Double ply sock and method of making same

• US 5,778,702 A
• Filed: 09/06/1996
• Issued: 07/14/1998
• Est. Priority Date: 09/06/1996
• Status: Expired due to Term

• Current Assignee: Jerry O. Wrightenberry
• Original Assignee: Jerry O. Wrightenberry
• Inventors: Wrightenberry, Jerry O.
• Primary Examiner(s): CALVERT, JOHN JAMES
• Application Number:
  US08/708,252
• Time in Patent Office: 676 Days
• Field of Search: 66/196, 66/171, 66/178 R, 66/185, 2/239
• US Class Current: 66/178.00R
• CPC Class Codes: A41B 11/005 Hosiery made essentially of a multi-ply construction
• CPC Class Codes: A41B 2400/34 antimicrobial or antibacterial
• CPC Class Codes: D04B 1/26 stockings
• CPC Class Codes: D10B 2401/021 hydrophobic
• CPC Class Codes: D10B 2401/022 hydrophylic
• CPC Class Codes: D10B 2403/023 Fabric with at least two, predominantly unlinked, knitted or woven plies interlaced with each other at spaced locations or linked to a common internal co-extensive yarn system

Abstract

A double layer sock has an inner ply having a foot portion that is undyed and a dyed outer ply covering the inner ply and joined to the inner ply at an upper end of the inner and outer plies. The inner ply is formed of antimicrobial and/or hydrophobic yarns.

A method of making a double ply sock includes knitting a singular tubular garment having a first section formed of undyed yarn and a second section of dyed yarn. The undyed section is inserted into the dyed section forming a two-ply construction having an undyed inner ply.

Claims

1. A hygienic, moisture management sock comprising a unitary, continuous tube of knitted material having a first end and a second end, said tube folded about a fold line such that a first portion of said tube extending between said fold line and said first end forms an outer ply and a second portion of said tube extending between said fold line and said second end forms an inner ply disposed within and substantially coextensive with said outer ply, said first end closed to form an outer toe portion, said second end closed to form an inner toe portion, said inner and outer plies each including a tubular foot portion, and wherein at least the entirety of said foot portion of said inner ply is undyed and said outer ply is at least partially dyed.

2. The sock of claim 1, wherein a common seam closes each of said first and second ends.

3. The sock of claim 1, wherein said outer ply is completely dyed.

4. The sock of claim 1 wherein said inner ply includes a dyed band immediately adjacent said fold line and an undyed upper portion extending between said dyed band and said foot portion of said inner ply.

5. A method of making a hygienic, moisture management two ply sock, comprising the steps of:

a) knitting a singular tubular garment having a first continuous section and a second continuous section, the first section being formed of undyed yarn and the second section being formed of dyed yarn;

b) inserting the first section into the second section so as to form a two-ply construction having an inner ply including at least the first section and an outer ply including the second section, the construction having a folded end and an open end opposite the folded end, the inner and outer plies being substantially coextensive and each having a tubular foot portion, the foot portion of the inner ply formed from the first

c) closing the open end.

6. The method of claim 5, wherein said step of knitting includes knitting the first section from an antimicrobial yarn.

7. The method of claim 5, wherein said step of knitting includes knitting the first section from a hydrophobic yarn.

8. The method of claim 5, wherein said step of knitting includes knitting the first section from hydrophobic and antimicrobial yarn.

9. The method of claim 5, wherein said step of knitting includes knitting the tubular garment so as to further include a third, dyed section between the first and second sections, and wherein said step of inserting includes inserting the third section into the second section along with the first section so that the inner ply includes the third section adjacent the folded end.

10. A hygienic, moisture management sock comprising a unitary, continuous tube of knitted material having a first end and a second end, said tube folded about a fold line such that a first portion of said tube extending between said fold line and said first end forms an outer ply and a second portion of said tube extending between said fold line and said second end forms an inner ply disposed within and substantially coextensive with said outer ply, said first end closed to form an outer toe portion, said second end closed to form an inner toe portion, said inner and outer plies each including a tubular foot portion, wherein at least the entirety of said foot portion of said inner ply is undyed and said outer ply is at least partially dyed;

and wherein at least said foot portion of said inner ply is knit from hydrophobic yarns.

11. The sock of claim 10, wherein a common seam closes each of said first and second ends.

12. The sock of claim 10, wherein said inner ply is knit from antimicrobial yarns.

13. The sock of claim 10, wherein said outer ply is completely dyed.

14. The sock of claim 10, wherein said inner ply includes a dyed band immediately adjacent said fold line and an undyed upper portion extending between said dyed band and said foot portion of said inner ply.

15. The sock of claim 10, wherein said inner ply is undyed in its entirety.

16. A hygienic, moisture management sock comprising a unitary, continuous tube of knitted material having a first end and a second end, said tube folded about a fold line such that a first portion of said tube extending between said fold line and said first end forms an outer ply and a second portion of said tube extending between said fold line and said second end forms an inner ply disposed within and substantially coextensive with said outer ply, said first end closed to form an outer toe portion, said second end closed to form an inner toe portion, said inner and outer plies each including a tubular foot portion, wherein at least the entirety of said foot portion of said inner ply is undyed and said outer ply is at least partially dyed;

and wherein at least said foot portion of said inner ply is knit from antimicrobial yarns.

17. The sock of claim 16, wherein a common seam closes each of said first and second ends.

18. The sock of claim 16, wherein said outer ply is completely dyed.

19. The sock of claim 16, wherein said inner ply includes a dyed band immediately adjacent said fold line and an undyed upper portion extending between said dyed band and said foot portion.

20. The sock of claim 16 wherein said inner ply is undyed in its entirety.

21. A hygienic, moisture management sock comprising a unitary, continuous tube of knitted material having a first end and a second end, said tube folded about a fold line such that a first portion of said tube extending between said fold line and said first end forms an outer ply and a second portion of said tube extending between said fold line and said second end forms an inner ply disposed within and substantially coextensive with said outer ply, said first end closed to form an outer toe portion, said second end closed to form an inner toe portion, said inner and outer plies each including a foot portion, wherein at least the entirety of said foot portion of said inner ply is undyed and said outer ply is at least partially dyed;

and wherein said foot portions are formed of plain stitches.

22. The sock of claim 21, wherein a common seam closes each of said first and second ends.

23. The sock of claim 21, wherein said inner ply is knit from hydrophobic yarns.

24. The sock of claim 21, wherein said inner ply is knit from antimicrobial yarns.

25. The sock of claim 21, wherein said inner ply is knit from antimicrobial and hydrophobic yarns.

26. The sock of claim 21, wherein said outer ply is completely dyed.

27. The sock of claim 21, wherein said inner ply includes a dyed band immediately adjacent said fold line and an undyed upper portion extending between said dyed band and said foot portion.

28. The sock of claim 21, wherein said inner ply is undyed in its entirety.

29. A hygienic, moisture management sock comprising a unitary, continuous tube of knitted material having a first end and a second end, said tube folded about a fold line such that a first portion of said tube extending between said fold line and said first end forms an outer ply and a second portion of said tube extending between said fold line and said second end forms an inner ply disposed within and substantially coextensive with said outer ply, said first end closed to form an outer toe portion, said second end closed to form an inner toe portion, said inner and outer plies each including a foot portion, wherein at least the entirety of said foot portion of said inner ply is undyed and said outer ply is completely dyed, wherein at least said foot portion of said inner ply is knit from hydrophobic, antimicrobial yarns, and wherein said foot portions are formed of plain stitches.

30. The sock of claim 29, wherein a common seam closes each of said first and second ends.

31. The sock of claim 29, wherein said inner ply includes a dyed band immediately adjacent said fold line and an undyed upper portion extending between said dyed band and said foot portion.