Abstract:
A flexible garment combining knitted portions with an expansive panel comprised of materials and specifically four way stretch materials to accommodate a range of leg sizes and a method of producing a flexible garment with an expansive panel.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present general inventive concept is directed to a flexible garment for wearing on the foot and leg, and to the particular field of socks and stockings configured for adapting to different leg sizes. 
         [0003]    2. Discussion of the Related Art 
         [0004]    Currently socks are worn by a prevalent number of people. Socks such as knee socks cover the foot and the lower leg and are typically retained by elastic at the top of the sock known as the band or elastic band. Typically the band positioned at the top of the sock circumscribes the leg including the user&#39;s calf. The calf presents a larger circumference than the ankle. This presents a challenge for the sock to stay in position as gravity and the smaller circumference of the ankle both work to bias movement of the sock towards a position nearer the ankle Sufficient retaining force can mark the skin and cause irritation. The position of the band at the top of the sock can cause pressure marks on the leg of the wearer, and lead to discomfort as the retention of the sock is concentrated in one section of the garment that typically surrounds the larger section of the leg. The band of a sock is often ill suited for the size of a wearer&#39;s leg and can cause indentation or discomfort over time, or even be impossible to wear because the band of the sock cannot expand to receive a larger leg size. Attempts have been made to address this problem such as U.S. Pat. No. 6,536,051 to Oh wherein the elastic band is repositioned at the ankle. The &#39;051 Patent suggest the relocation of the elastic band. What is needed is a more accommodative garment that provides vertical retention that is distributed across the upper part of the garment and accommodates a wider range of leg sizes. 
         [0005]    Socks can have a range of sizes corresponding to a range of shoe sizes. For example, socks can be sold in size 12 indicating that the socks will be suitable for a user who wears a man&#39;s shoe sized 10½ to 11 or a woman&#39;s shoe size of 11½ to 12. The shortcoming of this system is that socks cover the ankle and calf portions of the leg while shoes do not. Shoes are not sized with any regard to the size of the wearer&#39;s leg and the numerical component of a shoe size merely reflects the distance from the toe to heel of a given foot. Width components of shoe sizes are not considered in sock sizes. Thus, when socks are sized, manufactured, and sold, they present no accommodation related to the size of the wearer&#39;s calf or leg. Not all humans have the same sized leg, even a sample population corresponding to a single shoe size does not have uniform leg size or calf circumference. Traditional socks, such as tube socks, are knitted or constructed in a continuous circumference with no knit-in heel or toe. More sophisticated sock manufacture inserts a separate heel and toe section, but still provides a nearly uniform circumference for the leg section or the part of the sock that covers the calf. Socks are knit on a circular knitting machine. The fact that they are knit on a circular knitting machine dictates the size of the garment. The circumference of the circular knitting machine will determine the size or circumference of the sock while the needle count will determine the thickness of the knitted sock. Because socks are knit, woven fabrics are unavailable in conventional sock construction known in the art. To construct a decorative pattern into the sock, additional yarns are used to provide different colors. These yarns further limit the amount of stretch available in the sock. A plain sock comprises yarns in an interlocking pattern and this provides a modest amount of cross stretch. To knit a decorative pattern into a sock, colored yarns are used. These yarns are carried on the inside of the sock when they are not incorporated into the pattern, and these yarns are called float yarns. Where they are present, but not knitted, they appear as straight yarns and are not interlocking, and therefore do not provide any cross stretch. Decorative patterned socks therefore provide less stretch and are less accommodative to leg sizes. 
         [0006]    What is needed is a garment that can be manufactured to accommodate the various sizes of wearers&#39; legs, and especially patterned, decorative socks that are visually appealing and can accommodate various leg sizes. 
       SUMMARY OF THE INVENTION 
       [0007]    It is an aspect of the present invention to provide an accommodating garment that can comfortably receive and cover a range of leg sizes. The present invention provides a garment with an expansive panel to provide accommodation to a range of leg and calf sizes. The expansive panel can be made of a material that provides sufficient tension to keep the garment in place along with sufficient elasticity to avoid discomfort and the indentations and markings that accompany socks that are too tight. In an aspect of the invention, the expansive panel comprises a four way stretch material to accommodate the shape of the wearer&#39;s leg. An additional aspect of the invention is to provide an aesthetically pleasing sock that appears to be a conventional sock with conventional appearance and patterning available. It is a further aspect of the invention to provide a garment for the foot that can cover the calf or mid calf without loss of fit or retention when placed onto legs of different sizes. An expansive panel can be located at the calf region of the garment adjacent to an ankle region or spaced apart from the ankle region of a garment. 
         [0008]    An additional advantage of the invention is that the compressive force to keep the sock up is distributed over a larger area, avoiding the impact of elastic present only at the top of the sock. A further advantage of the invention is that the sock avoids bagging and sagging. Advantages include improved fit, vertical retention, comfort of the wearer, avoidance of restricted circulation, aesthetic appeal available in different colors and patterns, a construction method that allows for conventional materials in the foot portion of the garment that provide for wicking such as cotton or other natural yarns, or synthetic yarns, or yarn blends. 
         [0009]    The above aspects can be obtained by a garment comprising an expansive panel to accommodate the geometry of a user&#39;s calf and ankle In an embodiment, a sock can be knit on a circular machine to provide interlocking yarns and cross stretch. The yarns, including float yarns, can be colored to provide an attractive pattern in the sock. Additionally, a stretch fabric such as a four way stretch fabric can be utilized within an expansive panel to allow a sock to accommodate a range of leg sizes. The expansive panel can be formed of a material such as spandex and located in a visibly discreet location to maintain the conventional and fashionable appearance of the garment. The expansive panel can be positioned into the upper rear section of the sock so that the front of the sock as well as the ankle of the sock appears to be a conventional sock. This provides the wearer with the full range of fashion alternatives instead of wearing a sock that appears to be utilitarian and unattractive. Provided herein is an article of manufacture, a flexible garment for the foot comprising a foot section configured to receive a foot of a wearer; a leg section configured to receive a portion of a leg of said wearer; and an expansive panel connected to said leg section and positioned to receive at least a portion of a calf region of the leg of said wearer, wherein said foot section is knitted, and said leg section is knitted. A product by process, a flexible garment comprising a foot section produced by knitting and configured to receive a foot of a wearer; a leg section produced by knitting and configured to receive a portion of a leg of said wearer; and an expansive panel connected to said leg section by stitching said expansive panel to said leg section to create a continuous U-shaped seam. A method of making a flexible garment comprising the steps of providing a knitted sock; removing a U-shaped cutout from said knitted sock; providing an expansive panel; and connecting said expansive panel to said knitted sock by joining means. 
         [0010]    These together with other aspects and advantages which will be subsequently apparent, reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, will become apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which: 
           [0012]      FIG. 1  is a side view of a human foot and leg 
           [0013]      FIG. 2  is a side view of a foot and leg of a human with a high body mass. 
           [0014]      FIG. 3  is a side view of a conventional sock. 
           [0015]      FIG. 4  is a side view of a knitted sock with a U-shaped cutout. 
           [0016]      FIG. 5  is a front view of an expansive panel in an embodiment of the invention. 
           [0017]      FIG. 6  is a perspective view of a garment in an embodiment of the invention. 
           [0018]      FIG. 7  is a perspective view of a garment in an embodiment of the invention worn by a person. 
           [0019]      FIG. 8  is a perspective view of a patterned garment in an embodiment of the invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0020]    Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. 
         [0021]    The present inventive concept relates to an accommodative garment, such as a sock, that combines a knitted sock with an expansive panel to provide a sock that will accept and conform to a variety of leg sizes. 
         [0022]      FIG. 1  presents a view of a human foot and lower leg. The human foot has several different features that provide for walking and standing. The toes  10  are in the front of the foot. The heel  12  is positioned at the back of the foot. The arch  14  is positioned at the bottom of the foot while the instep  16  is positioned at the top of the foot. The ankle  18  defines the transition between the foot and the lower leg  20 . The lower leg  20  generally presents a flat profile in the leg front  22 . The shin bone or tibia contributes to the geometry of the leg front  22 . The calf  24  is positioned at the rear of the leg. The rear of the leg presents an expanding profile so that the lower leg  20  presents ankle circumference  17  at the ankle  18  and a calf circumference  21  measured around the calf  24 . A typical woman&#39;s ankle can have a circumference of 8 to 11 inches and a typical calf can have a circumference of 13 to 14 inches. A typical man&#39;s ankle can have a circumference of 10 to 13 inches and a calf circumference of 14 to 17 inches. 
         [0023]      FIG. 2  presents a side view of a foot and leg of a human with a high body mass. While weight is distributed differently among people, most commonly the foot does not reflect increased body mass as much as the lower leg  30 . Ankle  19  may have an increased ankle circumference of 9 to 13 inches. Calf  34  may be increased in size and contribute to increased calf circumference  31  of from 15 to 17 inches and in some cases more than 17 to 24 inches. The leg front  32  still presents a relatively smooth profile dominated by the underlying shin bone, not shown. The calf  34  is shown as enlarged and presents a profile that slopes outward. Men and women can have calf sizes ranging to 24 inches or more. 
         [0024]      FIG. 3  presents a side view of a conventional sock. Socks are typically knitted on a circular knitting machine. Tube socks are knitted without any regard to foot geometry and are produced as a tube or cylinder that is closed at the bottom and remains open at the top for insertion of the foot. More sophisticated methods include incorporating a toe section and an arcuate heel section to increase conformity with the foot as shown in  FIG. 3 . Toe section  50  can be knitted and left open and then sewn to create a toe seam to close the cylinder of the foot section  55 , or produced by other methods known in the art. Foot section  55  can be produced by knitting and configured to receive a foot of a wearer. Heel section  52  is knit and finished on a boarding machine as is known in the art to create a heel curve or arcuate heel section. Heel section  52  helps to form the sock into an L shape so that it mimics the shape of the foot and lower leg. Leg section  51  comprises leg front  58  and leg rear  59 . Leg section  51  can be produced by knitting in a generally tube shape and configured to receive a portion of a leg of a wearer, and terminates in band  56  where the knitting is finished. Band  56  can be ribbed and can be formed of elastic materials such as expansive threads or yarns. Band  56  can be knitted around an elastic material such as an elastic band (not shown) or other expandable material to provide compression and retain fit when worn on the leg. The limitations of this approach are discussed above. 
         [0025]      FIG. 4  presents a side view of a knitted sock with a U-shaped cutout. In order to accommodate the larger leg features shown in  FIG. 2 , a knitted sock is provided, and the knitted material is partially removed and shown at the right of the figure. Cutaway  60  may be a U-shaped cutout. Cutaway  60  can be removed by cutting, with scissors, or other means known in the art. Use of a mechanical shear or other automated device can be employed to remove cutaway  60  such as a piercing or punching process analogous to the use of a punch and die. The size of cutaway  60  is a portion of leg rear  59  as shown in  FIG. 3 . Cutaway  60  is a portion of the leg section  51  and the size may vary depending on the height of the sock or garment. Removal of cutaway  60  reveals opening bottom  62 , opening first side  64 , opening second side  66 , first opening top  67  and second opening top  68 . After removal of cutaway  60 , leg section  51  is partially tubular; being tubular, with a continuous circumference near the ankle of a wearer, adjacent heel section  52 , and non-continuous where cutaway  60  has been removed. 
         [0026]      FIG. 5  is a front view of an expansive panel  70 . Expansive panel  70  can be parabolic shaped or U-shaped with panel bottom  72 , panel first side  74 , panel second side  76 , panel first top  77  and panel second top  78 . Panel border  79  is shown and defines the upper edge of the expansive panel. It can be understood that expansive panel  70  would be provided in a shape substantially similar to cutaway  60  to facilitate replacement of cutaway  60  with expansive panel  70 . 
         [0027]    Conventional materials such as cotton thread, wool yarn, etc. include little inherent elasticity and can be stretched to a limited degree. Different knitting patterns provide an interlocking web configuration that can be pulled or stretched to provide additional elasticity. However, most interlocking stitching provides for cross stretching in either a vertical or horizontal direction at a time. The interlocking threads or fibers can be form a diamond shape that can be pulled horizontally or vertically, or some combination, but the ability of the knit to expand is limited. Conventional socks can stretch from 20% to 50% of the sock circumference. 
         [0028]    A sock knitted with yarn composed of cotton/polyester/spandex blend in a proportion of 61/37/2% in a single solid color with no knitted patterns can provide a stretch of about 25% of the circumference of the garment. Desirable materials for expansive panel  70  include materials such as stretch lace and Spandex. Spandex can stretch up to almost 500% to provide significant elasticity. Stretch fabrics, or elastomerics such as spandex (aka elastane) are commonly used in clothing. Materials such as spandex provide a four way stretch and are known as four way stretch materials. One suitable spandex material can be utilized in an embodiment with a weight greater than 150 grams per square meter, and in another embodiment with a weight of about 200 grams per square meter. Another suitable material is lace spandex having a weight of about 120 grams per square meter. Four way stretch material having a weight of 80 g to 300 g per square meter can be suitable for providing an expansive panel. 
         [0029]    Stretch fabrics are produced by a flat knit machine with yarn or thread comprising spandex fibers that are inherently expandable, and the fabric will expand in all directions at the same time. This is known in the industry as four way stretch fabric. The fabric does not rely solely on interlock or cross stretch but provides elasticity to expand in all directions by utilizing yarn or threads that are elastic and can expand. It is known that feet perspire, and socks have been constructed from materials that provide cushioning and allow the moisture to wick away from the foot. Cotton socks, for example, provide both cushioning and wicking. Materials such as spandex can be too slippery to be optimal for a foot section  55  of a sock. The current invention combines the advantages of different materials to provide different functions in the areas of a sock where they are needed. Knitted socks and hosiery garments have been traditionally knitted on a circular knitting machine that produces a tubular garment with a consistent or fixed diameter, especially in the leg section of the garment. An expansive panel  70  can be connected to the leg section  51  of a knitted sock, replacing cutaway  60  as shown in  FIG. 4 . Expansive panel  70  can be finished at panel border  79  prior to attachment to leg section  51 . In one embodiment, panel border  79  is finished with an overlock hem, also known as a serged hem. The finished hem can be between ⅛ th  of an inch, and one inch, for example, to create a clean finish and create panel border  79 . One particular method of creating the overlock hem is to utilize an overlock machine to produce two straight rows of stitching on the outside surface (not shown) and an interlocked stitch on the inside surface (not shown) to prevent fraying of the material of expansive panel  70 . Other stitching known in the art can also be utilized to create panel border  79 . 
         [0030]    Expansive panel  70  is shown with panel width  73  and panel height  75 . In various embodiments, the shape of expansive panel  70  may vary. For example, in a child&#39;s sock, panel width  73  may be 2 inches while panel height may be 3 inches. In another embodiment, for example, a thigh high sock, panel width  73  may be 12 inches while panel height  75  maybe 30 inches. Other ranges of intermediate dimensions may be utilized to produce different hosiery, socks, or other garments. In most embodiments, panel height  75  will be 1.5 to 2.5 times greater than panel width  73 . Additional dimensions can be utilized in crew length socks and knee high length socks. 
         [0031]      FIG. 6  presents a perspective view of an expansive garment in an embodiment of the invention. Expansive panel  70  has been attached to the sock by joining means, namely sewing the expansive panel  70  to leg section  51  and the two can be connected by machine stitch and clean finished. A surger machine can be used to machine stitch and clean finish the seam. This provides what is known as a serged stitch or overlock stitch. Other joining means of attachment can be utilized. Joining means can include hand sewing, machine sewing, gluing, or heat fusing synthetic threads or yarns. A shown in  FIG. 6 , opening bottom  62  has been joined to panel bottom  72  opening first side  64  has been joined to panel first side  74 , opening second side  66  has been joined to panel second side  76 , panel first top  77  has been attached to first opening top  67 , while panel second top  78  has been joined to second opening top  68 . One method of attachment of expansive panel  70  is to turn the sock inside out, align the panel as described herein, and stitch the expansive panel  70  to the leg section  51  using a serged stitch or overlock stitch. Expansive panel  70  is connected to leg section  51  by stitching to create a single U-shaped seam  95  (as shown in  FIG. 7 ) extending from panel first top  77  to panel second top  78 . Upon turning the sock right side out, the stitching is hidden on the inside of the sock garment. Other joining means for attachment are suitable including hand sewing, machine sewing, adhesive glue, heat fusing or a combination of joining means. 
         [0032]    The expansive panel  70  of the invention provides the additional benefit of retaining the sock against drooping or sagging as the tension required to resist gravity is distributed across a greater area. Further, the garment of the present invention provides increased comfort. The retaining tension of a convention sock is concentrated at the band while the device of the present invention distributes the retaining tension through the area of the expansive panel  70 . Expansive panel  70  enables the sock to stretch and recover much more than the conventional sock. A sock in an embodiment of the invention with an expansive panel  70  composed of a four way stretch fabric can provide a stretch of about 100 % of the circumference of the garment. For example, a 100 % stretch can accommodate an ankle circumference of 12 inches and a calf circumference while maintaining position and comfort about both the ankle and the calf of the user. 
         [0033]    Four way stretch spandex fabric including stretch lace, stretch mesh, or spandex knits with high elasticity and recovery are suitable materials for expansive panel  70 . The expansive panel  70  can be incorporated into a variety of socks and garments including, but not limited to those made from cotton, polyester blend, nylon blend, cashmere, wool, silk, linen, or bamboo blend. Spandex is a polyester-polyurethane copolymer that provides desirable elasticity and durability and is widely used in garments. A full length sock from seven inches to 30 inches can be knit in the conventional manner on a circular knitting machine. 
         [0034]      FIG. 7  presents a side view of a flexible garment on the foot and leg of a person. As shown, the expansive panel  70  panel is expanded to accommodate a user&#39;s leg. Finished hem  80  is shown at the top of expansive panel  70 . U-shaped seam  95  is shown between leg section  51  and expansive panel  70 . Socks worn with pants are typically only visible below the hem or cuff of the pants and the ankle region of the sock is revealed. Positioning the expansive panel above the hem line of the pants means that it is not visible. The ankle section is visible and can look like a conventional sock made of conventional knitted materials. The portion of the finished garment as shown in  FIG. 7  that is tubular can surround the ankle of a user, not shown. This is the lower portion of leg section  51  adjacent to heel section  52 . The garment can accommodate an ankle of a wearer that has, for example, an ankle circumference of 10 inches shown as ankle circumference  19  in  FIG. 2 . The garment can expand as shown in the figure to accommodate a calf  34  that has a increased calf circumference  31  as shown in  FIG. 2 ; thus an embodiment of the invention can expand to accommodate a calf circumference of 20 inches representing 100 % garment expansiveness from the ankle region to the calf region of a wearer.  FIG. 7 , although not drawn to scale shows an approximate 50% increase in diameter from ankle to calf, corresponding to the leg shown in  FIG. 2 , and assuming circular geometry, this represents 100 % increase in circumference. 
         [0035]      FIG. 8  presents a perspective view of an embodiment of the invention as worn by a user. Numerous knitting patterns are known in the art and novel patterns are continuously created. Knitting can utilize threads of different colors to created knitted patterns that are appealing or fashionable. Socks and hosiery with patterns can be more visually appealing and attractive and therefore more desirable. The present invention allows for colored threads or colored yarns to be utilized in providing or constructing a knitted sock. At least two colors of yarn can be utilized to create a contrasting pattern knitted into the sock. The method of the present invention can utilize a sock with a pattern in a leg section  51  or in a foot section  55 . Novel or conventional patterns and designs can be incorporated into a circular knit sock by means known in the art or newly discovered.  FIG. 8  shows a flexible garment with pattern elements  82 ,  84 , and  86  present in leg section  51  and foot section  55 . Expansive panel  70  comprises four way stretch material and can be selected in a complimentary color to pattern elements, for example pattern element  82 . U-shaped seam  95  is shown between expansive panel  70  and leg section  51 . Finished hem  80  is shown at the top of expansive panel  70 . In one particular embodiment, float yarns can be present in leg section  51 , to create, for example pattern element  82 , and expansive panel  70  is free of float yarns. Similarly, float yarns can be present in foot section  55  to create, for example, pattern element  84  and pattern element  86 . 
         [0036]    Further, the materials operations described herein can be replaced by any sensible substitute materials. The many features and advantages of the invention are apparent from the detailed specification and, thus, it is intended by the appended claims to cover all such features and advantages of the invention that fall within the true spirit and scope of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact article e of manufacture illustrated and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.