AND SYSTEM AND METHOD FOR PRODUCING SUCH SOCK

FIELD

[001] Some embodiments are related to the field of garments and clothing articles.

BACKGROUND

[002] A sock is an item of clothing worn on the foot. For example, a person may wear socks at home in order to obtain a warm feeling in the feet; or outdoors as a layer between a person's feet and a person's shoes or boots. Socks may absorb sweat which may be produced by the feet. In a cold weather, some socks may decrease the risk of frostbite.

[003] Many people change their socks often, for example, daily or every other day. Used socks are typically washed, either by hand or by using an electric washing machine. Washed socks may be dried, for example, by using an electric dryer machine.

[004] Unfortunately, multiple cycles of washing and/or drying of socks may gradually degrade the quality of the socks.

SUMMARY

[005] Some embodiments may include, for example, a sock as well as methods and systems for producing socks.

[006] In some embodiments, for example, a method of manufacturing a garment includes: knitting the garment from a non-colored raw cotton thread; washing the garment with a caustic material; treating the garment with a biopolishing enzyme; coloring the garment.

[007] In some embodiments, treating the garment comprises: pre -bleaching the garment with a mixture of non-ionic detergent, hydrogen peroxide, peroxide stabilizer, and caustic soda.

[008] In some embodiments, the pre -bleaching comprises, during the pre -bleaching: gradually increasing a temperature of the garment; maintaining an increased temperature of the garment; decreasing the temperature of the garment.

[009] In some embodiments, the pre -bleaching is followed by: treating the garment with peroxyl thermo-10; draining the garment.

[0010] In some embodiments, the draining is followed by: neutralizing the garment by treating the garment with an acetic acid; upon the garment reaching a pH level greater than or equal to 6.0 and smaller than or equal to 7.0, draining the garment.

[001 1] In some embodiments, the method further includes: washing the garment; draining the garment; checking absorbency of the garment.

[0012] In some embodiments, treating the garment with the biopolishing enzyme is performed subsequent to: adjusting pH level of the garment to be greater than or equal to 4.0 and smaller than or equal to 4.5; wherein treating the garment with the biopolishing enzyme is performed while gradually increasing temperature of the garment.

[0013] In some embodiments, treating the garment with the biopolishing enzyme comprises: removing miniscule cotton fibers which protrude out of the garment.

[0014] In some embodiments, treating the garment with the biopolishing enzyme (a) is performed once, and (b) is performed only prior to coloring the garment.

[0015] Some embodiments may include a garment produced by the method; for example, a sock.

[0016] In some embodiments, for example, a system for manufacturing a garment includes: a knitting unit to knit the garment from a non-colored raw cotton thread; a washing unit to wash the garment with a caustic material; a treatment unit to treat the garment with a biopolishing enzyme; a coloring unit to color the garment.

[0017] In some embodiments, the treating unit comprises: a pre-bleaching unit to pre-bleach the garment with a mixture of non-ionic detergent, hydrogen peroxide, peroxide stabilizer, and caustic soda.

[0018] In some embodiments, the system includes a temperature modifier to perform, during the pre-bleaching: gradually increasing a temperature of the garment; maintaining an increased temperature of the garment; decreasing the temperature of the garment.

[0019] In some embodiments, the pre-bleaching unit is able to perform, after the pre-bleaching: treating the garment with peroxyl thermo-10; draining the garment.

[0020] In some embodiments, the system includes: a neutralizing unit to neutralize the garment by treating the garment with an acetic acid; a draining unit to drain the garment upon the garment reaching a pH level greater than or equal to 6.0 and smaller than or equal to 7.0.

[0021] In some embodiments, the treating unit is to treat the garment with the biopolishing enzyme subsequent to adjusting pH level of the garment to be greater than or equal to 4.0 and smaller than or equal to 4.5; wherein the treating unit is to treat the garment with the biopolishing enzyme while gradually increasing temperature of the garment.

[0022] In some embodiments, the treating unit is to remove miniscule cotton fibers which protrude out of the garment.

[0023] In some embodiments, the treating unit is to perform a treatment of the garment with the biopolishing enzyme which (a) is performed once, and (b) is performed only prior to coloring the garment.

[0024] In some embodiments, the garment comprises a sock.

[0025] Some embodiments may provide other and/or additional benefits and/or advantages. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] For simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity of presentation. Furthermore, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. The figures are listed below.

[0027] Figure 1 is a schematic flowchart of a method of manufacturing a sock, in accordance with some demonstrative embodiments.

[0028] Figure 2 is a schematic block diagram illustration of a system in accordance with some demonstrative embodiments.

DETAILED DESCRIPTION

[0029] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of some embodiments. However, it will be understood by persons of ordinary skill in the art that some embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, units and/or circuits have not been described in detail so as not to obscure the discussion.

[0030] Some embodiments of the invention include, for example, a sock, a system for making sock(s), and a method of making sock(s).

[0031] In some embodiments, the sock may be laundry-resistant and/or tumble drier resistant. A conventional sock loses its brightness, shininess, color and/or smoothness upon one or more laundry cycles and/or tumble dry cycles; and becomes rough or coarse or covered with small cotton balls due to laundry cycles. In contrast, in some embodiments, a sock may maintain its brightness, shininess, color and/or smoothness (or other properties or qualities) upon one or more laundry cycles and/or tumble dry cycles; may substantially not degrade its brightness, shininess, color and/or smoothness upon one or more laundry cycles; and/or does not become rough or coarse or covered with small cotton balls due to laundry cycles and/or tumble-dry cycles.

[0032] In some embodiments, a sock which undergoes multiple or numerous cycles of laundry (e.g., thirty laundry cycles) and/or tumble drying, remains substantially similar in its quality, texture, smoothness, brightness, color, skinniness and/or other characteristics to a never-yet- washed conventional sock, or to a conventional sock that was manufactured and did not yet undergo any laundry and/or drying cycles. In some embodiments, a sock which undergoes multiple or numerous cycles of laundry maintains its original color, shade of color, brightness level, dye, or color nuance; particularly with regard to a sock having an initial dark color (e.g., black), which does not modify its color or shade (e.g., into grey or blue or green) due to multiple or numerous laundry cycles.

[0033] A conventional sock is typically produced by knitting of pre-colored cotton threads. In contrast, some embodiments include a method or a process for manufacturing laundry-resistant socks and/or dryer-resistant socks.

[0034] Reference is made to Figure 1 , which is a schematic flowchart of a method of manufacturing a sock, in accordance with some demonstrative embodiments.

[0035] In some embodiments, the method may include, for example, providing a non-colored raw cotton thread (block 110).

[0036] In some embodiments, the method may include, for example, knitting a sock from the non-colored raw cotton thread (block 120).

[0037] In some embodiments, the method may include, for example, washing the sock, or performing a laundry cycle on the sock, together with a caustic material, in order to remove or reduce wax, lipids, or other impurities which raw cotton may have (block 130).

[0038] In some embodiments, the method may include, for example, performing a process which adds and/or utilizes a particular enzyme, or a composition or mixture of multiple particular enzymes; or otherwise treating the sock with such one or more particular enzymes (block 140).

[0039] In some embodiments, the method may include, for example, coloring the sock (block 150).

[0040] In some embodiments, the fourth step, of performing a process which adds and/or utilizes a particular enzyme, results in removal or "shaving off of miniscule or microscopic cotton fibers which may otherwise protrude or extend out of the cotton, and results in a significantly smoother sock and a laundry-resistant sock.

[0041] In some embodiments, the fourth step, of performing a process which adds and/or utilizes a particular enzyme, is performed only once, prior to coloring the sock; and is not performed multiple times; and is not performed subsequent to coloring the sock; and is not performed both before and after the coloring of the sock; and is performed exactly once during the entire manufacturing process of the sock.

[0042] In some embodiments, the fourth step, of performing a process which adds and/or utilizes a particular enzyme, includes a multi-step process. Initially, the process begins at a temperature of approximately 40 degrees Celsius. A suitable material is added, in order to change the pH level to approximately 4.5. Then, the particular enzyme may be added, at a pre-defined concentration (e.g., a concentration of approximately one percent). The temperature is gradually increased from approximately 40 degrees Celsius to approximately 55 degrees Celsius. The sock is then maintained soaked, at his temperature, for a pre-defined period of time (e.g., approximately 40 minutes). Then, the water or other liquids are drained or removed or filtered- out, and the sock is washed using cold water.

[0043] In some embodiments, the particular enzyme used may include a mixture or composition of enzymes and/or chemicals and/or dyes. In some embodiments, the particular enzyme may include, for example, a material known as "Delta BP Plus" available from Delta Galil Industries Ltd. of Karmiel, Israel (website: www.DeltaGalil.com); such material or enzyme may be referred to herein as "Biopolishing Enzyme".

[0044] In some embodiments, the sock may be composed of: approximately 85 percent cotton; approximately 14 percent polyamide; approximately 1 percent Elasthane (or Spandex or Lycra).

[0045] In some embodiments, a similar or the same treatment process with similar or the same particular enzyme(s) may be used for substantially all types or colors of socks, for example, pale shades, medium shades, and dark shades.

[0046] In some embodiments, the treatment process may include the following steps:

[0047] (a) Pre -bleaching, for example, using: 1 gram-per-liter of non-ionic detergent, and 5 grams-per-liter of hydrogen peroxide 35 percent, and 0.5 gram-per-liter of peroxide stabilizer, and 2 grams-per-liter of caustic soda 48 percent. The temperature may be raised, for example, from approximately 40 degrees Celsius to approximately 95 degrees Celsius, at a pre-defined rate (e.g., raising gradually at a rate of approximately 2 degrees Celsius per minute); the temperature may then be maintained at approximately 90 degrees Celsius for approximately 45 minutes, and then cooled down to approximately 70 degrees Celsius. Then, 2 grams-per-liter of peroxyl thermo-10 may be added, for a 30-minutes treatment followed by draining. [0048] (b) Neutralizing, for example, using acetic acid to a pH level of approximately 6.0 to 7.0 at approximately 40 degrees Celsius within ten minutes, followed by draining.

[0049] (c) Washing for five minutes at approximately 40 degrees Celsius, followed by draining. Then, checking the absorbency of the sock, for example, according to American Association of Textile Chemists and Colorists (AATCC) Test Method 79, such that the test result is not greater than 2 seconds.

[0050] (d) Adjusting the pH level to approximately 4.0 to 4.5, and then adding the above- mentioned Biopolishing Enzyme, for example, at a ratio of 1 percent; raising the temperature from approximately 40 degrees Celsius to approximately 55 degrees Celsius, at a rate of approximately 3 degrees Celsius per minute; treating at this temperature for approximately 45 minutes, and then draining.

[0051] (e) Washing at approximately 40 degrees Celsius, for approximately 5 minutes, and then draining.

[0052] After the above-mentioned treatment, the process may dye the cotton (and optionally nylon components), according to the desired color or shade. In some embodiments, the resulting sock may provide excellent result (e.g., A-B) in the Marks & Spencer 18A Pilling Test, in contrast with a lower result (e.g., B-C) of a conventional sock.

[0053] Some embodiments may include a manufacturing line or a system for producing socks, or other articles of clothing, in accordance with the above-mentioned methods and treatments. The system may include one or more suitable components or units, for example, a pre-bleaching unit, a neutralizing unit, a soaking unit, a unit for increasing the temperature, a unit for decreasing the temperature, a draining unit, a unit for adjusting pH levels, a unit for storing enzymes or other materials, a unit for pouring and/or mixing enzymes or other materials, a soaking unit, a washing unit, and/or other suitable components, which may be automatically or semi-automatically controlled and/or operated, for example, by a machine, a controller, a logic circuit, or other logic unit.

[0054] Reference is made to Figure 2, which is a schematic block diagram illustration of a system 200 in accordance with some demonstrative embodiments. The system 200 of Figure 2 may be utilized, for example, to perform one or more of the operations described with reference to the method of Figure 1. [0055] In some embodiments, system 200 may include, for example: a knitting unit 201 able to knit a sock from a non-colored raw cotton thread 202; a washing unit 203 able to wash the sock with a caustic material 204, and/or a laundry unit 205 able to wash the sock with the caustic material 204; an enzyme treatment sub-system 207 able to treat the sock (e.g., by mixing, washing, laundering, soaking, bleaching, or the like) with a biopolishing enzyme 208; and a coloring unit 209 able to add one or more colorants 210 or pigments or other materials in order to color the sock.

[0056] In some embodiments, the enzyme treatment unit 207 may include one or more sub-units to perform the treatment process described above, for example: a pre-bleaching unit 211 to perform the pre-bleaching; a neutralizing unit 212 to perform the neutralizing; a washing/draining unit 213 to perform the washing and draining; a pH adjusting unit 214 to perform the pH adjusting; a temperature modifier 215 able to provide heating and/or cooling and able to reach and/or maintain a desired temperature; a temperature controller 216 to control the temperature in which the sock is washed or treated; a timing controller 217 to control the time allocated for the various operations and to ensure that the sock timely proceeds from one step to the next step; and other suitable units or sub-units.

[0057] Although portions of the discussion herein relate, for demonstrative purposes, to manufacturing of a sock, some embodiments may include manufacturing of other items, for example, underwear, bra, panties, legging, pants, shirt, glove, scarf, garment, item of clothing, piece of clothing, or other articles of clothing; or other cotton-based articles that are not necessarily worn (e.g., a towel, a sheet, a pillowcase, or the like).

[0058] Although portions of the discussion herein relate, for demonstrative purposes, to manufacturing of a sock from cotton, or substantially from cotton, some embodiments may include manufacturing of a sock (or other articles of clothing) from other material(s), or from cotton together with other materials.

[0059] The terms "plurality" or "a plurality" as used herein include, for example, "multiple" or "two or more". For example, the term "a plurality of items" includes two or more items.

[0060] Functions, operations, components and/or features described herein with reference to one or more embodiments, may be combined with, or may be utilized in combination with, one or more other functions, operations, components and/or features described herein with reference to one or more other embodiments, or vice versa. [0061] While certain features of some embodiments have been illustrated and described herein, many modifications, substitutions, changes, and equivalents may occur to those skilled in the art. Accordingly, the following claims are intended to cover all such modifications, substitutions, changes, and equivalents.