Composite Athletic Sock Yarn for Abrasion Resistance and Moisture Management
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Solution Overview
Problem
Athletic socks lack sufficient abrasion resistance, moisture management, and comfort, leading to discomfort and shifting during physical activity.
Innovation Solution
A sock made from a yarn combination of 35-75% Coolmax®, 15-35% cotton, and 10-30% Lycra® fibers, with specific zones for compression and terry construction to enhance fit and moisture wicking, providing improved abrasion resistance and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sock is made from traditional single-material yarn, then it is easy to manufacture, but it lacks sufficient abrasion resistance and moisture management
Solution Approach 1:
The patent applies composite materials by combining polyester, cotton, and spandex fibers in a single yarn construction. This multi-material approach provides superior abrasion resistance from polyester, moisture management from cotton, and elastic fit from spandex, resolving the contradiction between durability and manufacturing simplicity by integrating multiple functions into one composite yarn rather than requiring separate zones or layers
Solution Approach 2:
The patent implements multi-functionality by designing a single yarn that simultaneously delivers abrasion resistance, moisture wicking, and elastic compression. This universal yarn construction eliminates the need for complex multi-zone sock designs, maintaining ease of manufacture while achieving multiple performance benefits in one integrated material system
2Reliability
If a sock uses portions or zones with different fiber types for moisture management, then moisture management improves, but the sock structure becomes more complex
Solution Approach 1:
The patent merges multiple fiber types (polyester, cotton, spandex) into a single uniformly constructed yarn. This consolidation approach achieves moisture management functionality throughout the entire sock without requiring complex zoned constructions, thereby improving moisture management while minimizing structural complexity
Solution Approach 2:
The patent applies homogeneity by creating a uniform yarn composition that is consistent throughout the entire sock. This homogeneous multi-fiber yarn provides uniform moisture management properties across all sock areas, eliminating the need for heterogeneous zoned constructions and simplifying the overall sock structure
3Reliability
If a sock is made from cotton and elastane only, then comfort is improved, but abrasion resistance is insufficient
Solution Approach 1:
The patent uses composite materials by adding polyester to the cotton-elastane combination. The polyester component provides the necessary abrasion resistance and durability, while cotton maintains comfort and moisture management, and elastane provides elastic fit. This tri-component composite resolves the contradiction by assigning specific functions to each fiber type within a unified yarn structure
Solution Approach 2:
The patent applies parameter changes by modifying the fiber composition ratio to include polyester, cotton, and spandex in specific proportions (e.g., 65-80% polyester, 10-30% cotton, 5-20% spandex). By adjusting these compositional parameters, the yarn achieves optimal balance between abrasion resistance from polyester and comfort from cotton-elastane, resolving the performance contradiction through controlled material parameter optimization
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sock demonstrates superior abrasion resistance and comfort, maintaining fit and moisture management during extended wear, outperforming conventional athletic socks in both tests and user evaluations.
Implementation Method 1
Coolmax® is a mark of Invista North America S.A.R.L. of Wilmington, Del., for four-channel polyester fibers that are formed together in cross-sections to allow air to flow through the fabric
Implementation Method 2
Lycra®, also known as spandex or elastane, is also a mark of Invista for a lightweight, stretchy fiber formed from a polyurethane-polyurea copolymer
Data Source
AI summary
An athletic sock formed from a yarn comprising Coolmax® polyester fibers, cotton fibers and Lycra® polyurethane-polyurea copolymer fiber. The sock has a toe portion, at least one compression portion, a heel and ankle portion, and an upper band at the top portion of the sock.