Double sock construction

A double sock construction comprising inner and outer tubular socks each terminating at one end in a closed toe portion of reduced thickness. The inner and outer socks are joined at their ends opposite their toe portions to form a fold line. The inner sock is shorter than the outer sock, which feature coupled with the reduced thickness of the toe portions, prevents bunching of the toe of the double sock.

BACKGROUND OF THE INVENTION 
The present invention relates generally to socks for outdoor cold-weather 
wear and relates more particularly to a novel double sock construction. 
It is a fairly common practice among those who spend time outdoors in cold 
weather to wear two pairs of socks under insulated boots. Those who engage 
in hunting, hiking, skiing, snowmobiling, etc. have long appreciated the 
advantages of wearing a relatively thin soft inner sock in engagement with 
the foot, and a thick outer sock to provide insulating bulk and a 
comfortable cushioning of the foot. 
Although the practice of wearing two pairs of socks is relatively 
widespread, it is an inconvenient practice due to the need to provide two 
pairs of socks which together provide a compatible and comfortable fit 
with respect to a particular pair of boots. There is accordingly much 
trial and error in selecting appropriate inner and outer socks to 
accomplish this purpose. Generally, the outer sock should be a larger size 
than the inner sock but in some instances, the next larger size may prove 
too large to be accommodated within the shoe or boot space. There is 
additionally the problem of obtaining socks of suitable materials both as 
to thickness, comfort, durability and absorbency. Finally, there is a 
tendency for the inner sock to work downwardly with respect to the outer 
sock, and to work its way into an unreachable condition, requiring the 
removal of the boot and both pairs of socks in order to be correctly 
repositioned. This can be time consuming, annoying, and, under frigid 
conditions, dangerous as it permits exposure of uncovered skin to freezing 
conditions. 
Suggestions have, in the past, been made for the combining of two pairs of 
socks into a double sock. Difficulties were encountered, however, in 
aligning the inner sock with the outer sock so that the heel portions of 
each were proximate the heel of the wearer. Attempts to sew both the toe 
and the ankle portions of the inner and outer socks together did not 
wholly alleviate this problem and furthermore made washing of the double 
socks difficult. Furthermore, foreign matter could be trapped between the 
two sock layers and removal could be difficult. 
A further difficulty with previous double sock constructions as well as 
with the wearing of two separate pairs of socks together has been the 
discomfort experienced due to the bunching of the sock toe portions. Such 
bunching is normally associated with a sliding movement of one sock with 
respect to the other and with respect to the foot. One of the socks or 
sock portions, and normally the inner one, drifts downwardly resulting in 
discomfort in the toe region as well as a loss of the insulating and 
cushioning function of the sock in the region from which it has descended. 
BRIEF SUMMARY OF THE INVENTION 
The present invention comprises a double sock construction including inner 
and outer tubular socks which are joined at their upper ends along a fold 
line. The inner sock is shorter than the outer sock in length and the toe 
portions of both the inner and outer socks are of reduced thickness. Both 
the inner and outer socks are preferably knit with some stretch yarns to 
provide length-wise stretch of the socks. The inner sock may be withdrawn 
from the outer sock by turning it inside out to facilitate washing or the 
removal of foreign matter. The inner sock is preferably knit of a soft 
absorbent yarn such as cotton to provide a comfortable surface in 
engagement with the foot, while the outer sock may be knit of a bulkier 
yarn such as wool having good insulating and cushioning properties. 
It is accordingly a first object of the present invention to provide a 
double sock construction which is comfortable to wear and which may be 
readily put on and removed. 
It is a further object of the invention to provide a double sock 
construction as described wherein the inner sock may be easily withdrawn 
from the outer sock to facilitate washing or removal of foreign matter. 
Still another object of the invention is to provide a double sock 
construction as described which by utilizing stretch yarns need be made in 
only a few sizes which will accommodate a wide range of foot sizes. 
A still further object of the invention is to provide a double sock 
construction as described which will have the appearance of a single sock. 
Another object of the invention is to provide a double sock construction as 
described wherein the inner and outer socks are secured against relative 
downward movement. 
A still further object of the invention is to provide a double sock 
construction as described which is adapted to manufacture on automatic 
knitting machines. 
Additional objects and advantages of the invention will be more readily 
apparent from the following detailed description of an embodiment thereof.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring to the drawings, a double sock generally designated 10 in 
accordance with the present invention comprises an inner sock 12 and an 
outer sock 14. Both the inner and outer socks are of a tubular knit 
construction. One end of the inner sock 12 is sewn closed to form a toe 
portion 16 and, similarly, one end of the outer sock 14 is sewn closed to 
form a toe portion 18. The inner and outer socks are circumferentially 
joined along their respective ends opposite the toe portions 16 and 18 in 
a manner forming a fold line 20 which establishes the upper end of the 
double sock. The inner and outer socks are joined only at the fold line 20 
and the inner sock may accordingly be withdrawn from the outer sock as 
illustrated in FIG. 1 by turning the inner sock inside out. This is the 
preferred disposition of the sock for washing and also permits the removal 
of foreign matter which may have found its way into the inner sock. 
As shown in FIGS. 2 and 3, the inner sock in its relaxed state is somewhat 
shorter in length than the outer sock, a feature of considerable 
importance in providing a comfortable fit of the double sock. In addition, 
the toe portions 16 and 18 of the inner and outer sock are each of a 
reduced thickness with respect to the body of the socks as shown in FIG. 
3. 
The inner and outer socks are preferably knitted of different materials 
best suited to carry out their respective functions. The inner sock is 
preferably knitted predominently of cotton yarn with some stretch nylon 
added to produce the desired amount of resilience particularly in the 
lengthwise direction. In the embodiment illustrated, the body portion 22 
of the inner sock is of a rib knit structure and accordingly provides a 
relatively smooth, soft and absorbent surface in engagement with the 
wearer's foot. The inner sock toe portion 16 should preferably be formed 
predominently of a fine count cotton yarn to provide a flat fabric having 
substantially less thickness than that of the body portion 22. The toe 
portion 16 is sewn closed to form an arcuate end seam 24. 
The body portion 26 of the outer sock 14 is in the illustrated embodiment 
knitted in a basket weave construction of predominently wool yarn to 
provide a relatively thick insulating and cushioning outer layer. A 
certain degree of stretchability in the longitudinal direction is achieved 
by adding elastic yarn such as stretch nylon in an amount which will 
substantially equalize the stretchability of the inner and outer socks. 
The toe portion 18 of the outer sock 14 is, in a manner similar to that of 
the inner sock toe portion, formed of a finer yarn to produce a flat and 
thinner fabric. The closed end of the toe portion 18 is formed by sewing a 
closing seam 28 in an arcuate path which in the flattened condition of the 
double sock lies in the same plane as the seam 24 of the inner sock toe 
portion. The arcuate shape of the respective inner and outer sock toe 
portions need not be identical but should be compatible to conform with 
the wearer's foot. 
The upper ends of the inner and outer socks respectively terminate in rib 
knit cuff portions 30 and 32 which desirably contain a higher percentage 
of elastic yarns to hold the upper end of the double sock in place on the 
wearer's leg. The open ends of the cuff portions 30 and 32 are joined at 
the fold line 20 which as illustrated in FIGS. 3 and 4 includes a number 
of transverse elastic yarns 34 which are knitted circumferentially to 
define the fold line. The knitting of the fold line or welt at the upper 
end of the double sock provides a smoothly finished sock edge having the 
appearance of a single pair of socks. Furthermore, the knitted edge 
construction permits an accurate control of the length of the inner and 
outer socks and a strong and long-wearing connection of the inner and 
outer portions. This construction is adapted for manufacture on automatic 
knitting equipment in a continuous operation with only the cutting and 
sewing of the toe closures being required to complete the double socks. 
Although it might be feasible to form the upper edge of the double sock by 
sewing the inner and outer sock upper ends together, the sewn joint would 
not be as attractive in appearance nor would it permit as accurate a 
control of the relative lengths of the inner and outer socks. 
For application to a wearer's foot, the socks are disposed in the condition 
shown in FIGS. 2 and 3 with the inner sock disposed within the outer sock 
and the respective toe portions in parallel alignment. The foot is then 
inserted into both socks simultaneously with the toes substantially in the 
same plane as the toe portions of the inner and outer socks to achieve the 
most comfortable fit. In view of the shorter relaxed dimension of the 
inner sock, the inner sock will conform closely to the wearer's foot 
whereas the outer sock will conform in a somewhat looser manner and fill 
the available toe space in the boot or shoe. 
The shorter length of the inner sock as well as the reduced thickness of 
the toe portions of both the inner and outer socks combine to prevent 
bunching of sock material in the toe region which is a primary cause of 
discomfort when wearing two pairs of socks or double socks of other 
constructions. Although the relative lengths of the inner and outer socks 
may vary depending upon the overall sock length, the materials used in the 
respective sock portions and the knitting construction, in the embodiment 
illustrated which depicts a boot length sock, the inner sock is 
approximately 10% shorter than the outer sock. As indicated, this 
percentage could change depending upon the construction of the socks and 
on the amount of elastic yarn utilized in the inner and outer socks. 
Manifestly, changes in details of construction can be effected by those 
skilled in the art without departing from the spirit and scope of the 
present invention.