Abstract:
A sock having a toe portion, a heel and ankle portion, and a body portion disposed between the heel and ankle portion is disclosed. The body portion may comprise one or more elastic panels, which are incorporated in a manner to allow the sock to fit a wider range of standard foot sizes than a similar sock lacking the elastic panels disclosed herein.

Description:
FIELD OF THE INVENTION 
     The present invention relates to socks. More particularly, the invention relates to socks that are relatively highly stretchable. 
     BACKGROUND OF THE INVENTION 
     Standard market size ranges are provided for socks, such that a sock of a particular size range is capable of being worn by any person with a foot within that size range. An example of standard sock size ranges commonly used by a number of sock manufacturers in Australia is set out below:— 
     
       
         
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
             
           
               
                   
                   
               
               
                   
                   
                 Standard size range 
                   
               
               
                   
                 Category 
                 for each sock size 
                 Ages 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Infants 
                 000-00  
                 0-6 
                 mths 
               
               
                   
                   
                 00-1  
                 6-12 
                 mths 
               
               
                   
                   
                 1-2 
                 1-3 
                 yrs 
               
               
                   
                   
                 2-4 
                 3-5 
                 yrs 
               
               
                   
                 Children 
                 5-8 
                 5-8 
                 yrs 
               
               
                   
                   
                  9-12 
                 8-10 
                 yrs 
               
               
                   
                   
                 13-3  
                 10+ 
                 yrs 
               
             
          
           
               
                   
                 Teens 
                 2-8 
                 Teens 
               
               
                   
                 Adults - Men 
                  6-10 
                 Teens up 
               
               
                   
                   
                 11-14 
                 to adults 
               
               
                   
                 Adults - Women 
                 3-8 
                 Teens up 
               
               
                   
                   
                  6-10 
                 to adults 
               
               
                   
                   
               
             
          
         
       
     
     Infants&#39; and children&#39;s feet grow at such a rapid rate that shoes and socks are typically grown out of before they are worn out. Currently, if a parent buys socks for their child that is one year old and has a size 1 foot, the child can wear that sock for a maximum of two years until he or she has outgrown the sock and needs to move to a bigger size. If the child needs new socks when they are two and a half years old, with a size 2 foot, then the child can only wear the sock for six months before it is too small. However, the next size range up would be too big for the child&#39;s foot, as it is sized to fit up to a size 4. 
     As shown by the above table there are currently twelve different sock size ranges. This requires a manufacturer to produce twelve versions of everything from labels and packaging to shipping boxes. Retail outlets are required to provide shelf space for each type of sock in the different ranges. This means that in the infant department, each type of sock takes up four spaces. In the children&#39;s/teens department each type also takes up four spaces. In each of the men&#39;s and women&#39;s departments two spaces are required. 
     It is therefore an object of the present invention to provide a sock, or a collection of socks, that overcomes at least some of the above-mentioned problems. 
     SUMMARY OF THE INVENTION 
     In accordance with the invention, it has been realised that the objective can in part be met by the recognition that it is feasible to depart from the standard sock size ranges. 
     The invention provides, in a first aspect, a sock having a toe portion and a heel and ankle portion joined by a generally tubular body portion, wherein the body portion is formed in a composite fabric of an elastane and one or more other components such that the elastane density varies in the body portion in a manner effective to allow the sock to fit a wider range of standard foot sizes than for a similar sock having uniform elastane density in the body portion. 
     Preferably, said elastane density varies in the body portion by virtue of the body portion including one or more panel(s) of relatively higher elastane density separating, in a direction extending from the toe portion to the heel and ankle portion, panels of relatively lower elastane density. 
     Advantageously, a stitch length of the thread e.g. the course length, in the relatively higher elastane density panel(s) is greater than for the corresponding stitches in the panels of relatively lower elastane density. 
     In one embodiment, the respective panels of relatively higher and lower elastane density may conveniently be continuous bands arranged alternatively in said body portion of the sock. In a preferred embodiment, there is provided a single continuous band of relatively higher elastane density. The single band is advantageously positioned generally at the centre of the tubular body portion. The single band is typically positioned in that part of the sock that, when worn, is at the arch of the foot. 
     The invention provides, in a second aspect, a sock having a toe portion and a heel and ankle portion joined by a generally tubular body portion, wherein the body portion is formed in a composite fabric of an elastane and one or more other components and the body portion has one or more panels in which the stitch length of the thread, e.g. the course length is greater than for the corresponding stitches in the remainder of the sock. 
     Preferably, the composite fabric of said panels of relatively lower elastane density also forms said toe portion and said heel and ankle portion. 
     In the second aspect, the panel(s) may comprise one or more continuous bands arranged in said body portion of the sock. This may be a single continuous band. The single band is advantageously positioned generally at the centre of the tubular body portion. The single band is typically positioned in that part of the sock that, when worn, is at the arch of the foot. 
     In general, the density of the elastane in the panels of relatively higher elastane density may be between 1.5 and 3 times, for example about twice, the density of the elastane in the panels of relatively lower elastane density. 
     In an embodiment, the composite fabric comprises Lycra™ as the elastane and Nylon as another component. For the panels of relatively lower elastane density, suitable fabric is around 92% Nylon and 8% Lycra, in which case a suitable fabric for the panels of relatively higher elastane density is around 60% Nylon and 40% Lycra. As an alternative to Nylon, cotton may be used. In another suitable form of the invention, the higher elastane density material may be 60% Cotton and 40% Lycra. Typically, the higher elastane density panels have a 20% stronger recovery than the lower elastane density panels. 
     In another preferred embodiment, the fabric includes two threads, 2/30 ECC (English cotton count) cotton plated with around 92% Nylon and 8% Lycra. The panels of relatively higher elastane density include an additional thread of around 55% Nylon and 45% Lycra. In another preferred embodiment, the fabric includes two threads, 1/14 corespun ECC cotton plated with around 92% Nylon and 8% Lycra. The panels of relatively higher elastane density include an additional thread of around 60% Nylon and 40% Lycra. 
     In a further preferred embodiment, the fabric includes two threads. The panels of relatively higher elastane density include a substitute thread of higher elastane density. For example, a thread of 92% Nylon and 8% Lycra is replaced with a thread of 60% Nylon and 40% Lycra in the panel of relatively higher elastane density. 
     The invention provides, in a third aspect, a sock having a toe portion and a heel and ankle portion joined by a generally tubular body portion, wherein the body portion is formed in a composite fabric of an elastane and one or more other components and the body portion has one or more panels with at least one additional thread of elastane provided in each course in the panel(s) to provide a relatively higher elastane density than in the remainder of the sock. 
     The heel sub-portion of the heel and ankle portion, and the toe portion, may be reinforced with additional Nylon on the fabric, e.g. on the outside of the fabric. This may be affected by reverse plating with extra Nylon. 
     The sock is advantageously a sock sized to be worn by children. In this case, the wider range of standard foot sizes preferably consists of four or more Australian or U.S. infants foot sizes, for example 000 to 1, or six or more non-infants children&#39;s sizes, for example 1 to 5 or 13 to adult 5 (both six standard size ranges), or 6 to 14 (a nine standard size range). 
     In a fourth aspect, the invention provides a collection of socks differing only in size, intended to be displayed for sale at a common location, which socks are so formed in composite fabric of an elastane and one or more other components that the socks of the collection have only four distinct sizes able to fit feet over the children&#39;s size ranges, e.g. Australian sizes: infant 000-adult 5. 
     The fourth aspect of the invention is advantageously effected by socks according to the first, second or third aspect of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described, by way of example only, with reference to the accompanying drawing, which: 
         FIG. 1  is a side view of a sock according to a first embodiment of the present invention; 
         FIG. 2  is a side view of a sock according to a second embodiment of the present invention; 
         FIG. 3  is a side view of a sock according to a third embodiment of the present invention; 
         FIG. 4  is a diagrammatic representation of a cross-section of the threads forming a sock according to the present invention; and 
         FIG. 5  is a diagrammatic representation similar to  FIG. 4  of a sock according to another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     As can be seen from  FIG. 1 , a sock  10  is provided having a toe portion  12  and a heel and ankle portion  14 . The heel and ankle portion  14  comprises a heel sub-portion  16  and an ankle sub-portion  18  having a suitable elastic cuff portion  19  formed integrally with the upper end of the ankle sub-portion  18 . The heel and ankle portion  14  is joined to the toe portion  12  by a generally tubular body portion  20 . 
     The sock  10  is formed in the conventional manner using a standard circular knitting machine. 
     The body portion  20  is formed in a composite fabric of elastane and one or more other components, such as Nylon, cotton or any other suitable yarn. The elastane is preferably, spandex such as Lycra™. The elastane density varies in the body portion  20  by virtue of having one or more panels  22  of relatively higher elastane density separated in a direction extending from the toe portion  12  to the heel and ankle portion  14  by panels  24  of relatively lower elastane density. 
     The panels  22  of relatively higher elastane density and the panels  24  of relatively lower elastane density are formed as continuous bands arranged in succession in the body portion  20 . The continuous bands extend around the entire body portion  20  in the direction of the courses of knitting. It will be appreciated that while the bands  22 ,  24  illustrated in  FIG. 1  are of a uniform width, the width of the bands may vary and may take alternative forms, such as having a zig-zag profile. The bands  22 ,  24  may be knitted and dyed in a uniform colour such that the bands are not clearly visible. Alternatively, the bands may be shaped and dyed to create a pattern or visual feature on the sock. 
     The panels  22  of relatively higher elastane density have typically twice the elastane density as the panels  24  of relatively lower elastane density. Such a composite fabric for the lower elastane density panels  24  could be around 92% Nylon and 8% Lycra, with the higher elastane density panels  22  being around 60% Nylon and 40% Lycra. The higher elastane density panel will typically have a minimum of 20% stronger recovery than the lower elastane density panel. 
     The elastane density of the toe portion and heel and ankle portion will typically be of the same or similar density as the lower elastane density panels  24 . The toe portion  12  and heel sub-portion  16  will generally be reverse plated with extra Nylon on the outside of the fabric. 
     In the sock  100  illustrated in  FIG. 2 , there is provided a single continuous band  122  of relatively higher elastane density separating, in a direction extending from the toe portion  112  to the heel and ankle portion  114 , panels  124  of relatively lower elastane density. The location of the band  122  is generally in the centre of the body portion  120 , being at approximately the arch of the foot. The fabric includes two threads, 2/30 ECC (English cotton count) cotton plated with around 92% Nylon and 8% Lycra. The panels of relatively higher elastane density include an additional thread of around 55% Nylon and 45% Elastane. This particular construction is suited to a type of sock commonly referred to as a ‘School trainer’. 
     In the sock  200  illustrated in  FIG. 3 , there is again provided a single continuous band  222  of relatively higher elastane density separating, in a direction extending from the toe portion  212  to the heel and ankle portion  214 , panels  224  of relatively lower elastane density. The fabric includes two threads  230 ,  232  (shown in  FIG. 4 ), 1/14 corespun ECC cotton plated with around 92% Nylon and 8% Lycra. The panels of relatively higher elastane density include an additional thread  234  of around 60% Nylon and 40% Lycra. This particular construction is suited to a type of sock commonly referred to as a ‘School crew’ or ‘knee hi’. 
     As can be seen from  FIG. 4 , as well as an additional thread of Lycra-Nylon in the band  222 , the length of the course stitches (or the course length) for all three threads  230 ,  232 ,  234  is greater in this section. The combination of these features allows the band  222  to stretch approximately three times its relaxed measurement, and the use of the additional elastane allows it to fully recover after use. 
       FIG. 5  shows an alternative solution to that shown in  FIG. 4 . Instead of the additional thread  234 , the second thread  232  is replaced in the band  222  with an alternate thread  233 . The substitute thread is around 60% Nylon and 40% Lycra rather than 92% Nylon and 8% Lycra. 
     The advantage of the relatively higher elastane density panels  22  are their high stretch and high recovery. As the stretch of the panels  22  is relatively high, the body portion  20  of the sock  10  is able to vary in a manner effective to allow the sock  10  to fit a wider range of standard foot sizes than for a similar sock having uniform elastane density in the body portion. The body portion  20  is able to stretch in length and in diameter, such that as a foot grows, the sock is able to stretch to the larger foot size in the size range. The relatively high recovery rate allows the body portion  20  to consistently regain its smaller, unstretched size when not being worn. 
     An example of sock size ranges for a collection of socks according to the present invention is set out below:— 
     
       
         
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
             
           
               
                   
                   
               
               
                   
                   
                 Size range for 
                   
               
               
                   
                 Category 
                 each sock size 
                 Ages 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Infant 
                 000-1   
                 0-18 
                 months 
               
             
          
           
               
                   
                   
                 1-5  
                 18 mths-3 yrs 
               
             
          
           
               
                   
                   
                 6-12 
                 3-6 
                 years 
               
               
                   
                 Children 
                 13-5  
                 6-10 
                 years 
               
             
          
           
               
                   
                   
                 5-10 
                 Teens 
               
               
                   
                 Adults - men 
                 6-14 
                 Teens up to 
               
               
                   
                 Adults - women 
                 3-10 
                 adults 
               
               
                   
                   
               
             
          
         
       
     
     As shown by the above table the number of size ranges have been reduced from twelve to seven. As can be seen, the infant size ranges have been reduced from four to two. Only one sock size range each is required for men and women to cover all of their sock sizes. The sock  10  being able to fit a wider range of standard foot sizes means that manufacturers can reduce the number of different socks produced, additionally reducing costs associated with packaging and transport. Retail outlets will be able to reduce the shelf space for each type of sock, allowing them to increase their diversity of product. 
     One of the biggest advantages of the sock construction is that, within one household, socks  10  can be worn by several different children. By producing a sock that is able to grow with the child, a child is less likely to out-grow their socks before they wear them out. This reduces the number of socks that parents are required to buy as their child progresses through the sock size ranges. The ability for children of different ages and sock sizes to share their socks means that the variety of different socks required by a household can be reduced, reducing overall clothing costs for a household. 
     It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.