Therapeutic compression and cushion sock and method of making

• US 7,441,419 B1
• Filed: 10/07/2005
• Issued: 10/28/2008
• Est. Priority Date: 10/07/2005
• Status: Expired due to Fees

• Current Assignee: Carolon Company
• Original Assignee: Carolon Company
• Inventors: Dollyhite, Darrell, Wilson, Rodney Eugene, Hicks, George T.
• Primary Examiner(s): WORRELL JR, LARRY D
• Application Number:
  US11/246,750
• Time in Patent Office: 1,117 Days
• Field of Search: 661/78.A, 661/78.R, 661/83, 661/72.E, 223/9, 234/0
• US Class Current: 66/178.00A
• CPC Class Codes: A61F 13/08 Elastic stockings; for contracting aneurisms
• CPC Class Codes: D04B 1/02 Pile fabrics or articles having similar surface features
• CPC Class Codes: D04B 1/108 Gussets, e.g. pouches or heel or toe portions
• CPC Class Codes: D04B 1/265 Surgical stockings of unspecified knit construction and reinforced A41B11/02; of unspecified knit construction and elastic A61F13/08

Abstract

A knitted therapeutic compression and cushion sock and a method for making such a sock include a terry-knit cushioning layer in selected bottom portions of the sock, allowing for greater ventilation and cooling in the top portion. The sock includes graduated zones of compressive pressures. Gradual changes in compressive pressures from one zone of compressive pressure to another can be provided by compression flaring, or changing the feed rate of elasticized yarn during knitting at or near the interface of two zones having different compressive pressures. Such a sock is useful for padding and compressing foot and leg areas to both prevent and treat vascular and skin conditions such as foot and leg ulcers.

Claims

1. A sock, comprising:

a base layer comprising an elasticized yarn;

a cushion layer integrally knit with the base layer in selected portions on an inside of the sock;

a compressive pressure construction in a plurality of selected circumferential zones of the sock, each of the zones capable of exerting a predetermined amount of compressive pressure on a wearer,

wherein each of at least two zones of compressive pressure construction comprises a different compressive pressure capability,

wherein the compressive pressure capability of each of the plurality of zones decreases from a distal portion of the sock to a proximal portion of the sock; and

a transition region between adjacent zones of compressive pressure construction, wherein the elasticized yarn is knit at a gradually increasing rate of feed to provide a gradually decreasing compressive pressure capability in the transition region.

2. The sock of claim 1, wherein the cushion layer comprises a thickness greater than a thickness of the base layer.

3. The sock of claim 1, further comprising toe, foot, and heel portions, wherein the cushion layer is knit around a circumference of the toe portion and on a bottom of the foot and heel portions of the sock.

4. The sock of claim 1, wherein the cushion layer is knit around a circumference of each portion of the sock.

5. The sock of claim 1, wherein the cushion layer comprises a terry knit cushion layer.

6. The sock of claim 1, further comprising a bottom, a top, and two sides, wherein yarns of the cushion layer are cut and spliced near an interface of the bottom and the top on each side of the sock.

7. The sock of claim 1, wherein each of the zones of compressive pressure construction comprises a compressive pressure capability of 20-30 mm Hg, 30-40 mm Hg, or 40-50 mmHg.

8. The sock of claim 1, further comprising a heel portion, wherein the heel portion comprises a “

Y”

design heel pouch.

9. The sock of claim 1, further comprising a toe portion having a balloon style construction, wherein the balloon style construction comprises an increased number of stitches or a decreased tension on the stitches.

10. A sock comprising:

a base layer comprising an elasticized yarn;

a cushion layer integrally knit with the base layer in selected portions on an inside of the sock;

a compressive pressure construction in a plurality of selected circumferential zones of the sock, each of the zones capable of exerting a predetermined amount of compressive pressure on a wearer; and

a toe portion having a first toe seam and a second toe seam wider than and sewn over the first toe seam at a height less than a height of the cushion layer.

11. A sock, comprising:

a toe portion, a heel portion, a bottom, a top, and two sides;

a base layer comprising an elasticized yarn;

a terry knit cushion layer integrally knit with the base layer in selected portions on an inside of the sock;

a compressive pressure construction in a plurality of selected circumferential zones of the sock, each of the zones capable of exerting a predetermined amount of compressive pressure on a wearer;

each of at least two zones of compressive pressure construction comprising a different compressive pressure capability;

the compressive pressure capability of each of the plurality of zones decreasing from a distal portion of the sock to a proximal portion of the sock; and

a transition region between adjacent zones of compressive pressure construction,

wherein in the transition region the elasticized yarn is knit at a gradually increasing rate of feed to provide a gradually decreasing compressive pressure capability in the transition region,

wherein yarns of the cushion layer are cut and spliced near an interface of the bottom and the top on each side of the sock,

wherein the heel portion comprises a “

Y”

design heel pouch,

wherein the toe portion comprises a balloon style construction, the balloon style construction comprising an increased number of stitches or a decreased tension on the stitches, and

wherein the toe portion comprises a first toe seam and a second toe seam wider than and sewn over the first toe seam at a height less than a height of the cushion layer.

12. A method of making a sock, comprising:

knitting at least an elasticized yarn into a base layer;

integrally knitting a terry knit cushion layer with the base layer in selected portions on an inside of the sock;

knitting a plurality of zones of compressive pressure construction, each of which zones comprises a different compressive pressure capability capable of exerting a predetermined amount of compressive pressure on a wearer;

knitting a decreasing compressive pressure capability of each of the plurality of zones from a distal portion of the sock to a proximal portion of the sock; and

knitting a transition region between adjacent zones of compressive pressure construction by gadually increasing a rate of feed of the elasticized yarn to provide a gradually decreasing compressive pressure capability in the transition region.

14. The method of claim 12, further comprising cutting and splicing yarns of the cushion layer near an interface of a bottom and a top on each side of the sock.

15. The method of claim 12, further comprising knitting a heel pouch in a “

Y”

design.

16. The method of claim 12, further comprising knitting an increased number of stitches in a toe portion of the sock or knitting the toe portion with a decreased tension on the stitches.

13. A method of making a sock, comprising:

knitting at least an elasticized yarn into a base layer;

integrally knitting a terry knit cushion layer with the base layer in selected portions on an inside of the sock; and

knitting in a plurality of selected circumferential zones in the sock a construction capable of exerting a predetermined amount of compressive pressure on a wearer,

wherein knitting a compressive pressure construction further comprises

knitting the elasticized yarn at a first constant feed rate in a first zone to provide a first compressive pressure capability;

knitting the elasticized yarn at a gradually increasing feed rate until a second constant feed rate is achieved to provide a transition region between the first zone and an adjacent second zone, the transition region having a gradually decreasing compressive pressure capability; and

knitting the elasticized yarn at the second constant feed rate greater than the first constant feed rate in the second zone to provide a second compressive pressure capability less than the first compressive pressure capability.

17. A method of making a sock, comprising:

knitting at least an elasticized yarn into a base layer;

integrally knitting a terry knit cushion layer with the base layer in selected portions on an inside of the sock;

knitting in a plurality of selected circumferential zones in the sock a construction capable of exerting a predetermined amount of compressive pressure on a wearer; and

sewing a first toe seam, and sewing a second toe seam wider than and overlying the first toe seam so that both the first and second toe seams have a height no greater than a height of the cushion layer.