Toe Sock Elastic Part Wrinkle Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional toe socks are uncomfortable to wear due to stiffness caused by contraction deformation during the backstitching process, and the manufacturing process is complex, making them inconvenient and less marketable.
Innovation Solution
Toe socks with toe holes formed by vertical backstitch using stretch yarn (rubber thread) to create a wrinkled elastic part, which allows for easy toe insertion and maintains open shape, along with a vent hole for air permeability and backstitch indication lines for uniform stitching without additional jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vertical backstitch is used to form toe holes between toe sections, then the manufacturing process is simplified and appearance quality is improved, but the toe sock becomes stiff and uncomfortable to wear due to contraction deformation
Solution Approach 1:
The patent changes the material parameter of the backstitch yarn from ordinary yarn to elastic yarn containing rubber threads. This parameter change allows the backstitch region to maintain elasticity and flexibility, preventing the stiffness and discomfort caused by contraction deformation while preserving the simplified manufacturing process and appearance quality benefits of vertical backstitching.
2Device complexity
If ordinary yarn is used for backstitch, then the manufacturing process is simple, but the backstitch region contracts and narrows causing discomfort
Solution Approach 1:
The patent modifies the physical-chemical parameter of the yarn by incorporating elastic rubber threads into the backstitch yarn composition. This parameter change enables the backstitch region to maintain its width and prevent contraction deformation, solving the shape distortion problem while keeping the manufacturing process relatively simple through vertical backstitching.
3Manufacturing precision
If additional foot-shaped jig is inserted for backstitch positioning, then backstitch position accuracy is improved, but workability is decreased and manufacturing complexity increases
Solution Approach 1:
The patent implements self-service by incorporating backstitch indication lines directly into the sock body during the knitting process. These visible lines automatically guide the backstitch positioning without requiring external jigs or additional positioning devices, thereby maintaining manufacturing precision while significantly improving workability and reducing manufacturing complexity.
Solution Approach 2:
The backstitch indication lines are formed in advance during the knitting process before the backstitching operation. This preliminary action of creating visual guides during knitting eliminates the need for complex positioning jigs during the subsequent backstitching step, improving both precision and productivity.
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 toe socks provide comfortable and convenient wear with reduced contraction deformation, improved appearance quality, and enhanced marketability through the use of stretchable elastic parts and vent holes, while simplifying the manufacturing process.
Implementation Method 1
a portion for forming toe holes by backstitch is formed as a wrinkled elastic part by weaving with stretch yarn (rubber thread)
Implementation Method 2
enhanced marketability through the use of stretchable elastic parts and vent holes
Data Source
AI summary
The present invention relates to: a toe sock having toe holes, which are formed by vertically backstitching between the toes of a sock and into which the toes are separately inserted; and a manufacturing method therefor and, more specifically, provided is a part, which has toe holes formed by vertically backstitching between the toes of a sock, formed into a flexible elastic part (20), wherein the elastic part (20) is manufactured by being woven with a flexible yarn and continuously forming wrinkles (22) flexible in the widthwise direction, thereby enabling the toes to be conveniently inserted and worn by the flexible movement of the elastic part (20) and providing an excellent appearance quality because of the low contraction deformation of the appearance of the sock.