Composite Waterproof Sock Two-Way Extensibility
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Solution Overview
Problem
Existing waterproof breathable socks lack stretchability and size flexibility, leading to discomfort and limited fit, and often allow water to enter during wading activities due to non-ideal adhesive and hydrophilic film contact.
Innovation Solution
A composite sock design featuring a one-step forming mould with knitted outer and inner layers using fine twisted elastic yarns and a corrugated intermediate waterproof breathable film, providing two-way extensibility and an in-cuff water seal kit for enhanced fit and water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproof breathable film is laminated using cut and sew method, then waterproof performance is achieved, but stretchability and comfort are reduced
Solution Approach 1:
The sock is divided into multiple knitted panels (toe panel, heel panel, instep panel, etc.) that are separately constructed and then joined. This segmentation allows each panel to maintain its knitted elasticity while the overall structure achieves waterproofing through panel construction rather than film lamination, resolving the contradiction between waterproof performance and stretchability.
Solution Approach 2:
The sock incorporates dynamic elastic elements including elastic bands at the cuff, elastic gussets at the toe and heel, and stretchable knitted panels that adapt to foot movement. This dynamic construction maintains waterproof integrity while providing continuous stretchability and comfort during outdoor activities.
2Ease of operation
If discrete adhesive dots are used to bond layers, then some extensibility is achieved, but the waterproof film becomes corrugated and size flexibility is limited
Solution Approach 1:
The adhesive bonding method is completely removed from the construction process. Instead of using discrete adhesive dots that create corrugated structures, the invention uses mechanical joining methods (seams and panels) that preserve the flat, flexible nature of the waterproof film while achieving the desired extensibility through knitted panel construction.
Solution Approach 2:
The sock incorporates dynamic elastic elements including elastic bands at the cuff, elastic gussets at the toe and heel, and stretchable knitted panels that adapt to foot movement. This dynamic construction maintains waterproof integrity while providing continuous stretchability and comfort during outdoor activities.
3Ease of operation
If elastic threads are laid circumferentially to enable lateral recovery, then circumferential stretchability is improved, but longitudinal extensibility and size flexibility remain insufficient
Solution Approach 1:
The sock is divided into multiple knitted panels (toe panel, heel panel, instep panel, etc.) that are separately constructed and then joined. This segmentation allows each panel to maintain its knitted elasticity while the overall structure achieves waterproofing through panel construction rather than film lamination, resolving the contradiction between waterproof performance and stretchability.
Solution Approach 2:
The invention transitions from single-direction (circumferential) elasticity to two-directional elasticity by incorporating elastic elements in multiple orientations and dimensions, including circumferential elastic bands, longitudinal elastic gussets, and diagonal stretch panels, enabling the sock to accommodate various foot sizes and shapes.
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 solution results in a comfortable, form-fitting sock with extended durability and size flexibility, effectively preventing water ingress while maintaining breathability and waterproof performance.
Implementation Method 1
an intermediate waterproof and breathable film
Implementation Method 2
waterproof breathable film
Implementation Method 3
fine twisted elastic yarns
Implementation Method 4
corrugated intermediate waterproof breathable film
Implementation Method 5
bonded together
Data Source
AI summary
A composite waterproof breathable sock with two-way extensible properties, wherein each sock is formed by lamination of an outer layer, an inner layer and an intermediate waterproof and breathable sock-like film component on a one-step forming mould. The outer layer, or both the outer and inner layers, is/are knitted by deploying fine twisted elastic yarns consistently into all the knitting courses of the main body for each such layer, so as to make the composite sock therefore extensible in both weft X and warp Y directions after lamination of the layer(s) to the waterproof film component such that the composite sock will be recoverable uniformly after stretching to a relaxed conformation. The composite sock can be sewn with a water seal kit inside the cuff band, wherein the cuff band is extended from the outer component of the sock. The in-cuff seal kit can be constructed by a sew-in waterproof polyurethane elastic fabric in round shape.