GB2516121A

GB2516121A - A composite waterproof breathable sock with two-way extensible properties

Info

Publication number: GB2516121A
Application number: GB1317866.0A
Authority: GB
Inventors: Qian Xu
Original assignee: SHANGHAI UNIWISE INTERNAT CO Ltd
Current assignee: SHANGHAI UNIWISE INTERNAT CO Ltd
Priority date: 2013-07-08
Filing date: 2013-10-09
Publication date: 2015-01-14
Anticipated expiration: 2033-10-09
Also published as: GB2516121B; CN103330294A; GB201317866D0

Abstract

A composite waterproof breathable sock has two-way extensible properties, wherein each sock is formed by lamination of an outer layer 3, an inner layer 5 and an intermediate waterproof and breathable film 4 on a one-step forming mould 10. The outer component 3, or both the outer 3 and inner 5 components, is knitted by deploying fine twisted spandex yarns 11 consistently into all the knitting courses of the main body 12, so as to make the composite sock very stretchable. The spandex yarns are 350 twists per metre with a ration of main body yarns and spandex yarns of 75:25. The sock is made with a water block seal sewn into the cuff band (13, figure 6).

Description

tM:;: INTELLECTUAL .*.. PROPERTY OFFICE Applieslion No. (3B13 17866.0 RTM Dale:21 November2013 The following terms are registered trade marks and should be read as such wherever they occur in this document: Thermolite Coolmax Gore-Tex P ore lie Intellectual Property Office is an operaling name of Ihe Patent Office www.ipo.gov.uk A composite waterproof breathable sock with two-way extensible properties

Field of the Invention

The invention relates to a kind of waterproof breathable sock for outdoor uses, and specifically relates to a kind of waterproof composite socks which have two-way extensible properties therefore can be stretched circumferentially and longitudinally.

Background

The performance for outdoor garments is waterproof and breathable, in order to get the protection in arduous environment whilst to keep the wearing comfort ability. Along with the commercialization of the waterproof and breathable film technology by W.L. Gore, the dual function performance was rapidly developed in the field of outdoor sportswear. Also with the protective demand extending to the outdoor sports accessories, the technology was also applied to the outdoor socks where people need to protect their feet dry and comfort in outdoor sports and related activities.

The well known waterproof breathable sock is developed by W.L. Gore. The sock in the kind is assembled by cut and sew method using the waterproof breathable fabric laminate (as shown in the figure 1). Although the sock, or bootie, is functionally performed, it is not as stretchable and close fitting as the normal knit outdoor sock, therefore loses the comfort performance that a sock should have for outdoor activities, due to the non-stretchable laminate and seam tapes laminated along its stitching line.

In order to overcome said problem, the document US5483703 provides a sandwiching lamination technology, wherein the sock is constructed by an inner sock, an outer sock, and an intermediate barrier, wherein the intermediate barrier is a waterproof but moisture vapour permeable film.

As in the figure 2, the outer component 3 is a seamless knitting sock, normally using the abrasion resistant, easy to drip dry nylon or polyester yarns. The inner sock component 5 uses such performance materials as Merino wool or Thermolite or Coolmax yarns, the last two are the registered trademark of Invista. The waterproof breathable barrier 4 is available in the market e.g. the microporous or hydrophilic membranes such as Gore-Tex film by W.L.Gore or Porelle film made by PIL Membanes Ltd. The adhesion of the three layers can be made by using PA, PES or TPU hot melt adhesive systems in powder spreading technology.

By using the sandwiching mould 6, the three components are bonded together whilst the waterproof breathable film is sandwiched in the waterproof composite sock.

Another prior art US5244716 addressed the discrete dotting adhesive technology. As shown in the figure 3, the three layers are bonded by discrete adhesive dots. To realize the construction, the elastic inner and outer fabrics should be stretched to the extension of the non-stretchable waterproof breathable film size then laminated at that position. In this way, the non-stretchable waterproof breathable film will have a corrugated or ruched structure as shown in the figure 2(a), after lamination off the form. The corrugated structure gives the no stretchable film a certain range of extensible properties, so as to give the composite fabric a certain elasticity that the said laminate fabric used for cut and sew bootie does not have.

A further development US6 139929 provided a composition and forming technology that further improved the embodiment of the above technology onto the waterproof composite II) socks. As in the figure 4, this technology adopted a kind of wide former 8, specifically at least 150% wider than the relaxed size of the sock components used. Accordingly as illustrated in the figure 4(b), the sock component is knitted with weft course displayed, circumferentially laid in elastic threads 9, from toe to the cuff along the sock tube, which can make the finished composite sock at least 50% lateral recovery after the lamination off the wide former IS 8. Due to the lateral recovery, the non-stretchable waterproof film component sandwiched in between is made corrugated, or ruched, in the longitudinal direction along the sock tube, as shown in the figure 4(a), therefore it could be extensible circumferentially when the composite sock is stretched laterally.

However, even the composite sock in this technology is extensible laterally by adopting the above said laid-in elastic thread 9, the sock does not have an ideal elasticity, extensibility, along the sock length (longitudinal) direction. Due to the above shortcoming, the composite sock by this technology has to insert a waterproof breathable film component at a pre set foot size (as showed in the figure 4, the length A), and as a result, the finished sock has very little size flexibility that a normal sock should have. In reality, the foot sizes vary a lot from person to person, therefore the composite sock made by the above said technology does not fit to the foot closely in a real length flexibility sense, nor meets the durability demand in the outdoor sports activities, when the non-stretchable waterproof breathable film component is easily rubbed through by the toes at the toe part if the sock is tightly fitting.

In addition, none of the above documents gives a solution to the problem that the water comes over into the top of the waterproof socks during the wading activity. The document US6807683 provides a simple method to stop the water from entering the sock from the top.

It extends the waterproof film barrier upwards to exceed the length of inner sock, whilst extends the elastic cuff part of the outer sock further up over the waterproof barrier component. By this, the elastic cuff band of the outer sock presses the elongated part of the waterproof film tightly over the leg calf so as to functionalize as a round seal to stop the water from splashing in.

However, this technology has two shortcomings to cause bad body feelings. On one hand,

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the adhesive powders spread on the interior surface of the waterproof film, which are applied for bonding to the inner sock, are easily scrubbed off and fall over to the skin. On the other hand, the hydrophilic type of waterproof film touching directly to the skin has a clammy feeling when it gets wet. Both side effects cause the wearer an uncomfortable outdoor experience.

The present invention provides a one package solution to improve the technical shortcomings of the prior technologies explained above. Besides the waterproof and breathable performance, the waterproof composite socks made by the present technology are also all way stretchable to fit close to the feet both circumferentially and longitudinally, ID whilst having the perfect size flexibility. In addition, this invention claims a new and practical way to stop the water from flowing into the waterproof socks. The present invention not only improves the comfort ability of the composite socks, but also extends much longer the use life of the waterproof socks. In production point of view, the forming mould adopted in this invention is much smaller, compared to the one adopted in the document US6 139929, IS so as to raise the productivity significantly.

Summary of the Invention

The invention claims a composite waterproof breathable sock with two-way extensible properties, wherein each sock is formed by lamination of an outer layer, an inner layer and an intermediate waterproof and breathable film on a one-step forming mould, wherein the outer component, or both the outer and inner components, is knitted by deploying the fine twisted spandex yarns consistently into all the knitting courses of the main body. By adopting this material composition and using the ad hoc forming mould, the composite sock obtains the longitudinal extensibility especially along the sock bottom, therefore offers the ideal size flexibility to the users, normally only 4 sizes available for a type of composite socks.

This invention eliminates the uncomfortable feeling, either too tight or too loose (size up), and significantly reduces the possibility of scrubbing the waterproof film through at the toe part, which happens sometimes on the composite socks made by the prior technology.

Furthermore, the twisted spandex yarns added in the outer component are 350 twists per meter.; Furthermore, the ratio of the main body yarns to the added-in twisted spandex yarns is 75:25; Furthermore, the outer component, or both the outer and the inner components, are knitted on the single-cylinder 4.0 inches jacquard hosiery machine; Furthermore, the adhesives used for lamination between the outer, the inner, and the intermediate waterproof breathable film are heat activated TPU material; Furthermore, the intermediate waterproof breathable film should be made up into a sock-like component in advance, with the TPU adhesive spread on both interior and exterior surfaces in discrete dots or powder before lamination. The said sock-like component should be larger than the relaxed inner and outer socks, so as to shrink with the inner and outer socks after lamination off the mould back to the regular size. By this arrangement, the waterproof breathable film sandwiched in between the outer and inner has a corrugated structure in both wefts X and warp Y directions, so it will be able to be stretched circumferentially and longitudinally.

Furthermore, the forming mould for the one-step, heat press lamination is a sock-like plate, ID which has the same size as the said sock-like film component said above; Furthermore, the specific assembly method is, firstly to pull the outer sock over the larger forming mould described above, secondly to slip the sock-like film component over outside the outer sock on the mould, thirdly to pull the inner sock directly over outside the film component, lastly to heat press the set of components on the forming mould for a one-off lamination.

Furthermore, the composite sock has a cuff band with the water seal kit inside, wherein the cuff band is extended from the outer component of the sock, and wherein the in-cuff seal kit is constructed of two-way stretchable waterproof polyurethane fabric (e.g. highly elastic eco fabric for swimwear); Furthermore, the two-way stretchable PU fabric is round sewn inside cuff band; Furthermore, the height, along the sock longitude, of said round sewn PU elastic fabric is equal to or longer than 2cm. By the inventor's internal experiments, the in-cuff water block kit for the type of waterproof sock is only functional to stop the water flowing in when the height of water block material is at or above a certain level; Furthermore, the height of said round shape polyurethane elastic fabric is 5cm.

Description of the Drawings

Figure 1 is a schematic perspective view of the waterproof bootie by cut and sew fabric laminate using the Gore-Tex technology; Figure 2 is a cross sectional view of the construction of a waterproof composite sock; Figure 3 is a cross sectional view of the configuration of three plies lamination using the discrete adhesive dots; Figure 4 is a schematic diagram of the waterproof composite sock using the sock component with circumferentially lay in elastic threads; Figure 5 is a schematic diagram of the waterproof composite sock with two-way extensible properties disclosed by the present invention.

Figure 6 is a cross sectional view of the in-cuff seal kit disclosed in the present invention.

Description of figure notes

Figure 2(a) is a cross sectional view of the corrugated structure for the intermediate waterproof breathable film; Figure 4(a) is an illustration diagram for the corrugated texture of the intermediate film in longitudinal direction; Figure 4(b) is a schematic diagram to illustrate the circumferentially laid in elastic threads displayed along the weft courses of the main body in its sock component; Figure 5(a) is a cross sectional view of the wave structure corrugated in both X and Y directions for the intermediate film; Figure 5(b) is a schematic diagram to illustrate the consistent combination of the twisted spandex yarns with the main body yarns in its sock component; 1, Laminated fabric; 2, Seam taping on stitching line; 3, The outer sock component; 4, The intermediate waterproof breathable film component; 5, The inner sock component; 6, The forming mould; 7, The adhesive dot for discrete securement; 8, One former used in the prior technology; 9, The circumferentially displayed elastic thread; 10, The one-step heat press forming mould disclosed in the present invention; 11, The fine twisted spandex yarns; 12, The main body yarns; 13, The cuff band extended from the outer sock; and 14, The in-cuff water block kit round sewed inside the cuff band.

Description of the preferred Embodiment

Embodiment 1: A waterproof breathable composite sock with two-way extensible properties, as shown in the figure 5, wherein each sock is formed by lamination of an outer layer 3, an inner layer 5 and an intermediate waterproof and breathable film component 4 on a one-step forming mould 10, bonded by discrete hot melt adhesive dots 7, wherein the outer component 3, or both the outer 3 and inner 5 components, is knitted by deploying the fine twisted spandex yarns 11 consistently into the main body yarns 12, as shown in the figure 5(b). The twisted spandex yarns 11 in this composition have excellent elasticity to make the sock component very stretchable. The waterproof breathable film component 4, which is made up in sock shape in advance, is at the same size as the sock-like forming mound 10, but at a larger size than the relaxed size of the outer sock 3 and the inner sock 5. By this composition and configuration, the said film component 4 sandwiched in between the outer sock 3 and the inner sock 5 shrinks under the tension of the sock components and has an internal puckered structure in both X and Y directions (like a wave texture) after lamination off the mould, as illustrated in the figure 5(a), therefore is extensible both circumferentially and longitudinally. The waterproof composite socks by this technology have two-way stretchable properties in particular in sock length (longitude) direction therefore has a large range of flexibility for a single sock size. The flexibility offers the wearer a stretchable fitting and eliminates the possibility of scrubbing the film to leak at the toe part during the tough sports. Also by this composition, the outer sock 3 can be knitted in tighter courses so it also eliminates the possible problem that the intermediate film component 4 might show through between the knitting courses of the sock component 3, as sometimes happened for the composite socks with the heavily laid in elastic threads. The show through' problem can easily damage the performance barrier particularly during the tough outdoor sports activities.

Embodiment 2: As shown in the figure 5(b), the twisted spandex yarns, which are knitted with the main body yarns and are consistently deployed in all the knitting courses, perform as all way recovery tension for the composite sock. The spandex yarns are 350 twists per meter and the ratio of the main body yarns to the twisted spandex yarns is 75:25. The adhesive system used for lamination of the outer 3, the inner 5, and the intermediate waterproof breathable component 4 is hot melt TPU material being spread on the interior and exterior surfaces of the film component 4 in discrete dotting or powder techniques. The sock outer 3, or both the sock outer 3 and the inner 5, is knitted on the single-cylinder 4 inches jacquard hosiery machine. By the said composition, the finished composite sock obtains the best elastic modulus in both circumferential and longitudinal directions. In addition, using the said hosiery machine and the yarn combination, the present technology can make the composite sock in complex jacquard design which is theoretically difficult to be knitted in the prior technology due to the heavily laid in elastic threads in the outer component 3.

Embodiment 3: As shown in the figure 6, the composite sock made by the present invention can be made with an in-cuff water block seal, wherein the cuff band 13 is extended upwards from the outer component 3, and the in-cuff seal kit 14 is constructed of the two-way stretchable waterproof polyurethane fabric sewed around inside the cuff band. The waterproof PU elastic fabric in the type is modern developed for high quality swimwear and has excellent all way elasticity. The elastic fabric sewed with the cuff of the knit sock provides a comfortable tight over the leg calf, therefore stops the water from coming into the composite sock over the top.

Embodiment 4: On the basis of the above waterproof composite sock, the height of round fabric 14 should be equal to or more than 2cm. By the internal experiments, when the waterproof sock with the in-cuff seal kit illustrated above was in use, and when the water splashed onto the top of the sock, the water block kit could effectively stop the water entering in only when the height of the water block material exceeded a certain value. On the other hand, the wearer felt uncomfortable if the waterproof fabric kit is too high. The 5cm height was the optimal combination of water blocking and the wearing comfort ability as per the test results.

The present invention overcomes the technical shortcomings existing in the prior technologies. The composite sock made by the invention is waterproof and breathable, whilst has the comfortable two-way stretchable properties as well as the in-cuff water block ID function. The invention provides a way to make the waterproof composite socks that have very much improved comfort ability for the wearer in real site experience, and also a practical method to increase the productivity of the composite socks by using the smaller forming mould considering the hand assembling process.

The document discloses a few of examples of the embodiment, but they are not limiting the application scope. The technical people in the related fields can modify andJor alter the embodiments if they do not violate the fundamental technology of the invention.

Claims

CLAIMS1, A composite waterproof breathable sock with two-way extensible properties, wherein each sock is formed by lamination of an outer layer, an inner layer and an intermediate waterproof and breathable film on a one-step forming mould, wherein the outer component, or both the outer and inner components, is knitted by deploying the fine twisted spandex yarns consistently into all the knitting courses of the main body.
2, The waterproof breathable sock according to claim 1, wherein the fine twisted spandex yarns deployed into the main body of the sock component are 350 twists per meter.
3, The waterproof breathable sock according to claim t or 2, wherein the ratio of the main body yarns to the twisted spandex yarns added in is 75:25.
4, The waterproof breathable sock according to claim 1 to 3, wherein the outer component, or both the outer and the inner components, is knitted on the single-cylinder 4.0 inches jacquard hosiery machine.
5, The waterproof breathable sock according to claim 1 to 4, wherein the adhesives used for lamination between the outer, the inner, and the intermediate waterproof breathable film are heat activated TPU materials.
6, The waterproof breathable sock according to claim 1 to 5, wherein the intermediate waterproof breathable film should be made up into a sock-like component in advance, with the TPU adhesive spread on both interior and exterior surfaces in discrete dots or powder before lamination. The said sock-like component should be larger than the relaxed inner and outer socks, so as to shrink with the inner and outer socks after lamination off the mould back to the regular size. By this arrangement, the waterproof breathable film sandwiched in between the outer and inner has a corrugated structure in both wefts X and warp Y directions, so it will be able to be stretched circumferentially and longitudinally.
7, A one-step forming mould and an assembly method of making a waterproof composite sock with two-way extensible properties, wherein the said mould is a sock-like plate, in the same size as the said sock-like film component, being used for heat press lamination process(sandwiching). The said assembly method is firstly to pull the outer sock over the larger forming mould described above, secondly to slip the sock-like film component over outside the outer sock on the mould, thirdly to pull the inner sock directly over outside the film component, lastly to heat press the set of components on the forming mould for a one-off lamination.
8, The waterproof breathable sock according to claim 1, wherein the composite sock has a cuff band with the water seal kit inside, wherein the cuff band is extended from the outer component of the sock, and wherein the in-cuff seal kit is constructed of a two-way stretchable waterproof polyurethane elastic fabric.
9, The waterproof breathable sock according to claim 8, wherein the two-way stretchable PU elastic fabric is sewn round inside cuff band.
10, The waterproof breathable sock according to claim 8 or 9, wherein the height, along the sock longitude, of said round sew polyurethane elastic fabric is equal to or longer than 2cm.
11, The waterproof breathable sock according to claim 8 to 10, wherein the height of said round sew polyurethane elastic fabric is 5cm.Amendments to the Claims have been filed as follows:CLAIMS1. A composite waterproof breathable sock with two-way extensible properties, wherein each sock is formed by lamination of an outer layer, an inner layer and an intermediate waterproof and breathable film on a one-step forming mould, wherein the outer layer, or both the outer and inner layers, is knitted by deploying fine twisted spandex yams consistently into all the knitting courses of the main body, knitted with the yarns of the main body.2. A composite waterproof breathable sock according to claim 1, wherein the fine twisted spandex yarns deployed into the main body of the sock layer are 350 twists per meter.3. A composite waterproof breathable sock according to claim 1 or 2, wherein the ratio of the main body yarns to the twisted spandex yams added in is 75:25.4. A composite waterproof breathable sock according to claim 1 to 3, wherein the outer layer, or both the outer and the inner layers, is knitted on the single-cylinder 4.0 *0 inches jacquard hosiery machine.* 5. A composite waterproof breathable sock according to claim 1 to 4, wherein the adhesives used for lamination between the outer layer, the inner layer, and the intermediate waterproof breathable film are heat activated thermoplastic polyurethane (TPU) materials.6. A composite waterproof breathable sock according to any one of claims 1 to 5, * * wherein the waterproof breathable film sandwiched in between the outer layer and inner layer has a corrugated structure in both wefts X and warp Y directions, so it will be able to be stretched circumferentially and longitudinally.7. A composite waterproof breathable sock according to claim 1, wherein the composite sock has a cuff band with a water seal kit inside, wherein the cuff band is extended from the outer layer of the sock, and wherein the water seal kit is constructed of a two-way stretchable waterproof polyurethane (PU) elastic fabric.8. A composite waterproof breathable sock according to claim 7, wherein the two-way stretchable waterproof polyurethane (PU) elastic fabric is sewn round the inside of the cuff band.9. A composite waterproof breathable sock according to claim 7 or 8, wherein the height, along the sock longitude, of said round sew polyurethane elastic fabric is equal to or longer than 2cm.10. A composite waterproof breathable sock according to claim 7 to 9, wherein the height of said round sew polyurethane elastic fabric is 5cm.11. A method of making a waterproof breathable sock according to claim 1 to 6, wherein the intermediate waterproof breathable film is made up into a sock-like component in advance, with thermoplastic polyurethane (TPU) adhesive spread on both interior and exterior surfaces in discrete dots or powder before lamination, the said sock-like component being larger than the relaxed inner and outer layers, so as to shrink with the inner and outer layers after lamination off the mould back to the regular size.
12. An assembly method of making a waterproof composite sock with two-way extensible properties using a one-step forming mould, wherein the said mould is a sock-like plate, in the same size as a sock-like film component, being used for a heat press lamination process (sandwiching), the said assembly method being firstly to pull an outer sock over the forming mould which is larger than the said mould, secondly to slip the sock-like film component over outside the outer sock on the mould, thirdly to pull an inner sock directly over outside the film component, the outer sock or both the a outer sock and the inner sock being knitted by deploying fine twisted spandex yarns * consistently into all the knitting courses of the respective outer/inner sock so that the fine twisted spandex yarns are knitted with yarns of the main body of the outer/inner -.*.sock and lastly to heat press the set of components on the forming mould for a one-off lamination. * S. * **.. _.*I S