Triangular Ankle Panels in Knit Socks for Secure Fit
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Solution Overview
Problem
Commercially manufactured socks, particularly footies, often have a circular opening at the ankle area that can result in an inadequate fit, as the circular knitting process does not effectively secure the foot, leading to potential slippage and discomfort.
Innovation Solution
A method of knitting socks using a circular knitting machine that incorporates medial and lateral triangular ankle panels, creating a non-circular opening, such as an oval shape, which provides a better fit by using specific needle configurations to form these panels with elastic yarn, allowing for a more secure and comfortable fit around the ankle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circular opening is used at the ankle area, then the manufacturing process is simple, but the fit around the ankle is inadequate
Solution Approach 1:
The ankle opening is segmented into multiple sections: a front panel, a back panel, and lateral panels connecting them. This segmentation allows each panel to be shaped independently to match the contours of the ankle, providing a better fit while still using circular knitting machinery. The front panel covers the instep area, the back panel contours to the heel and Achilles tendon, and the lateral panels connect these sections, creating a non-circular opening that adapts to the ankle's geometry.
Solution Approach 2:
Different portions of the ankle opening are given different qualities and shapes to match specific anatomical features. The front panel is shaped to fit the instep, the back panel is contoured for the heel and Achilles tendon area, and the lateral panels bridge these regions. This local differentiation of panel shapes and elastic properties provides a customized fit for each region of the ankle, improving overall fit precision without requiring completely different manufacturing processes.
2Manufacturing precision
If a non-circular opening is created, then the fit around the ankle is improved, but the knitting process becomes more complex
Solution Approach 1:
The knitting process dynamically adjusts needle participation based on the panel being knitted. Different sets of needles are activated for different panels: front panel needles, back panel needles, and lateral panel needles. This dynamic reconfiguration of needle usage allows the creation of complex non-circular shapes while using a single circular knitting machine, avoiding the need for multiple specialized machines or excessively complex fixed needle arrangements.
3Reliability
If elastic yarn is used in triangular panels, then the secure fit is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The triangular panels are designed with asymmetric properties to match the asymmetric anatomy of the ankle. The front panel extends further forward to cover the instep, the back panel is positioned to accommodate the heel and Achilles tendon, and the lateral panels are angled to follow the natural contours. This asymmetric configuration, combined with elastic yarn, provides a secure fit that adapts to the wearer's anatomy while maintaining manufacturability through systematic needle assignments.
Data Source
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AI summary
A knit garment is provided to be worn on the foot that has a toe, foot, and heel area. The garment also has a medial triangular ankle panel and a lateral triangular ankle panel. The medial triangular ankle panel has a first medial vertex near the rear, top portion of the foot area, a second medial vertex near the top of the heel area, and a third medial vertex below and between the first and second medial vertices. The lateral triangular ankle panel has a first lateral vertex near the rear, top portion of the foot area, a second lateral vertex near the top of the heel area, and a third lateral vertex below and between the first and second lateral vertices. The sides of the medial and lateral triangular panels extending between the respective first and second medial and lateral vertices define an opening of the garment for a foot.