Integrally Knit Athletic Sock With Zoned Grip and Breathability
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Solution Overview
Problem
Traditional athletic socks lack features such as zoned cushioning, zoned grip, zoned breathability, and fit, making them unsuitable for activities like running and hiking, which pose challenges like foot shifting, debris entry, sweating, and joint impact.
Innovation Solution
A knit sock with integrally knit ankle welts, zoned cushioning and breathability, and strategically positioned grip strips to enhance stability and comfort during athletic activities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional athletic socks are used, then they are simple and easy to manufacture, but they lack zoned cushioning, grip, and breathability needed for athletic activities
Solution Approach 1:
The sock is divided into multiple functional zones with different knit structures: cushioning zones with higher yarn density for impact absorption, breathability zones with lower yarn density for airflow, and grip zones with textured surfaces for traction. Each zone is independently designed and knitted to perform its specific function during athletic activities.
Solution Approach 2:
Different regions of the sock are assigned different material properties and knit densities tailored to local requirements. The heel and midfoot areas have higher cushioning density, while the instep and toe areas have optimized breathability. Grip elements are strategically placed on the sole contact points. This local differentiation resolves the contradiction by making the complex structure necessary for performance while keeping each local region relatively simple.
2Ease of operation
If zoned cushioning and breathability are implemented, then comfort and performance are improved, but manufacturing complexity increases
Solution Approach 1:
Multiple functional zones are integrated into a single continuous knit structure rather than assembling separate components. The cushioning, breathability, and grip zones are all formed in one knitting operation using programmed needle movements, which maintains manufacturing simplicity while achieving complex functional zoning. This merging approach resolves the contradiction by eliminating assembly steps while preserving comfort benefits.
3Stability of the object's composition
If grip strips are added to prevent foot shifting, then stability is improved, but the sock becomes more complex
Solution Approach 1:
The grip strips are designed with dynamic characteristics including varying heights, textures, and densities that adapt to foot movement and terrain conditions. The grip elements can compress and deform with foot motion while maintaining traction, and their distribution pattern changes with weight distribution during different activities. This dynamic design achieves stability without rigid complexity.
Solution Approach 2:
The grip strips utilize variations in knit parameters such as yarn density, stitch type, and fabric height to create different grip characteristics in different zones. By changing these parameters during the knitting process, the sock achieves multiple grip functions (heel grip, midfoot grip, toe grip) through a single integrated structure, resolving the contradiction between stability and complexity.
4Object-affected harmful factors
If ankle welts are integrally knitted to prevent debris entry, then protection is improved, but manufacturing precision requirements increase
Solution Approach 1:
The ankle welt is knitted as an integrated component during the initial sock formation process rather than being added as a separate protective element. The welt structure is built into the sock's foundational knit pattern, creating a pre-formed barrier that prevents debris entry from the outset. This preliminary integration resolves the contradiction by eliminating subsequent assembly steps and reducing precision requirements for separate components.
Data Source
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AI summary
A knit sock having a leg portion and an integrally knit ankle welt extending around a circumference of the leg portion and positioned at a lower end of the leg portion. The knit sock further includes an integrally knit tab located at a back aspect of the ankle welt.