Double-Layer Sock Cushion Patches for Heel and Ball Support

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Solution Overview

Problem

Existing double-layered socks are bulky, prone to slippage, and may not provide adequate cushioning and support for the heel and ball areas of the foot, which can lead to discomfort and pain during physical activities.

Innovation Solution

A double-layered sock design featuring elastomeric cushion patches made of silicone or similar materials, integrated between the outer and inner layers, with a honeycomb structure for enhanced cushioning and support at the heel and ball areas, using manufacturing methods that include folding and affixing the patches within a single continuous fabric tube.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If double-layered socks are used to provide enhanced insulation and warmth, then the sock becomes bulkier, but this makes it less comfortable in tight-fitting shoes

Engineering Contradiction:

Improveinsulation and warmthVSAvoidbulkiness

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

The patent applies local quality by placing cushion patches only at specific high-impact areas (heel and ball of foot) rather than uniformly throughout the sock. This allows targeted thermal insulation and cushioning where needed most, while keeping other areas thin and flexible for comfort in tight-fitting shoes.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The sock is segmented into multiple functional layers: an inner layer, an outer layer, and discrete cushion patches positioned between them. This segmentation allows each layer to serve its specific function (insulation, protection, cushioning) without requiring the entire sock to be bulky.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If double-layered socks are used to reduce friction and prevent blisters, then the inner layer rubs against the outer layer, but this sliding creates slippage and makes walking less comfortable

Engineering Contradiction:

Improvefriction reduction and blister preventionVSAvoidwalking comfort

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The cushion patches are permanently attached to both the inner and outer layers, merging these previously separate sliding layers into a unified structure at critical areas. This eliminates slippage between layers while maintaining the friction-reducing benefit of the double-layer design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cushion patches are pre-positioned and permanently affixed to the layers during manufacturing, ensuring proper alignment and preventing any sliding or slippage before the sock is worn. This preliminary attachment resolves the slippage issue that plagues conventional double-layered socks.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If polymer cushions and patches are added to socks to provide targeted cushioning and shock absorption, then the added thickness may make it challenging to fit into some shoes, but the cushioning enhances comfort and alleviates pressure

Engineering Contradiction:

Improvepressure and shock absorptionVSAvoidthickness

Core Design Contradiction:

Object-affected harmful factorsVSVolume of moving object

Solution Approach 1:

Cushion patches are strategically positioned only at the heel and ball of foot areas where pressure and shock are greatest. This localized approach provides maximum cushioning benefit while minimizing overall thickness, allowing the sock to fit into shoes with snug or narrow designs.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cushion patches use elastomeric materials with specific durometer ranges (Shore A 20-40) that provide optimal balance between cushioning softness and structural stability. This parameter optimization ensures adequate shock absorption without excessive thickness that would prevent fitting into certain shoes.

Inventive Principle:

Principle #35Parameter changes

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 design provides targeted cushioning and support, reducing pressure points and enhancing comfort, while maintaining flexibility and fit, and can extend the sock's lifespan by distributing weight evenly across the foot.

Implementation Method 1

The cushion patch is provided in the form of one or more elastic patches having a honeycomb structure that provides cushioning for the foot

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12490777B2Sock and a method of knitting a sock

Publication Date: 2025.12.09 MATTER TAYLOR

AI summary

A method of producing a double-layered sock with a cushion patch positioned between an external and an internal layer of yarn or fabric is provided. The method comprises the external layer over the internal layer of a tubular lay flat fabric. The method also comprises attaching a first polymer cushion patch to the external or internal layer about two inches from one end. The method also comprises a step of attaching a second polymer cushion patch to the external layer about five inches from the first cushion patch. After drawing the external layer over the internal layer, the cushion patch is encased inside the sock. The cushion patch has a honeycomb grid pattern and includes one or two areas of high compression having larger hexagonal cells designed to distribute high compression impact away and throughout the cushion patch, thereby improving user comfort during walking or running.