Sock Knitted Straps Elastomeric Yarn Integration
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Solution Overview
Problem
Traditional sock laces require additional post-processing steps for attachment, increasing manufacturing costs and time, and can be difficult for wearers with disabilities to use due to their design.
Innovation Solution
The integration of knitted straps into the sock body using a circular knit machine, where elastomeric yarns create a tubular-like structure with curled longitudinal edges, allowing for secure attachment and easy manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional laces are used and attached in post-processing, then the sock can be secured to the wearer's foot, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the lace and sock body into a single integrated knitted structure. The lace is formed as an integral part of the sock during the knitting process itself, eliminating the need for separate attachment steps. This is achieved through a circular knit machine that knits the lace and sock body simultaneously, reducing manufacturing complexity while maintaining the secure fit function.
Solution Approach 2:
The lace structure is prepared and formed during the main knitting process before the sock is completed. The circular knit machine knits the lace portion first, then continues to knit the sock body, so that when the sock is finished, the lace is already in place and ready for use, eliminating post-processing attachment steps.
2Reliability
If traditional laces are used and attached in post-processing, then the sock can be secured to the wearer's foot, but the manufacturing time increases
Solution Approach 1:
The patent combines the lace formation and sock manufacturing into a single continuous knitting process. The circular knit machine performs both operations without interruption, producing a complete sock with integrated lace in one cycle, thereby increasing manufacturing speed and productivity.
Solution Approach 2:
The knitting process continues uninterrupted from forming the lace to completing the sock body. The circular knit machine maintains continuous operation, with the lace portion knitted first and the sock body knitted immediately afterward, eliminating idle time and post-processing steps to maximize productivity.
3Reliability
If traditional braided or woven laces are used, then the laces can secure the sock, but they are difficult for wearers with disabilities to manipulate
Solution Approach 1:
The patent changes the physical parameters of the lace by knitting it with elastomeric yarn that provides stretch and elasticity. This creates a more flexible, softer, and more compliant lace structure that is easier to manipulate for wearers with disabilities, while still maintaining the ability to secure the sock effectively through elastic tension.
Solution Approach 2:
The patent uses composite yarn construction, combining elastomeric fibers with other fibers to create a lace that has both structural integrity for securing and sufficient flexibility for easy manipulation. The elastomeric component provides stretch and recovery, making the lace more user-friendly while maintaining functional performance.
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
This approach reduces manufacturing steps, enhances the sock's secure fit and ease of use, particularly for individuals with disabilities, by eliminating the need for separate lace attachment and providing a tubular shape that aids in donning.
Implementation Method 1
at least a portion of the plurality of knitted courses comprises an elastomeric yarn
Data Source
AI summary
Aspects herein are directed to a sock having a first knitted strap extending from a lateral aspect of a collar of the sock, and a second knitted strap extending from a medial aspect of the collar of the sock. Each of the first knitted strap and the second knitted strap is knit with a plurality of courses extending from a first longitudinal edge to a second longitudinal edge of the respective knitted strap where at least a portion of the courses are formed using an elastomeric yarn. Use of an elastomeric yarn extending widthwise across each knitted strap causes the longitudinal edges of the knitted strap to curl toward a respective longitudinal midline along the technical back of the knitted strap which, in turn produces a tubular-like shape for each of the first knitted strap and second knitted strap.