Sock with double-layer foot portion and bottom toe seam

Abstract

A double layer sock and a sock having a seam under the toes of a wearer are described. The sock includes a tubular outer layer and an inner layer. The tubular outer layer includes a foot portion and a leg portion. The foot portion defines a foot bottom portion and an upper instep portion. The inner layer includes a number of edges that define a perimeter and is substantially aligned with the foot bottom portion of the tubular outer layer. One of the yarns extends between the inner layer and the tubular outer layer to connect the inner layer and the tubular outer layer around the perimeter of the inner layer and at spaced apart wales and courses. A region of the double layer sock corresponding to the upper instep portion is single-layered while a region of the double layer sock corresponding to the foot bottom portion is double-layered.

What is claimed is: 
     
         1 . A double layer sock formed on a circular knitting machine from at least two yarns, the double layer sock comprising:
 a tubular outer layer knit of at least one yarn and having wales and courses, the tubular outer layer having a foot portion and a leg portion merging substantially at the ankle of a wearer, wherein the foot portion defines a foot bottom portion and an upper instep portion; and   an inner layer knit of at least one other yarn and having wales and courses, wherein the inner layer comprises a plurality of edges, wherein the edges define a perimeter of the inner layer,   wherein the inner layer is substantially aligned with the foot bottom portion of the tubular outer layer,   wherein one of the yarns extends between the inner layer and the tubular outer layer to connect the inner layer and the tubular outer layer around the perimeter of the inner layer and at spaced apart wales and courses,   wherein a region of the double layer sock corresponding to the upper instep portion of the tubular outer layer is single-layered, and a region of the double layer sock corresponding to the foot bottom portion of the tubular outer layer is double-layered.   
     
     
         2 . The double layer sock according to  claim 1 , wherein the yarn extending between the inner layer and the tubular outer layer is knit into both layers. 
     
     
         3 . The double layer sock according to  claim 2 , wherein the yarn extending between the inner layer and the tubular outer layer is knit predominately in one layer and is knit for connection purposes only in the other layer. 
     
     
         4 . The double layer sock according to  claim 3 , wherein the yarn extending between the inner layer and the tubular outer layer is knit predominately in the inner layer and is knit for connection purposes only in the tubular outer layer as tuck stitch loops. 
     
     
         5 . The double layer sock according to  claim 1 , wherein the foot portion of the tubular outer layer further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and at least one of the heel portion or the toe portion is made via reciprocated knitting. 
     
     
         6 . The double layer sock according to  claim 5 , wherein at least one of the heel portion or the toe portion comprises terry loops. 
     
     
         7 . The double layer sock according to  claim 1 , wherein the foot portion of the tubular outer layer further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and a portion of the inner layer is substantially aligned with part of the leg portion of the tubular outer layer proximate the heel portion. 
     
     
         8 . A method of knitting a double layer sock on a circular knitting machine, the method comprising:
 knitting at least one yarn into courses and wales to form a tubular outer layer of the sock, the tubular outer layer having a foot portion and a leg portion merging substantially at the ankle of a wearer, wherein the foot portion defines a foot bottom portion and an upper instep portion;   knitting at least one other yarn into courses and wales to form an inner layer of the sock, wherein the inner layer is knit concurrently with at least a portion of the tubular outer layer, and the inner layer comprises a plurality of edges, wherein the edges define a perimeter of the inner layer; and   connecting the inner layer and the tubular outer layer together around the perimeter of the inner layer and at spaced apart wales and courses by causing one of the yarns to extend between the inner layer and the tubular outer layer concurrently with the knitting of the tubular outer layer and the inner layer,   wherein the inner layer is substantially aligned with the foot bottom portion of the tubular outer layer, and   wherein a region of the double layer sock corresponding to the upper instep portion of the tubular outer layer is single-layered, and a region of the double layer sock corresponding to the foot bottom portion of the tubular outer layer is double-layered.   
     
     
         9 . The method according to  claim 8 , wherein the yarn extending between the inner layer and the tubular outer layer is knit into both layers. 
     
     
         10 . The method according to  claim 9 , wherein the yarn extending between the inner layer and the tubular outer layer is knit predominately in one layer and is knit for connection purposes only in the other layer. 
     
     
         11 . The method according to  claim 10 , wherein the yarn extending between the inner layer and the tubular outer layer is knit predominately in the inner layer and knit for connection purposes only in the tubular outer layer as tuck stitch loops. 
     
     
         12 . The method according to  claim 8 , wherein the inner layer is knit on dial needles of the circular knitting machine, and the tubular outer layer is knit on cylinder needles of the circular knitting machine. 
     
     
         13 . The method according to  claim 8 , wherein the foot portion of the tubular outer layer further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and at least one of the heel portion or the toe portion is made via reciprocated knitting. 
     
     
         14 . The method according to  claim 13 , wherein at least one of the heel portion or the toe portion comprises terry loops. 
     
     
         15 . The method according to  claim 8 , wherein the foot portion of the tubular outer layer further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion, and a portion of the inner layer is substantially aligned with part of the leg portion of the tubular outer layer proximate the heel portion. 
     
     
         16 . A sock formed on a circular knitting machine from at least one yarn, the sock comprising:
 a tubular body having a foot portion and a leg portion merging substantially at the ankle of a wearer, wherein the foot portion defines a foot bottom portion and an upper instep portion and further comprises a heel portion positioned adjacent the foot bottom portion at a first end of the foot portion and a toe portion positioned adjacent the foot bottom portion at a second end of the foot portion; and   a toe seam positioned within the toe portion proximate the foot bottom portion, such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer.   
     
     
         17 . The sock according to  claim 16 , wherein at least one of the toe portion or the heel portion is made via reciprocated knitting. 
     
     
         18 . The sock according to  claim 16 , wherein at least one of the heel portion or the toe portion comprises terry loops. 
     
     
         19 . The sock according to  claim 16 , wherein at least a portion of the sock is double-layered. 
     
     
         20 . A method of knitting a sock comprising a tubular body having a foot portion and a leg portion on a circular knitting machine, the foot portion defining a foot bottom portion and an upper instep portion, the method comprising:
 knitting at least one yarn into courses and wales to form the leg portion;   reciprocating at least one yarn into courses and wales to form a heel portion at a first end of the foot portion;   knitting at least one yarn into courses and wales to form the foot bottom portion and the upper instep portion adjacent to the heel portion;   reciprocating at least one yarn into courses and wales on the opposite side of the sock as the heel portion to form a toe portion adjacent the foot bottom portion at a second end of the foot portion; and   closing the toe portion with a toe seam positioned within the toe portion proximate the foot bottom portion, such that, when the sock is donned by a wearer, the toe seam is disposed under the toes of the wearer.