Method of making a knit sock/heel

Abstract

A method of making a sock having a leg portion, a gusset, a foot and a toe includes knitting a tubular member having a cylindrical body with a closed end, using, preferably a conventional circular knitting machine. The circular body is shaped to look like a sock and then subjected to heat and/pressure causing the fibers of the body to set. The circular body is knit from standard fiber yarns, including yarns made from natural and artificial fibers.

1 . A method of making a sock comprising:
 knitting a tubular sock including a cylindrical body from fibers;   shaping said cylindrical body into a sock-shaped body; and   setting said fibers to cause said sock-shaped body to maintain its shape.   
     
     
         2 . The method of  claim 1  wherein said shaping includes drawing said cylindrical body over a foot shaped-form to make said foot-shaped body. 
     
     
         3 . The method of claim,  2  wherein said setting is performed while said cylindrical body is disposed on said form. 
     
     
         4 . The method of  claim 1  wherein said fibers selected from the group consisting of acrylic, polyester, cotton, nylon, rayon and spandex. 
     
     
         5 . The method of  claim 4  wherein said cylindrical body is knit from a blend of said fibers. 
     
     
         6 . The method of  claim 1  wherein said fibers are set by heating said fibers. 
     
     
         7 . The method of  claim 1  wherein said fibers are set by steaming said fibers. 
     
     
         8 . The method of  claim 7  wherein said fibers are set using steam at a pressure of about 1.8 lbs/sq. in. 
     
     
         9 . A method of making a sock having a toe, a foot, gusset, and leg body, said method comprising:
 knitting a tubular member on a circular knitting machine from fibers, said tubular member having a cylindrical body open at one end and closed at the opposite end; and   shaping said cylindrical body into the shape of a sock; and   setting the fibers causing said sock to retain its shape.   
     
     
         10 . The method of  claim 9  wherein said cylindrical body includes a first section and a second section, and wherein after said setting, said first section is formed into said leg body and said second section is shaped to form said foot and said gusset. 
     
     
         11 . The method of  claim 10  wherein said cylindrical body is set with said closed end forming the toe. 
     
     
         12 . The method of  claim 9  wherein said step of shaping includes drawing said cylindrical body over a form, said form having an outer foot-shaped surface. 
     
     
         13 . The method of  claim 9  wherein said step of setting includes applying heat to said cylindrical body. 
     
     
         14 . The method of  claim 9  wherein said fibers are made from at least one of acrylic, polyester, cotton, nylon, rayon and spandex. 
     
     
         15 . The method of  claim 14  wherein said fibers are a blend of at least two of acrylic, polyester, cotton, nylon, rayon and spandex. 
     
     
         16 . The method of  claim 9  wherein said step of setting includes one of heating and applying pressure to said cylindrical body.