Custom-fit sock and method of making the same

A custom-fit sock is described. The sock includes a tubular body formed from a number of courses and wales. The tubular body includes a foot portion and a leg portion merging substantially at the ankle of a wearer. The foot portion defines a foot bottom portion and an upper instep portion and further includes a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion. A first course includes a first number of stitches formed using a first number of selected needles of the circular knitting machine. The first number of selected needles is less than a total number of needles of the circular knitting machine.

FIELD OF THE INVENTION

The present disclosure relates generally to custom-fit socks, and more particularly to socks having a customized number of stitches in each course.

BACKGROUND

In general, conventional socks are formed by knitting the hem or welt first, followed by the leg, heel, foot, and then toe. After the toe is knit, a seam is formed to attach the opposite sides of the toe pocket to each other, closing the toe. Conventional socks may be manufactured in a variety of sizes and may be designed for particular ages, genders, activities, and the like. Socks that do not conform to a wearer's foot may cause chafing, blisters, and other painful conditions, particularly for active individuals who spend a lot of time on their feet, such as professional athletes.

The inventor has identified a number of deficiencies and problems associated with the conventional socks and associated methods described above. Through applied effort, ingenuity, and innovation, many of these identified problems have been solved by developing solutions that are included in embodiments of the present invention, many examples of which are described in detail herein.

BRIEF SUMMARY

Embodiments of the invention described herein provide improved socks and methods for making the same. In particular, the inventor has identified a need for socks that are customized to fit the foot of a wearer. Accordingly, embodiments of the socks described herein are formed to conform more exactly to the foot of a wearer to provide an optimal fit.

Accordingly, embodiments of the invention provide a sock formed on a circular knitting machine from at least one yarn. The sock comprises a tubular body formed from a plurality of courses and wales and having a foot portion and a leg portion merging substantially at the ankle of a wearer. The foot portion defines a foot bottom portion and an upper instep portion and further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion. A first course comprises a first number of stitches formed using a first number of selected needles of the circular knitting machine, and the first number of selected needles is less than a total number of needles of the circular knitting machine.

According to certain embodiments, non-selected needles of the first course may be non-adjacent to other non-selected needles of the first course. In some embodiments, the first number of stitches may be determined via three-dimensional imaging of the foot of the wearer.

According to certain embodiments, a second course may comprise a second number of stitches formed using a second number of selected needles of the circular knitting machine. In some embodiments, the second number of selected needles may be less than the total number of needles of the circular knitting machine. In certain embodiments, the second course may be adjacent the first course. In further embodiments, the first number of selected needles may be different than the second number of selected needles. In some embodiments, non-selected needles of the second course may be non-adjacent to other non-selected needles of the second course. In further embodiments, the second number of stitches may be determined via three-dimensional imaging of the foot of the wearer.

In another aspect, a method of knitting a sock on a circular knitting machine is provided. In such a method, the sock comprises a tubular body formed from a plurality of courses and wales and having a foot portion and a leg portion merging substantially at the ankle of a wearer such that the foot portion defines a foot bottom portion and an upper instep portion and further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion. The method includes selecting a number of needles for each course to achieve a determined circumferential length of the course to custom fit the foot of a wearer, and knitting a first course. The first course comprises a first number of stitches formed using a first number of selected needles of the circular knitting machine, and the first number of selected needles is less than a total number of needles of the circular knitting machine.

According to certain embodiments, the method may further comprise providing a three-dimensional image of the foot of the wearer, and selecting the number of needles for each course to achieve the determined circumferential length of the course as determined by the three-dimensional image of the foot of the wearer. In some embodiments, non-selected needles of the first course may be non-adjacent to other non-selected needles of the first course.

According to certain embodiments, the method may further comprise knitting a second course. In some embodiments, the second course may comprise a second number of stitches formed using a second number of selected needles of the circular knitting machine. In further embodiments, the second number of selected needles may be less than the total number of needles of the circular knitting machine. In certain embodiments, the second course may be adjacent the first course. In further embodiments, the first number of selected needles may be different than the second number of selected needles. In some embodiments, non-selected needles of the second course may be non-adjacent to other non-selected needles of the second course. In certain embodiments, the method may further comprise closing the toe portion.

In yet another aspect, a knit article formed on a circular knitting machine from at least one yarn is provided. The article comprises a tubular body having a plurality of courses and wales such that a first course comprises a first number of stitches formed using a first number of selected needles of the circular knitting machine, and the first number of selected needles is less than a total number of needles of the circular knitting machine.

According to certain embodiments, the article may comprise a sleeve, a cuff, a pant leg, a shirt, a unitard, a waistband, an undergarment, a glove, or a sock. In some embodiments, non-selected needles of the first course may be non-adjacent to other non-selected needles of the first course. In further embodiments, the first number of stitches may be determined via three-dimensional imaging of a body part of a wearer to achieve a desired circumferential length.

According to certain embodiments, a second course may comprise a second number of stitches formed using a second number of selected needles of the circular knitting machine. In some embodiments, the second number of selected needles may be less than the total number of needles of the circular knitting machine. In certain embodiments, the second course may be adjacent the first course. In further embodiments, the first number of selected needles may be different than the second number of selected needles. In some embodiments, non-selected needles of the second course may be non-adjacent to other non-selected needles of the second course. In further embodiments, the second number of stitches may be determined via three-dimensional imaging of a body part of a wearer to achieve a desired circumferential length.

DETAILED DESCRIPTION OF THE DRAWINGS

Conventional socks may be manufactured in a variety of sizes and may be designed for particular ages, genders, activities, and the like. Socks that do not conform to a wearer's foot may cause chafing, blisters, and other painful conditions, particularly for active individuals who spend a lot of time on their feet, such as professional athletes. Other knit articles, like clothing items such as shirts, undergarments, and the like, may pose similar problems. For example, areas of excess fabric may bunch and apply excess pressure or friction to corresponding areas of contact with the wearer's skin as the wearer moves. Conversely, areas of fabric that are sized too small may cut off circulation or cause irritation to the wearer.

Through applied effort, ingenuity, and innovation, many of these identified problems have been solved by the inventor. Accordingly, embodiments of the invention provide improved custom-fit socks, methods for knitting custom-fit socks, and custom-fit knit articles that are designed to specifically match the configuration (e.g., size and shape) of the corresponding body part of the wearer on which the article is worn.

Turning now toFIG. 1, a custom-fit sock10is illustrated according to an example embodiment of the invention. The sock10may be single-layered or may be completely or partially knit of a double layer construction. In certain embodiments in which the sock includes double layer construction, such portions may be characterized by two layers being connected together at spaced apart locations during the knitting thereof, such as described in U.S. Pat. No. 6,612,136 and U.S. patent application Ser. No. 15/609,172, incorporated herein by reference. Turning to the sock in more detail, the sock10has foot portion12extending from a toe portion14to a heel portion16, and a leg portion18extending from the heel portion16of the foot portion12to a top opening (e.g., a cuff11) at its upper end. The foot portion12and the leg portion18merge substantially at the ankle of a wearer. The foot portion12also defines a foot bottom portion13and an upper instep portion15. The heel portion16is positioned adjacent the foot bottom portion13at a first end of the foot portion12, and the toe portion14is positioned adjacent the foot bottom portion13at a second end of the foot portion12. According to embodiments of the present invention, the sock10is formed from a plurality of courses C and wales W, with each course having a selected number of stitches customized to correspond the size of the course to a size of the foot of the wearer at a corresponding location. For example, a first course20, described in more detail below with regard toFIG. 2A, may comprise a first number of stitches, while a second course25, described in more detail below with regard toFIG. 2B, may comprise a second number of stitches that differs from the first number of stitches.

As shown inFIG. 2A, a configuration for a first course20may use a first number of selected needles22of the circular knitting machine. The first number of selected needles22may be less than a total number of needles of the circular knitting machine. The first course20may include a first number of stitches that corresponds to the first number of selected needles22. The non-selected needles24of the first course20may be non-adjacent to other non-selected needles of the first course.

For example, in the illustrated example ofFIG. 2A, the first course20includes 12 needles, numbered1-12. Of the 12 needles, needles1,3,5,6,7,9, and11are selected needles, such that these selected needles will be used to form stitches for the first course20. Thus, the first course20in this example will have seven (7) stitches. Needles2,4,8,10, and12are non-selected needles of the first course20. Thus, in this example, the five (5) non-selected needles will be prevented from forming stitches for the first course20. As a result, out of a maximum of 12 stitches, only 7 stitches will be formed for the first course20, such that a corresponding circumferential length of the first course20is shorter than the length if all of the needles (1through12) were used to form the stitches.

FIG. 2Billustrates a configuration for a second course25. The second course25may use a second number of selected needles26of the circular knitting machine. The second number of selected needles26may be less than a total number of needles of the circular knitting machine. The second course25may include a second number of stitches that corresponds to the second number of selected needles26. The non-selected needles28of the second course25may be non-adjacent to other non-selected needles of the second course. In the depicted embodiment of the sock10, the second course25is adjacent the first course20, and the first number of selected needles22is different than the second number of selected needles26.

For example, in the illustrated example ofFIG. 2B, the second course25includes 12 needles, numbered1-12. Of the 12 needles, needles2,4,6,8,10, and12are selected needles, such that these selected needles will be used to form stitches for the second course25. Thus, the second course25in this example will have six (6) stitches. Needles1,3,5,7,9, and11are non-selected needles of the second course25. Thus, in this example, the six (6) non-selected needles will be prevented from forming stitches for the second course25. As a result, out of a maximum of 12 stitches, only 6 stitches will be formed for the second course25, such that a corresponding circumferential length of the second course25is shorter than the length if all of the needles (1through12) were used to form the stitches.

In this regard, each course will have a certain number of selected needles and non-selected needles that will vary from course to course. Each course may be knit in the same direction in a circular formation in accordance with the arrangement of the circular knitting machine. The term “non-selected needle(s)”, as used herein, may generally refer to the process of holding back certain needles in a particular course so that these “non-selected needles” do not engage a thread. The non-selected needles may be non-adjacent both between courses and within the same course in order to prevent the visual appearance of a hole.

According to certain embodiments and as mentioned above, the number of selected needles (e.g., the first number of selected needles, the second number of selected needles, etc.) corresponds to the number of stitches in a course. In some embodiments, for example, the number of stitches in each course may be determined by measuring average foot circumference of a wearer at incremental points. In further embodiments, for instance, the number of stitches in each course may be determined via three-dimensional imaging of the foot of the wearer. For example, in some embodiments in which a course corresponds to a larger portion of the foot, the course may require a larger circumferential length. In such embodiments, for instance, a larger number of needles may be selected to remain in the active race. In other embodiments in which a course corresponds to a smaller portion of the foot, for example, the course may require a smaller circumferential length, and fewer needles may be selected to remain in the active race. For example, in a 200-needle knitting machine, reducing the circumference by 1% would remove 2 needles, and reducing the circumference by 5% would remove 10 needles. Such needles would be removed in the area where fabric is not needed. In further embodiments, only part of a course or several courses may use reduced needles to, for example, make a shape on one side of a sock. For instance, the number of stitches in the foot bottom could be reduced without reducing the instep or the sock. In this regard, each course may be tailored to a size of the corresponding portion of the body. The respective size information, as determined by, for example, three-dimensional imaging, may be input into the circular knitting machine, and the number and positioning of the selected and non-selected needles may be chosen accordingly.

In accordance with certain embodiments, the sock10may be knit on a conventional circular knitting machine having a cylinder and dial capable of knitting socks. In some embodiments, for example, the sock10may be knit on a 4-inch diameter 108-needle cylinder circular knitting machine. Other examples of such machines may include a 4-inch diameter 156-needle cylinder circular hosiery knitting machine with a cooperating dial having needles therein and with or without a LIN-TOE® toe closing device, and a 4-inch diameter 112-needle cylinder circular knitting machine with a cooperating dial and a LIN-TOE® device. Such knitting machines are conventionally provided with two yarn feeds that supply yarns to the cylinder and dial needles at spaced apart locations around the circular knitting machine. Although examples of dual feed circular knitting machines are provided, the sock may be knit on a machine with any needle count or cylinder diameter as understood by one of ordinary skill in the art, including, but not limited to, a single feed circular knitting machine, a circular knitting machine without a dial, and/or the like as long as the machine allows for needle-by-needle selection.

As shown inFIG. 3, the main yarn feed of the knitting machine (not shown) may feed a first yarn to the cylinder needles to form stitch loops32arranged in courses C1-C4and wales W1-W4.FIG. 3also illustrates an example of a stitch pattern resulting from a customized combination of selected needle stitches34and non-selected needle stitches (i.e., float stitches)36. Non-selected needle stitches36may be straight and may not form a stitch loop as with selected needle stitches34because the needle is not in action for non-selected needle stitches36. In some embodiments, and as shown in FIG.3, the non-selected needle stitches36(as also indicated by the arrows) may be made, for example, by every other needle in every other course. In such embodiments, the original stitch may remain on the needle until the next course, where the stitch may be knit off. In a portion of a course having a non-selected needle, the yarns may contract to form a course having a smaller circumferential length. In this regard, the number of non-selected needle stitches36and their locations within the sock may control the fit of the sock, with the circumferential length decreasing as the number of non-selected needle stitches36increases, the circumferential length decreasing in particular in the areas of the non-selected needle stitches36. For illustration only, the stitch pattern shown inFIG. 3is a plain or jersey stitch pattern, but one of ordinary skill in the art in light of this disclosure would understand that the sock10may be knit in any desired stitch pattern.

In some embodiments, the heel portion16and the toe portion14may be made via reciprocated knitting. Reciprocated knitting, according to certain embodiments, may refer to the process of selecting opposite needles to remain in the active race and removing the remaining needles to the inactive race during knitting. In general, because the opposite needles are reciprocating, the swing of the cylinder changes to match the active needles, such that the reciprocated portions (e.g., the heel portion16and the toe portion14) are knit back-and-forth rather than in the conventional circular manner. In other embodiments, however, reciprocated knitting may not be used in knitting the sock. For example, reciprocated knitting may not be used in forming a tube sock in accordance with certain embodiments. After the sock blank has been knit, the toe may be closed, such as by a LIN-TOE® device or seaming machine.

InFIG. 4, for example, a schematic block diagram is shown illustrating a method40of knitting a sock according to an example embodiment of the invention. As shown inFIG. 4, the method40may optionally include an initial step of providing a three-dimensional image of the foot of the wearer at block41. The method may further include selecting a number of needles for each course to achieve a determined circumferential length of the course to custom fit the foot of a wearer at block42, and knitting a first course at block43. The method may further optionally include knitting a second course at block44, and closing the toe portion at block45.

The sock10may be knit using any of various types of yarn in various weights as understood by one of ordinary skill in the art in light of this disclosure. In some cases, the selection of natural or synthetic yarn, textures, and patterns may depend on the anticipated use to which the socks may be put. For example, the sock10may be made thicker by selecting a higher weight yarn. As another example, the foot portion12, such as the heel portion16or the toe portion14of the foot portion12, may be formed using terry loops knit therein.

Further embodiments of the present invention may include a custom-fit knit fabric article. A knit fabric article may be formed on a circular knitting machine from at least one yarn. In some embodiments, for instance, the knit fabric article may comprise a sleeve, a cuff, a pant leg, a shirt, a unitard, a waistband, an undergarment, a sock, a glove, or any article that may be knit from at least one yarn on a circular knitting machine as understood by one of ordinary skill in the art.

According to certain embodiments, the knit fabric article may comprise a tubular body having a plurality of courses and wales. In some embodiments, a first course may comprise a first number of stitches formed using a first number of selected needles of the circular knitting machine. In further embodiments, a second course may comprise a second number of stitches formed using a second number of selected needles of the circular knitting machine. In certain embodiments, each of the first number of stitches and the second number of stitches may be determined via three-dimensional imaging of a body part of a wearer, as described above in more detail. The body part of the wearer that is imaged is dependent upon the desired knit fabric article and how it is meant to be worn (e.g., on what body part), as understood by one of ordinary skill in the art. In some embodiments, the non-selected needles of each of the first course and the second course are non-adjacent to other non-selected needles of the first course and the second course respectively. Each of the first number of selected needles and the second number of selected needles may be less than a total number of needles of the circular knitting machine, and the first number of selected needles may be different than the second number of selected needles. Moreover, the second course may be adjacent the first course in the knit fabric article, as described above.