METHOD OF MAKING A KNIT SOCK/HEEL
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.