*****

DESCRIPTION

Field of the Invention

The present invention generally refers to the field of socks and similar items of clothing, and in particular concerns a garment in the form of stockings, hose or sock having breathable effect, in order to allow the escape of moisture which would otherwise become stagnant between the foot and the sock itself.

The invention further relates to a method of manufacturing such a garment on circular machines for hosiery and knitwear.

State of the art

In traditional shoes, i.e. those without means to discharge moisture, the socks often end up carrying out a sponge function: moisture and sweat retained in the shoe are absorbed by the sock, and as a result the user's foot is not kept dry.

Therefore some users prefer not to wear socks when the weather makes it possible, but this is not the most suitable solution: the contact between the shoe and the skin of the foot does not allow the latter to breathe. In addition, the moisture remains trapped inside the shoe; not only this is not very comfortable, but it is not particularly convenient even from a hygienic point of view and can contribute to the onset of blisters or mycoses.

In the clothing sector, and in particular in the sportswear sector, shoes designed to allow moisture to be discharged outside the shoe itself are known. However, the performance of this type of shoes is reduced by the use of socks.

In order to overcome these drawbacks, socks provided with areas having elongated stitches for defining openings, or in any case having less-tight knit, have been proposed in an attempt to allow the escape of moisture. However these openings, as have been done up to now, are not able to carry out their task effectively, giving at most a partial result.

For example, the document US 4 057 981 relates to a sock provided with areas extending at the sock sides and having open stitches in order to allow air to pass through; the sock also has a knit terry in order to form a pad at least at the sole portion of the sock. The sock thus created, however, does not allow ventilation of the lower part of the foot but, on the contrary, the knit terry provided in contact with the lower portion of the foot has the effect of imbibe moisture thereby retaining it in contact with the foot itself, with an uncomfortable result. In addition, the knit terry is particularly thick and is therefore not suitable for socks of any type. In addition the user's foot portion, which is at the open stitches, is in contact with the shoe, which actually obstructs these stitches, thus frustrating the effect thereof. Finally, the holes are made by a combination of tuck stitches and float stitches. Through this type of construction only small holes can be made, or alternatively holes not totally empty but actually crossed by floating yarns, due to the type of work, can be formed.

On the other hand, Patent Application US 3 247 685 A refers to socks having decorative patterns, such as laceworks or openwork elements. However, these works can be made in different portions of the sock, in particular at the portion to be worn on the user's leg, only with aesthetic purpose but without any additional function.

The document FR 2 912 879 A1 claims a textile device to protect the body in the form of a sock having at least one element in the form of a pad of polymeric material, assembled to the sock structure, at the portion to be fitted on the back of the foot. These pads have the function of protecting the user's foot and are made of a material which not only does not help the sweat to be absorbed/discharged, but rather can generate additional perspiration, when in contact with the skin.

Document FR 2 923 142 A1 also concerns a sock to protect the foot during a sporting activity. According to the invention, the sock comprises a series of thicknesses, in particular arranged at the back of the user's foot. The sock may also comprise an area obtained in an upper portion at the metatarsus and constituted by stitches having dimension larger than the stitches constituting the remaining portion of the sock. However, these stitches are not suitable for allowing the escape of moisture formed at the foot, especially the lower portion thereof.

Document JP H09 31705 A refers to a sock having a plurality of holes made in its upper and lower portions only at the toes; the sock also has a series of ring-shaped elements made of synthetic resin and applied so as to protrude from the sock both at the holes and in other parts of the lower portion of the sock, for a massaging effect. The protruding elements therefore have a massaging function and are made of a synthetic material; this type of material can be adapted to obtain the desired massaging effect, but at the same time it can give rise to perspiration thereby being quite uncomfortable, especially when the sock is used in a sporting activity.

Finally, document DE 20 2014 102491 relates to a sock having a plurality of holes formed only in the leg portion, wherein the edge of each hole is delimited by a sort of eyelet, so as to prevent the hole from enlarging. Also in this case the holes cannot ventilate the whole foot of the user but only his leg; moreover, the edge of the holes are solidified by applying an element similar to an eyelet which has the function of preventing the hole from deforming during the use of the sock.

Object and Summary of the Invention

Object of the present invention is to overcome the drawbacks of the known art by proposing a garment in the form of stockings, hose or sock which is breathable, i.e. which allows the moisture to actually escape.

Another object is to provide a garment which allows moisture to escape at least at the lower part of the user's foot, and preferably at the whole foot.

It is a further object to provide a sock which is comfortable and hygienic for the user and which is actually breathable, i.e. that does not retain moisture on the skin, while preventing the foot skin from contacting the inner surface of the shoe.

These objects are achieved by a breathable sock according to claim 1 ; in particular, the sock has a breathable portion which comprises a plurality of holes each surrounded by a plurality of embossed elements, wherein the embossed elements are entirely constituted of stitches; preferably the breathable portion extends at least at the sole portion of the sock.

"Breathable sock" and "breathable portion" refer to a sock, or a portion thereof, provided with means allowing the escape of moisture caused, in particular, by the perspiration of a user's foot.

Advantageously, the breathable portion comprises a plurality of holes, which promote the escape of moisture and are surrounded at least partially by embossed elements, so that the portions of the foot left uncovered by the holes are kept distant from the shoe; in this way the direct contact between the surface of the shoe and the user's skin can be prevented, as well as the obstruction of the holes. Moreover, the embossed elements consist entirely of stitches, so that they turn out to be particularly comfortable, not being a source of perspiration and being adapted to be worn in any shoe. Moreover, the embossed elements, being formed of stitches like the rest of the sock, are deformable and adaptable to the user's foot like the rest of the sock knit; therefore, there is no friction with the foot or shoe, thus preventing the creation of areas that can be a source of discomfort, as well as the development of blisters. In addition, the so-shaped embossed elements are particularly pleasing to the eye and also constitute decorative patterns. Finally, consisting of stitches, they can be made with the desired thickness, so that different breathable socks can be provided according to the sector of use. Therefore, the combination of holes and embossed portions formed by stitches allows a sock truly breathable in all conditions and situations of use to be obtained.

Moreover, the sock is provided with a breathable portion at its lower portion named sole, to be fitted on the lower part of the user's foot, or in contact with the planum of the foot. Actually, a breathable portion at the sole of the user's foot is particularly advantageous because it allows moisture in the foot part more prone to perspiration to be discharged. Clearly, the sock according to the present invention will allow the achievement of the best performance if it is made of suitable yarns (for example with antibacterial-type yarn) and when combined with a shoe which in turn is equipped with means for discharging the foot moisture. Namely, breathable shoe and breathable sock have a synergic effect.

Advantageously, the sock may be either in the form of an insock and therefore comprise only the part of the sole between a heel portion and a toe portion, so as to contain only the lower part of the user's foot, or be in the form of a sock and therefore it may comprise also an upper portion and two side portions which are to be worn on the right side and the left side of the user's foot and which extend from opposite sides between the sole portion and the upper portion, so that the sole portion, the side portions and the upper portion wrap the whole user's foot, including the side, the back and possibly the instep. The sock may be equipped also with a portion adapted to cover at least part of the user's leg and to be worn thereon, such as stocking, over-the-knee socks, knee-highs, etc., with or without a finishing edge.

Preferably, the breathable portion also extends to the side portions and/or the upper portion of the sock, if any. Even more preferably, the breathable portion is also provided at the heel and/or toe portions of the sock, so as to have a sock which allows perspiration, thus the escape of moisture and sweat, at the whole user's foot.

Advantageously the shape, size and number of holes may be the same in all breathable portions of the same sock, or may vary depending on the portion of the sock in which they are obtained.

Correspondingly, the embossed elements may also have shape, size and be in different quantities at different breathable portions and/or different portions of sock.

Advantageously, the embossed elements have geometric shape, for example polygonal shape, and the holes are arranged inside them; in a preferred solution they have rhomboidal shape. Preferably, the embossed elements are joined together so as to form a lattice.

As an alternative, the embossed elements may be in the form of segments, either linear or wavy, or may have any shape, regular or irregular, and be joined together or separate from one another, provided that they are arranged so as to at least partially surround each hole.

The embossed elements can be made in one piece, that is to say they can be an integral part of the fabric or knit of the sock, or else they can be applied to the sock as separate elements, for example they can be glued.

The sock comprises at least one main yarn, which may be an elastic yarn and may be wrapped or covered with any fiber (natural, artificial or synthetic), to constitute, for example, a covered elastomer; or a yarn of any fiber (natural, artificial or synthetic), whether or not combined with a so-called bare elastomer, i.e. without coating; or else a yarn of any fiber (natural, artificial or synthetic), combined with an elastomer covered with a yarn of any nature. If the sock comprises at least two yarns, they will be knitted so that a yarn is at the inner surface of the sock and therefore in contact with the user's foot, and the other constitutes the outer surface of the sock.

Preferably, the sock consists of a sequence of stitches formed at least by the main yarn, and the holes correspond each to the lack of one or more stitches.

Additionally or alternatively, one or more holes can be obtained or enlarged by cutting or perforating the sock.

Advantageously, the sock has no embossed elements which are obtained by printing or applying elastic or anti-slip material on the sock, or in the form of eyelets obtained by seams applied after the formation of the sock and/or applied to the edge of the holes. In fact, the finishing elements described above can be rigid and/or create areas of friction with the user's foot or the shoe, thereby being not very comfortable for the user.

The invention also relates to a method of manufacturing a breathable sock according to claim 9, entirely made by means of a circular machine for knitwear or hosiery comprising a revolving cylinder provided with needles, and at least one feeding station to feed at least one main yarn.

In particular, the method provides for:

a) manufacturing a sock comprising at least one heel portion, one toe portion and one sole portion by leading at least part of the needles to a knit position in which they are led to a height such as to intercept at least one main yarn and to form stitches; and

b) manufacturing a breathable portion comprising a plurality of holes, each hole being at least partially surrounded by embossed elements and characterized in that the embossed elements are made through stitches of at least one yarn.

Preferably, the breathable portion is manufactured at least at the sole portion.

Preferably, step b) provides in turn the following steps, each to be carried out in correspondence with at least one course, i.e. a complete or partial revolution of the revolving cylinder:

c) manufacturing a portion of a plurality of embossed elements by leading

- at least one needle to the knit position, and/or

- at least one needle to a so-called tuck position, in which the needle is at an intermediate height so as to intercept at least the main yarn and restrain the main yarn intercepted in the preceding course of the revolving cylinder, thereby manufacturing at least one so called tuck stitch, and/or

- at least one needle at a so-called miss position, in which the needle is held at a lowered position so as to not intercept the main yarn and restrain the main yarn intercepted in the preceding course of the revolving cylinder, thereby manufacturing at least one so-called float or miss stitch, and/or

d) manufacturing a plurality of holes and a possible intermediate portion of a plurality of embossed elements by leading one or more needles to an inactive knit position, in which the needles are led to a knit height but not fed with any yarn, and possibly leading a plurality of needles to the miss position and;

wherein steps c) and d) are reiterated to manufacture all the embossed elements and holes of the breathable portion.

Advantageously, therefore, the needles held in the tuck position and the miss position manufacture the embossed portions, while the needles held in the inactive knit position, when lowered, not being fed with any yarn, leave the holes formed. The quantity of needles held in the inactive knit position may depend both on the number and fineness of the needles of the circular machine used and/or the size of the hole to be obtained.

Preferably, in a circular machine for hosiery provided with at least 400 needles, at least one, preferably at least two and more preferably three needles are held in the inactive position in order to form corresponding holes each at the lack of at least one, preferably at least two and more preferably three stitches.

Advantageously, the method is implemented by a circular machine for knitwear or hosiery having at least two and preferably at least four yarn feeding stations, at least one of which, during the manufacturing of the breathable portion, feeds at least the main yarn to the needles in order to manufacture the embossed elements, and at least another one of which does not feed any yarn to the needles, so as to form the holes.

In addition, the method may provide the steps of manufacturing also an upper portion at which a breathable portion can be made and/or manufacturing a breathable portion also at the heel portion and/or the tip portion of the sock, so that the breathable portion extends at some sock portions, or else on the whole sock.

Brief Description of the Drawings

However, the invention will be further illustrated in the following description with reference to the attached indicative and non-limiting drawings, in which:

- figure 1 shows a view of a breathable-effect sock according to the present invention; - figure 2 shows an enlargement of the portion of the sock circled in Fig.

1 ;

- figure 2a shows an enlarged representation of the stitches required to form a sock portion similar to that of Fig. 2;

- figure 3 shows a schematic view of part of a circular machine for hosiery or knitwear in a first working condition;

- figure 4 shows a detail of the machine of Fig. 3;

- figure 5 shows the machine of figure 3 in a second working condition; and

- figure 6 shows a textile pattern of a sock according to the invention.

Detailed description of the Invention

In said drawings, numeral 1 globally denotes a garment in the form of stockings, hose or sock. The garment could also be an insock to be fitted on the lower part, toe and heel of a user's foot, or a sock of any shape and size and provided or not with a portion to be worn also on at least part of the user's leg, such as stocking, an over-the-knee sock, a knee-high, etc.

The sock comprises a heel portion 2 and a toe portion 3 and a sole portion 4 extending therebetween, the latter being worn on the planum and at least partially on the sides of a user's foot.

The sock may also comprise - as shown in Figure 1 - an upper portion 5 which wraps the back and possibly the instep of the user's foot and two side portions 5', each extending at a left or right side of the sock between said sole and top portions, and a finishing edge 6.

According to the invention, the sock comprises at least one breathable portion 7 which, in a preferred embodiment, extends at least at the sole portion 4.

The breathable portion is defined by a plurality of holes 8 and a plurality of embossed elements 9. The embossed elements are arranged so as to at least partially surround each hole and consist of stitches. The holes have the function of allowing the escape of moisture, whereas the embossed elements are intended to prevent direct contact between the foot and either the shoe worn by the user or another surface.

The remaining part of the sock may have any works known per se.

The breathable portion may also be provided at the upper portion of the sock and/or at the heel portion. The toe portion may have a breathable portion too.

The breathable portion can therefore be provided at the entire surface of the sock wrapping the foot, or only at parts of the sock itself. For example, in order to prevent the structure of the sock to be weakened in an area particularly prone to friction and wear, no breathable portions, and in particular no holes may be provided in the toe portion intended to cover the end part of the toes.

The embossed elements have geometric shape, for example polygonal, preferably closed so as to completely surround each hole. As an alternative, the embossed elements may have any shape, either closed or open and be joined together or separate from one another, so as to form a lattice or a series of separate elements arranged around each hole, so that the skin of the user's foot that remains exposed at the holes is kept away from the inner surface of the shoe.

Figure 1 shows rhomboidal embossed elements, but elements having other shapes, such as honeycomb, circle, square, etc. could be provided. Preferably, the embossed elements are joined together, forming a lattice.

Even the holes can have any shape and size. Preferably they have circular or elliptical shape. The shape, size and quantity of holes may be the same in all breathable portions of a sock, or may vary according to the portion of the sock in which they are obtained; for example, the holes located on the upper portion can be different in quantity and/or size with respect to those obtained at the heel portion.

Correspondingly, the embossed elements at different breathable portions and/or different sock portions may also have different shape or size and be in different quantities. The embossed elements can be made in one piece with the sock, or applied thereto, for example by gluing.

The sock comprises at least one main yarn 10, which may be an elastic yarn wrapped by or coated with any fiber, of natural, artificial or synthetic type, to constitute, for example, a covered elastomer.

As an alternative, the main yarn 10 can be of any fiber, natural, artificial or synthetic, and be combined with a second yarn 1 1 , preferably elastic and of different linear mass density.

In this case, the two yarns 10, 1 1 are joined together so that one of the two yarns 10, 1 1 is located at the inner surface of the sock, and therefore in contact with the user's foot, and the other one constitutes the outer surface of the sock itself.

The sock may consist of stitches or a fabric. If the sock consists of a sequence of stitches, the holes correspond each to the lack of one or more stitches.

As an alternative, the holes can be formed in the sock with different techniques, for example by means of punches, presses, dies or the like.

The sock described above can be manufactured entirely by means of a circular machine 12 for knitwear or hosiery.

The machine is provided with a revolving cylinder 13 capable of at least partial revolutions named courses and in which a plurality of needles 14 are slidably mounted. The machine further comprises at least one feeding station 15, 16, 17, 18 to feed to the needles at least the main yarn 10, the second elastic yarn 1 1 , if necessary, and any other yarn that can be used to produce the sock or else to make works or decorative patterns.

The needles 14 of the revolving cylinder 13 can be selectively led to a lowered position named miss position A, to an intermediate position named tuck position B, and to raised position named knit position C, or inactive knit position D, respectively, depending on whether at least the main yarn is fed to the needles or not. The method of manufacturing the garment provides for feeding at least the main yarn 10 and leading at least part of the needles of the cylinder to the knit position C in order to form a sock 1 , which comprises at least one heel portion 2, one toe portion 3 and one sole portion 4 as described above; and, by appropriately driving the yarn feeding stations and conveniently selecting the needles among the aforesaid knit position C, miss position A, tuck position B and inactive knit position D, making a breathable portion 7, preferably at least at the sole portion, so that the breathable portion comprises a series of holes 8 surrounded by embossed knit elements 9. The embossed elements 9, as visible in Figure 2a, are formed by stitches and in particular by so-called tuck stitches obtained by restraining the yarn on a needle held in the tuck position B, in correspondence with two or more revolutions of the revolving cylinder and forming a knit with all yarns simultaneously in correspondence with a subsequent revolution of the revolving cylinder. Said holes 8, on the other hand, are obtained by holding at least one needle in the inactive knit position D in which said at least one needle remains in a raised position in which it does not restrain neither intercept any yarn. This type of knitting construction allows holes of any size, completely open, i.e. not crossed by any yarn, to be formed.

In a preferred embodiment, between each hole 8 and the embossed element 9 which at least partially surrounds the hole itself, an intermediate, preferably plain-knitted, portion 9' is provided, so as to increase the sock area kept separate from the shoe the user wears, thereby increasing the effectiveness of the breathable portion.

In other words, a part of the sock can be formed by feeding at least the main yarn to part of the cylinder needles led to the knit position C; and another part or other parts, corresponding to one or more breathable portions 7, can be formed by suitably driving the yarn feeding stations and selecting the needles among the above mentioned knit, miss and tuck positions, in order to form a plurality of holes 8 each surrounded, at least partially, by embossed knit elements 9, at the sole portion, or on the whole sock. Such embossed knit elements are in the form of ribs and may have different shapes to define embossed elements having geometric shape, for example rhomboidal, square, circular, honeycomb and the like, or any other shape, even irregular or in any case not geometric.

Either a single breathable portion, at the whole sole portion, or more breathable portions at different points of the sole portion can be made.

Additionally, further breathable portions may be provided also next to at least part of the heel portion and/or at least part of the toe portion.

In detail, the manufacture of each breathable portion is carried out by alternating a first step in which a portion of a part of the embossed elements is manufactured by selecting the needles so as to lead at least one needle to the knit position C, to make at least one plain-knitted stitch, and/or at least one needle to the tuck position B and/or holding at least one needle in the miss position A, in correspondence with at least one course of the revolving cylinder; and a second step in which both a possible intermediate portion of a plurality of embossed elements and a plurality of holes are manufactured, the former by optionally holding a plurality of needles in the miss position A, the latter by leading one or more needles to the inactive knit position D, that is, without feeding any yarn to the needles, in correspondence with at least one subsequent course of the revolving cylinder.

Actually, each needle in the tuck position B intercepts at least the main yarn and at the same time restrains the main yarn intercepted in the previous course of the revolving cylinder, thereby forming thickenings defined by a plurality of tuck stitches; and each needle in the miss position A does not intercept the main yarn, but restrains the main yarn intercepted in the previous course of the revolving cylinder, thereby manufacturing an elongated stitch.

The holes may have any shape and size, and are formed by the needles led to an inactive knit position D. In fact, these needles rise and no yarn is fed thereto. These needles being closed when they come down, they leave a hole, as the corresponding stitch is skipped, and therefore is missing. In order to form a hole having a suitable size to allow the escape of moisture, at least one, at least two, or at least three needles can be held in the inactive knit position so as to form holes corresponding to at least one, two or three missing stitches.

The circular machine for knitwear or hosiery may be provided with a yarn feeding station, but preferably at least two yarn feeding stations, or even more preferably at least four yarn feeding stations - as shown in Figures 3, 4 and 5.

In case of two yarn feeding stations, during the manufacturing of the breathable portion, a first feeding station 15, or 16, or 17 feeds at least the main yarn and the needles are led to the knit position C, the tuck position B and the miss position A at this feeding station 15, or 16, or 17, while a second feeding station 18 feeds no yarn and the needles are led to the inactive knit position C at the second feeding station itself.

In case of four yarn feeding stations, during the manufacturing of the breathable portion, three yarn feeding stations 15, 16 and 17 feed at least the main yarn to the needles which are selectively led to the knit position C, the tuck position B and the miss position A to make the embossed elements, and a feeding station 18 remains inactive and therefore feeds no yarn to the needles, which are then in the inactive knit position D, to form the holes.

The sock may also comprise two side portions 5', an upper portion 5, a possible portion to be worn on the user's leg and a finishing edge 6; in this case, for manufacturing them, the required steps are provided, as well as the steps required for manufacturing a possible breathable portion also at the side portions and/or the upper portion 5 in order to improve the effectiveness of the breathable sock and allow the escape of moisture at the user's entire foot.