Integrally Knit Sock Tab for Donning and Doffing
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Solution Overview
Problem
Traditional sock tabs added in post-manufacturing steps often lack effective positioning and structural integrity for easy donning and doffing, and may not withstand repeated use.
Innovation Solution
An integrally knit tab is incorporated into the sock, positioned interior to the collar, with a two-layer construction and ribs for enhanced durability and traction, allowing the tab to act as a primary structure for donning and doffing while reducing wear-and-tear on the collar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a tab is added in a post-manufacturing step by stitching, then the tab can be positioned to assist donning and doffing, but the manufacturing process becomes more complex and the tab lacks structural integrity
Solution Approach 1:
The tab is integrally knit with the sock body as a single continuous structure, merging the tab formation with the main sock manufacturing process. This eliminates separate stitching operations and ensures the tab has the same structural integrity as the rest of the sock, while still providing the necessary function for easy donning and doffing.
2Productivity
If the tab is formed with the sock in an integral manner, then manufacturing steps are reduced, but the tab is often not positioned to effectively help the wearer
Solution Approach 1:
The tab is positioned specifically at the interior surface of the collar, which is the optimal location for assisting donning and doffing. This localized positioning ensures that the tab provides effective help to the wearer while being integrated into the overall sock structure during manufacturing.
3Ease of manufacture
If the tab is made with single-layer construction, then manufacturing is simpler, but the tab lacks durability to withstand repeated use
Solution Approach 1:
The tab is constructed with a two-layer knit structure, creating a composite construction that enhances durability and withstands repeated use. The layered construction provides structural strength while maintaining ease of manufacture through integral knitting processes.
4Ease of operation
If the tab extends beyond the collar, then it is more visible and accessible, but it increases wear-and-tear on the collar
Solution Approach 1:
The tab acts as an intermediary structure that extends from the interior surface of the collar outward. This positioning allows the tab to be accessible and visible for donning and doffing operations while the collar itself remains protected from direct wear and tear, as the tab serves as the primary stress-point handling element.
Data Source
Figure 1
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AI summary
Aspects herein are directed to a sock (100) having an integrally knit, two-layered tab (112) positioned interior to a collar (110) of the sock, where the collar defines an opening for a wearer's foot. By positioning the tab interior to the collar, the tab can be used to assist the wearer in donning and/or doffing the sock by acting as the primary structure by which the wearer pulls an elastic collar around the wearer's foot when donning the sock.