer is encapsulated between the inner layer and the outer layer.

In an embodiment of the second aspect, the middle layer is applied in a solid form by adhering a polymer shape directly onto the exterior surface of the inner layer.

In another embodiment of the second aspect, the middle layer is applied as a viscous, spreadable gel formula as a screen print.

In another embodiment of the second aspect, the middle layer is knit into the inner layer as a thread, yarn, or fiber.

In another embodiment of the second aspect, the inner layer of material is knit on a circular knitting machine.

In another embodiment of the second aspect, the outer layer of material is knit continuously after knitting the inner layer of material without the circular knitting machine cutting or dropping the sock after knitting the inner layer of material.

In another embodiment of the second aspect, the outer layer of material is folded back over the inner layer and middle layer such that the sock is multiple layers.

In another embodiment of the second aspect, the middle layer is applied in a series of coatings to allow for different thicknesses.

In another embodiment of the second aspect, an open end formed after folding the outer layer over the inner layer and middle layer is closed to form a toe region.

In another embodiment of the second aspect, the middle layer is applied by a mechanical strainer.

The following detailed description describes the present embodiments with reference to the drawings. In the drawings, reference numbers label elements of the present embodiments. These reference numbers are reproduced below in connection with the discussion of the corresponding drawing features.

Socks can also provide medical benefits and be used therapeutically. For example, socks may be used to reduce the formation of blisters on the individual's feet. Friction from moving results in the individual's skin layers pulling away from each other, leading to blister formation. Socks may reduce the friction that an individual experiences while moving and accordingly reduces the likelihood of blisters forming. Socks may also have compressive qualities and can be used to reduce swelling. Socks with compressive qualities are able to facilitate the return of blood and fluids to the individual's body and may be used as a form of medical treatment for conditions involving swelling.

Turning now to the drawings, multi-layered socks utilizing elastomeric padding in accordance with embodiments of the invention are provided. In various embodiments, multi-layered socks provide foot support and reduce foot motion when worn by a user, as further described below. In many embodiments, multi-layered socks may include a toe region positioned at a first end for receiving one or more toes of a user's foot. In several embodiments, multi-layered socks may also include a mid-foot region having a first side connected to the toe region and a second side connected a heel region. In various embodiments, the heel region may be positioned for receiving a heel of the user's foot. In some embodiments, multi-layered socks may also include an ankle region connected to the heel region, where the ankle region may include an opening for the user to slide a foot in and out of the multi-layered sock. In several embodiments, the multi-layered sock may form a hollow tubular shape that is closed at the toe region and open at the ankle region, as further described below.

In many embodiments, multi-layered socks may include a sole positioned from the toe region through the mid-foot region to the heel region. In various embodiments, the sole of multi-layered socks may include a plurality of layers. For example, a sole may include various layers including, but not limited to, an inner layer, a middle layer, and an outer layer. In some embodiments, the inner layer may make contact with the user's foot when the multi-layered sock receives the user's foot. In some embodiments, the middle layer may be of varying thickness and may be encapsulated between the inner layer and the outer layer at various points corresponding to various locations of the user's foot. In many embodiments, the thickness of the middle layer may be greater in the heel region and/or in the toe region. By using multi-layered socks of the present invention, a user may benefit from support at key areas of the user's foot, promoting general foot health. For example, the multi-layered socks may utilize a sole having a middle layer of varying thickness corresponding to various locations of a user's foot thereby reducing foot motion and thus preventing formation of blisters, particularly during periods of physical activity. Multi-layered socks in accordance with embodiments of the invention are further discussed below.

Socks with Multiple Layers

Typically, socks include a single layer of material that provides an interface between a user's foot and the user's outside environment. Traditionally, conventional single layer socks are optimized to absorb perspiration from a user's foot (the foot is among the heaviest producers of sweat in the body) and/or to help keep a user's foot warm. In contrast, multi-layered socks in accordance with embodiments of the invention may be optimized for conventional features (e.g., sweat absorption, warmth, etc.) and additional features not typically considered in conventional single layer socks. For example, multi-layered socks may be optimized for protection and/or comfort of specific locations on a user's foot, as further described below.

A cross-sectional view of a multi-layered sock in accordance with an embodiment of the invention is illustrated in. The sockmay include a toe region, a midfoot region, heel region, and ankle region. The ankle regionmay form an openingfor receiving a use's foot. For example, a user may insert their foot into the sockusing the openingand sliding their foot into the socksuch that the user's toes rest in the toe regionand the user's heel rests in the heel region. Traditionally, the toe regionprovides a front boundary of the sockwhile the heel regionprovides a rear boundary of the sock. Typically, the toe region, midfoot region, and heel regionform a hollow shape which can contain and protect a user's foot while providing a comfortable interface between the user's foot and a user's shoe or other environmental surfaces.

In reference to, the sockmay also include a solethat may include an inner layerand an outer layer. In many embodiments, the solemay also include a middle layer. In various embodiments, the middle layermay be an interface between an inner layerand an outer layer. In many embodiments, the middle layermay have a variable thickness so as to create cushions at key points along the sockwhich correspond to one or more locations of a user's foot. For example, the middle layermay include a ball cushionthat is configured to protect the ball of the user's foot. Further, the middle layermay include a heel cushionthat is configured to protect the heel of the user's foot. Typically, a user's stride starts with the user's heel striking the ground, after which the user's weight rolls forward. The user's heel and the user's midfoot (or ball) are very important in the user's weight distribution as the user rolls their foot in the process of walking. A user may experience problems with their feet when their gait causes their foot to roll too far in any direction. When a user's foot rolls too far in any given direction, it causes parts of the user's foot to bear more weight than they normally would. The resulting problems to the user's foot can thereafter cause further health problems, including back pain. In some embodiments, the ball cushionmay be located between the toe regionand midfoot region. In some embodiments, the heel cushionmay be located in the heel region.

A bottom view of a pair of multi-layered socks in accordance with an embodiment of the invention is illustrated in. The pair of socks may include a left sockand a right sock. The left sockmay include a left ball regionand a left heel region. The left sockmay also include a left inner layerand a left middle layer. In several embodiments, the left middle layer may have a variable thickness. In many embodiments, the left middle layer may be thicker in particular areas corresponding to locations along a user's foot. For example, the left middle layer may have areas of greater thickness in the left ball regionand the left heel regionwhich may form a left ball cushionand left heel cushion, respectively. Moreover, in several embodiments, the left sockmay include a left ball cushionand/or a left heel cushionutilizing elastomeric padding, as further described below. In many embodiments, the left ball cushionmay be configured to correspond to the portions of a user's ball bearing the user's weight distributing the weight across the user's foot. In some embodiments, the left cushionmay be wider at a location corresponding to an inside of a user's foot and more narrow at a location corresponding to an outside of a user's foot. In many embodiments, the left cushionmay have a uniform width.

The right sockmay include a right ball regionand a right heel region. The right sockmay also include a right inner layerand a right middle layer. In several embodiments, the right middle layer may have a variable thickness. In many embodiments, the right middle layer may be thicker in particular areas corresponding to locations along a user's foot. For example, the right middle layer may have areas of greater thickness in the right ball regionand the right heel regionwhich may form a right ball cushionand right heel cushion, respectively. Moreover, in several embodiments, the right sockmay include a right ball cushionand/or a right heel cushionutilizing elastomeric padding, as further described below. In many embodiments, the right ball cushionmay be configured to correspond to the portions of a user's ball bearing the user's weight distributing the weight across the user's foot. In some embodiments, the right cushionmay be wider at a location corresponding to an inside of a user's foot and more narrow at a location corresponding to an outside of a user's foot. In many embodiments, the right cushionmay have a uniform width.

A top view of a multi-layered sock in accordance with an embodiment of the invention is illustrated in. In many embodiments, the sockmay include an ankle region. In various embodiments, the ankle regionmay include an openingwhich a user may use to position their foot into the sock. In many embodiments the sockmay contain an outer layerwhich contacts the outside environment of the sock.

A cross-sectional view of a multi-layered sock's multiple layers in accordance with an embodiment of the invention is illustrated in. In many embodiments, a multi-layered sock may include a plurality of layers. For example, the plurality of layers can include an inner layer, a middle layer, and an outer layer. In many embodiments, the inner layerand outer layermay be constructed using various materials such as, but not limited to, cotton, wool, etc. In several embodiments, the middle layermay be constructed using an elastomeric material (may also be referred to as an “elastomeric padding”). The elastomeric padding may create a specific geometric pattern which allows the elastomeric padding to fit naturally to the shape of the sock. In many embodiments, the elastomeric padding may include a specific grid pattern that allows for air and moisture transfer while providing localized support in key pressure point areas, as further described below. In some embodiments, the middle layermay have varying thickness so as to accommodate key areas corresponding to particular locations along a user's foot, as further described below. In some embodiments, the thickness of the middle layermay have a maximum thickness of 2.00 mm. In some embodiments, the elastomeric padding may have a hardness between Shore 00-0 and Shore A-40. In some embodiments, the elastomeric padding may have a maximum density of 4.50 g/cc. In some embodiments, the elastomeric padding may have a compressive strength between 5 MPa and 35 MPa. In some embodiments, the elastomeric padding may have a maximum water absorption of 3 percent. In some embodiments, the elastomeric padding may have a maximum modulus of rigidity (20 C) of 1.00 MPa.

Although specific multi-layered socks for providing improved general foot health are discussed above with respect to, any of a variety of multi-layered socks including a variety of layer thicknesses, cushions, and/or materials as appropriate to the requirements of a specific application can be utilized in accordance with embodiments of the invention. Middle layer configurations of multi-layered socks in accordance with embodiments of the invention are discussed further below.

As described above, multi-layered socks may be optimized for protection and/or comfort of specific locations on a user's foot. In many embodiments, multi-layered socks may include a middle layer with variable thickness so as to create cushions at key points of the sock which may correspond to various locations along a user's foot. For example, the middle layer may include a ball cushion that is configured to provide extra support and/or movement reduction to the ball of the user's foot. Further, the middle layer may include a heel cushion that provides protection and/or support to a heel of the user's foot. Although specific examples of locations along a user's foot are provided (e.g., the ball and heel), the middle layer may have regions of increased thickness in any location on the multi-layered sock as appropriate to the requirements of a specific application. For example, the regions of increased thickness in the middle layer can include elastomeric padding.

A cross-sectional view of another multi-layered sock in accordance with an embodiment of the invention is illustrated in. In several embodiments, the multi-layered sockmay include an outer layerthat interfaces (e.g., is in contact) with the outside environment. For example, when the multi-layered sockreceives a user's foot through opening, the outer layermay interface with the outer environment including, but not limited to, a ground surface, the inside of a user's shoe, etc. In many embodiments, the multi-layered sockmay also include an inner layerthat interfaces with the user's foot. For example, when the multi-layered sockreceives a user's foot, the inner layermay interface directly with the skin of the user's foot. In several embodiments, a middle layermay have an increased thickness in the toe regionand the heel region. For example, elastomeric padding may be utilized in the toe regionand the heel regionresulting in a ball cushionand a heel cushion, respectively. In some embodiments, the outer layermay surround the inner layerso that the middle layerincluding the ball and heel cushions,are entirely encapsulated.

In some embodiments, the cushion or cushions in the middle layer are flexible in at least one direction (e.g., vertically, laterally, etc.). The cushion or cushions in the middle layer may have similar or different flexibility. For example, the ball cushion and the heel cushion may have same, similar, or different flexibilities. These flexibilities may depend on the desired support of the user or the activity the user is engaged in. Additionally, the cushion or cushions in the middle layer, when encapsulated between the inner layer and the outer layer, may be fixed in place between the inner layerand outer layer. This fixed position may allow for consistent support at those specified locations. Further, the thickness of the middle layer may differ between various regions. For example, in some embodiments, there may be a greater thickness in the heel cushionthan in the ball cushion for, and thus the thickness of the middle layer may vary. Further, the middle layer may also have cushion (and thus increased thickness) in various regions including, but not limited to, in the midfoot regionor the ankle region.

In reference to, in several embodiments, during the construction process, the outer layermay be folded over the inner layerand middle layer cushions,, as further described below. In several embodiments, the inner layerand the outer layermeet at the toe stitch. The toe stitchallows for the creation of a seam that closes the toe region of the sockin a way that does not cause discomfort for the user. For example, the toe stitchmay be located at a position corresponding to knuckles of a user's toes. The precise location of the toe stitch may vary with the method of knitting the sock.

The extent to which the outer layer may cover the inner layer may vary in different embodiments. The need for the outer layer to cover the entirety of the inner layer may depend on the type of physical activity the user is engaged in. For less strenuous activities, multiple layers in all regions of the sock may not be necessary. However, having multiple layers may provide additional moisture wicking properties in the respective regions that have multiple layers. Other benefits of multiple layers may include blister reduction and increased padding that may provide comfort to the user's foot. A cross-sectional view of a multi-layered sock with a single-layered ankle region in accordance with an embodiment of the invention is illustrated in. In some embodiments of the invention, the outer layerof the sockmay not fully cover the inner layer. The length of the outer layermay vary depending on the intended activity of the user. In various embodiments, the outer layermay or may not be covering the inner layernear the ankle region. In other embodiments, the outer layermay cover the entirety of the inner layer.

To provide support or comfort or other benefit to a user's foot during strenuous activity, in various embodiments, the outer layermay cover the entirety of the inner layerand middle layer cushions,to reduce friction when the user's foot comes into contact with an outer surface. The amount of the inner layercovered by the outer layermay vary between embodiments. For example, some embodiments may only have multiple layers (e.g., the inner layerand the outer layer) on the sole of the sock (e.g., toe region, midfoot region, and heel region) and a single layer on the top of the sock and near the ankle region. The single layer may be either an inner layeror an outer layer. Other embodiments may have multiple layers around the entirety of the sock. The presence of multiple layers in the various regions may be according to a user's preference or according to ease of manufacturing.

The number and locations of middle layer cushions utilizing elastomeric padding may also vary depending on the support required by the activity of the user. A cross-sectional view of a multi-layered sock with a single-layered ankle region and three middle-layer cushions in accordance with an embodiment of the invention is illustrated in. The sockmay have a middle layer with an increased thickness in the heel areaand ankle area, creating an extended heel cushionthat provides support and/or comfort for the user's foot in both the heel areaand the ankle area. This extended heel cushioncan offer support and prevent blisters in the heel areaand/or the ankle area, providing extra protection against motion-related discomfort. This may be particularly useful in circumstances where the user's external environment is in direct contact with a user's heel area such as, but not limited to a hiking boot, ski boot, or other environment contacting the user's heel.

In further reference to, the middle layer may have an increased thickness near the first metatarsal, resulting in a first metatarsal cushion, providing extra support to the first metatarsal and reducing foot movement in this area to reduce blister formation in the toe region. This particular location may be advantageous during strenuous activity such as, but not limited to, running or hiking that can often result in blisters on the first metatarsal. The shape, size, and location of this and all other middle layer cushions may vary depending on the aid required for particular activities. The shape, size, and location of the cushions may vary as needed to provide support. Additionally, the extent to which the outer layercovers inner layermay vary, as further described above.

In some embodiments, other middle layer cushions may be added to improve support in key areas and/or reduce movement and/or associated blisters. A bottom view of an inner layer and middle layer of a multi-layered sock with middle-layer cushions in accordance with an embodiment of the invention is illustrated in. In this view, the outer layer is removed to show a left inner layerand a right inner layerand various possible middle layer cushion configurations. For example, the right and left multi-layered socks,may include first metatarsal cushions,, respectively. The right and left multi-layered socks,may also include fifth metatarsal cushions,, respectively. Further, the right and left multi-layered socks,may include ball cushions,, respectively. In addition, the right and left multi-layered socks,may include heel cushions,, respectively. Althoughillustrates the right and left multi-layered socks,including the various cushions, in some embodiments, the right or left multi-layered sock,may not include one or more of the cushions.

In reference to, the middle layer cushions may have a foot-specific shape depending on whether the sock is a sock designed for a user's left foot (e.g., the left multi-layered sock) or a sock designed for a user's right foot (e.g., the right multi-layered sock). In some embodiments, the middle layer may have an elastomeric padding creating greater thickness in areas within the toe regions,, creating a first metatarsal cushion,. In some embodiments, the elastomeric padding may cause thickness of the middle layer to create ball cushions,. In some embodiments, the middle layer may have an elastomeric padding creating greater thickness in the toe regions,such that fifth metatarsal cushions,are present. The fifth metatarsal cushions,of the middle layer may provide further support to the toe areas,. In some embodiments, the middle layer may have an elastomeric padding creating thickness in the heel regions,so as to create heel cushions,. In many embodiments, the precise shape of the cushions in the middle layer may vary. Additionally, the thickness of the cushions in the middle layer may vary. For example, the middle layer heel cushion may have a greater thickness than the middle layer ball cushion or the middle layer metatarsal cushions. Any combination of these or other cushions in the middle layer may be utilized in accordance with embodiments of the invention.

In addition, in some embodiments, middle layers may have cushions that are not right foot and left foot specific. These embodiments may allow the user to easily match up a pair of socks without needing to consider left and right orientations. Such embodiments may also provide for more efficient manufacturing. A bottom view of an inner layerand middle layer of a multi-layered sock where the right and left socks have similarly shaped middle-layer cushions in accordance with an embodiment of the invention is illustrated in. In some embodiments, the shape of the middle layer ball cushionin the toe regionof sockmay be symmetric. Further, in the heel region, the shape of the heel cushionof the middle layer may be symmetric. In many embodiments, the shape of the various cushions such as, but not limited to the ball cushionand the heel cushionmay be the same whether the sock is a left sock or a right sock. As described above, the symmetric nature of the cushion paddings may allow for such embodiments. In various embodiments, the middle layer may have a thickness utilizing elastomeric padding such that other middle layer cushions may be present. In some embodiments, the middle layer may have greater thickness in only one region, creating a cushion in only one area. For example, the middle layer may only have a thickness in the ball region of the foot, creating a ball cushion. In some embodiments, the shape of the middle layer cushions may differ from those depicted in the figure. The shape of the middle layer cushions may differ depending on the activity of the user.

Additional cushions in the ankle region may provide additional support and movement reduction during activities that involve shoes with ankle protection. Such physical activity may include activities such as, but not limited to, hiking, skiing, or basketball. A cross-sectional view of a multi-layered sock with ankle cushions in accordance with an embodiment of the invention is illustrated in. The sockmay have middle layer ankle cushionsin the ankle region. There may be one or more ankle cushion(s). The ankle cushionmay help reduce blister formation that may occur at the ankle region when the user's ankle is in contact with an external surface. In several embodiments, the outer layermay fully encapsulate the ankle middle layer cushion(s)by covering the inner layer. The middle layer being encapsulated may allow for greater comfort for the user. The middle layer being encapsulated may also increase the durability of the middle layer cushions by keeping the middle layer cushions,from being exposed to an external environment.