Zone-Variable Layer Sock Design for Friction and Ventilation
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Solution Overview
Problem
Current dual-layer socks face issues such as poor ventilation, odor buildup, and discomfort due to overlapping seams, as well as manufacturing complexities and increased costs from separately knitting and attaching inner and outer layers.
Innovation Solution
A sock design featuring zones with varying numbers of layers, where a double-layer zone provides cushioning and friction reduction, and a single-layer zone enhances perspiration evaporation, manufactured from a continuous tube with strategically aligned and attached layers to prevent bunching and twisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two pairs of socks are worn simultaneously, then cushioning and blister prevention are improved, but ventilation deteriorates causing athlete's foot and odor
Solution Approach 1:
The sock is divided into multiple zones with different layer configurations. The first zone (toe area) has a double layer structure for blister prevention, while the second zone (upper sock area) has a single layer for ventilation. This segmentation allows each area to serve its specific function optimally.
Solution Approach 2:
Different parts of the sock have different structural properties tailored to local needs. The toe area receives enhanced protection through double layer construction, while the upper portions maintain breathability through single layer design, ensuring each region has the quality it requires.
2Reliability
If two pairs of socks are worn simultaneously, then cushioning is improved, but overlapping seams cause abrasion and discomfort
Solution Approach 1:
The invention merges the functions of two separate socks into a single integrated garment. The double layer first zone provides cushioning equivalent to two socks, while the unified construction eliminates overlapping seams that would otherwise cause abrasion and discomfort.
3Stability of the object's composition
If inner and outer socks are knitted separately and attached, then layer independence is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The invention combines the manufacturing of what would traditionally be two separate socks into a single continuous knitting process. The sock is formed as one integrated piece with varying layer zones, eliminating the need for separate knitting and attachment operations while maintaining structural integrity.
Solution Approach 2:
The sock is designed with pre-determined fold lines and zone divisions that are built into the knitting pattern itself. This preliminary structuring during the knitting process eliminates the need for post-manufacturing alignment and attachment operations.
4Ease of manufacture
If inner socks are not attached to outer socks, then manufacturing is simplified, but layers move independently causing bunching and twisting
Solution Approach 1:
The invention merges the layers into a single continuous knitted structure that maintains layer alignment throughout. The varying zone design with strategic fold lines ensures that inner and outer layers remain properly positioned relative to each other without requiring separate attachment operations.
Data Source
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AI summary
A sock (400) with zones of varying numbers of layers is formed as a single tube (200) on a circular knitting machine. At least one end of the tube (200) is doubled back over a portion of the remainder of the tube (200) to form a double layer zone (408). The sock (400) further may include a single layer zone (408) adjacent to the double layer zone (408), where no such folding occurs.