US20210071322A1

US20210071322A1 - Device and Process for Manufacturing a Layered Weighted Yarn

Info

Publication number: US20210071322A1
Application number: US16/563,224
Authority: US
Inventors: Kathrin Hamm
Original assignee: Bearaby Inc
Current assignee: Bearaby Inc
Priority date: 2019-09-06
Filing date: 2019-09-06
Publication date: 2021-03-11
Also published as: WO2021046513A1

Abstract

A device configured to manufacture a layered weighted yarn includes a formation channel configured to receive a first material and a second material; and a sewing machine including at least one needle, the sewing machine configured to sew a seam on the first material. The formation channel being further configured to receive the first material and form the first material into an outer tube; receive the second material and insert the second material into the outer tube; locate the first material in a position to be sewn by the sewing machine to form the seam on the outer tube; and discharge the outer tube including the first material and the second material inserted into the outer tube as a layered weighted yarn.

Description

BACKGROUND

1. Field of the Disclosure

The disclosure is directed generally to a device for manufacturing a layered weighted yarn. The disclosure is also directed to a process for manufacturing a layered weighted yarn with a device.
The disclosure is further directed generally to a device and process to manufacture a layered weighted yarn for a weighted blanket. More specifically, the disclosure is directed generally to a device and process to manufacture a layered weighted yarn for a weighted blanket for deep pressure therapy. In particular aspects, the disclosure is directed generally to a device and process to manufacture a layered weighted yarn for a weighted material that is configured to be used as a weighted blanket to provide a person with deep pressure therapy.
It is widely accepted in the medical community that deep pressure therapy may bring relief to those suffering from various disorders, such as insomnia, anxiety, sensory disorders, and the like.

2. Related Art

Some techniques of deep pressure therapy involve placing across the body, a blanket that has weights in it to apply pressure, stimulating a feeling of safety that is also experienced as being hugged or swaddled. In order to be effective, the blanket needs to weigh 10-20% of the person's body weight, leading to the blanket weighing 5 to 45 pounds.
Conventional deep pressure therapy blankets are typically weighted blankets that are made of a plurality of fabric layers with added weighted materials disposed between the layers. The added weighted materials typically include, for example, plastic pellets or balls, glass beads, sand, gravel, linked chain objects, and the like. The added weighted materials are usually placed in units inside the blanket. For example, the added weighted materials are usually placed in quadratic patches that are sewn or stitched to hold the weights. In these conventional approaches, the added materials are required to provide weight because the conventional fabric and multiple layers of fabric are not heavy enough to effectively provide deep pressure therapy when placed on a person.
The need for the added weights, however, carries with it several disadvantages. For example, the added weights limit breathability of the blanket. The added weights and the multiple layers of fabric reduce natural airflow through the blanket. This makes it particularly difficult to regulate a body temperature of an individual when the blanket is placed on them.
As another example, the added weights are prone to moving and/or shifting within the blanket. This substantially impairs equal, even, and/or continuous weight distribution, which is needed to effectuate deep pressure therapy. Also, the added weights typically cause the blanket to be overly thick and less bendable, preventing the blanket from naturally taking the body shape of a person lying under it and thereby diminishing the surface contact area of the deep pressure therapy.
Accordingly, what is needed is a device and process to manufacture a layered weighted yarn for a weighted material. Additionally, what is needed is a device and process to manufacture a layered weighted yarn for a weighted material that can be used as a blanket to effectively produce deep pressure therapy to an individual, without the need for additional weight materials. Moreover, what is needed is a device and process to manufacture a layered weighted yarn for a weighted material that can be used as a blanket to effectively produce deep pressure therapy to an individual without limiting breathability. Additionally, what is needed is a device and process to manufacture a layered weighted yarn for a weighted material that can be used as a blanket to effectively produce deep pressure therapy to an individual without diminishing the surface contact area of the deep pressure therapy.

SUMMARY

As will be described in greater detail below, the disclosure describes a device and process to manufacture a layered weighted yarn for a weighted material for a weighted blanket that is configured to effectuate deep pressure therapy, without the need for additional weights, such as external weights, internal weights, and the like. For example, internal layers of fabric of the layer weighted yarn form a weighted material without the need for additional internal weights as further described herein.
In one example, a device and process to manufacture a layered weighted yarn for a weighted material is provided. The resulting weighted material is configured to effectuate deep pressure therapy to a person when a piece of the weighted material is used as a blanket over the person's body. A length of layered weighted yarn is interlooped to form the piece of weighted material. The layered weighted yarn includes an outer tube extending longitudinally from a first end to a second end. The outer tube defines a conduit extending longitudinally therethrough from the first end to the second end. A plurality of inner layers of material are disposed within the conduit and extend longitudinally from the first end to the second end. The interlooped length of yarn creates a weighted blanket that is configured and sufficiently weighted to effectuate, by itself, deep pressure therapy to a person when the blanket lies over the person's body. Various other systems and methods are also disclosed.
One general aspect includes a device configured to manufacture a layered weighted yarn including: a formation channel configured to receive a first material and a second material. The device also includes a sewing machine including at least one needle, the sewing machine configured to sew a seam on the first material. The device also includes an outer tube material delivery system configured to deliver the first material to the formation channel. The device also includes an inner layer material delivery system configured to deliver the second material to the formation channel. The formation channel being further configured to receive the first material from the outer tube material delivery system and form the first material into an outer tube. The formation channel being further configured to receive the second material from the inner layer material delivery system and insert the second material into the outer tube. The formation channel being further configured to locate the first material in a position to be sewn by the sewing machine to form the seam on the outer tube. The formation channel being further configured to discharge the outer tube including the first material and the second material inserted into the outer tube as a layered weighted yarn.
Implementations may include one or more of the following features. The formation channel being further configured to reverse an orientation of the first material. The formation channel includes a first surface structure and a second surface structure configured to form a gap therebetween. The gap is configured to receive the first material. The formation channel includes a sewing aperture being configured to locate the first material in the position to be sewn by the sewing machine to form the seam on the outer tube. The formation channel includes a tubular structure configured to receive the first material and the second material. The formation channel includes a bracket for attachment to the sewing machine. The formation channel being attached to the sewing machine by the bracket. The outer tube material delivery system includes a spindle to support the first material. The outer tube material delivery system includes a guide structure to guide the first material to the formation channel. The inner layer material delivery system includes a spindle to support the second material. The device may also include a racing roller configured to engage the layered weighted yarn and advance the first material and the second material through the formation channel and the sewing machine. The racing roller further including a lower fabric-engaging roller and an upper fabric-engaging roller. The device configured to manufacture a layered weighted yarn where: a length of the layered weighted yarn is configured to be interlooped to form a piece of weighted material. The device may also include the piece of weighted material, by itself, is configured and sufficiently weighted to effectuate deep pressure therapy to a person as a deep pressure therapy blanket when placed over a person's body.
One general aspect includes a method of constructing a layered weighted yarn, the method including: receiving a first material and a second material with a formation channel. The method of constructing also includes sewing a seam on the first material with a sewing machine including at least one needle. The method of constructing also includes delivering the first material to the formation channel with an outer tube material delivery system. The method of constructing also includes delivering the second material to the formation channel with an inner layer material delivery system. The method of constructing also includes receiving the first material from the outer tube material delivery system and forming the first material into an outer tube with the formation channel. The method of constructing also includes receiving the second material from the inner layer material delivery system and inserting the second material into the outer tube with the formation channel. The method of constructing also includes locating the first material in a position to be sewn by the sewing machine to form the seam on the outer tube with the formation channel. The method of constructing also includes discharging the outer tube including the first material and the second material inserted into the outer tube as a layered weighted yarn with the formation channel.
Implementations may include one or more of the following features. The method of constructing a layered weighted yarn further including reversing an orientation of the first material with the formation channel. The method of constructing may also include where the formation channel includes a first surface structure and a second surface structure configured to form a gap therebetween. The method of constructing may also include where the gap is configured to receive the first material. The method of constructing may also include where the formation channel includes a sewing aperture being configured to locate the first material in the position to be sewn by the sewing machine to form the seam on the outer tube. The method of constructing a layered weighted yarn where the formation channel includes a tubular structure configured to receive the first material and the second material. The method of constructing may also include where the formation channel includes a bracket for attachment to the sewing machine. The method of constructing may also include where the formation channel being attached to the sewing machine by the bracket. The method of constructing a layered weighted yarn where the outer tube material delivery system includes a spindle to support the first material. The method of constructing a layered weighted yarn where the outer tube material delivery system includes a guide structure to guide the first material to the formation channel. The method of constructing a layered weighted yarn where the inner layer material delivery system includes a spindle to support the second material. The method of constructing may also include a racing roller configured to engage the layered weighted yarn and advance the first material and the second material through the formation channel and the sewing machine. The racing roller further including a lower fabric-engaging roller and an upper fabric-engaging roller. The method of constructing a weighted material with the layered weighted yarn including: interlooping a length of the layered weighted yarn to construct a piece of weighted material. The method of constructing may also include where the piece of weighted material, by itself, is configured and sufficiently weighted to effectuate deep pressure therapy to a person as a deep pressure therapy blanket when placed over a person's body.
Features from any of the above-mentioned aspects may be used in combination with one another in accordance with the general principles described herein. These and other aspects, features, and advantages will be more fully understood upon reading the following detailed description in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate a number of exemplary aspects and are a part of the specification. Together with the following description, these drawings demonstrate and explain various principles of the disclosure.

FIG. 1 is a perspective view of a device to manufacture a layered weighted yarn for a weighted material, according to an aspect of the disclosure.

FIG. 2 is a partial perspective view of the device of FIG. 1, according to an aspect of the disclosure.

FIG. 3A is a partial perspective view of the device of FIG. 1, according to an aspect of the disclosure.

FIG. 3B is a partial perspective view of the device of FIG. 1, according to an aspect of the disclosure.

FIG. 3C is a partial perspective view of the device of FIG. 1, according to an aspect of the disclosure.

FIG. 4 is a bottom side perspective view of a formation channel, according to an aspect of the disclosure.

FIG. 5A is a front side perspective view of the formation channel of FIG. 4, according to an aspect of the disclosure.

FIG. 5B is a front side perspective view of the formation channel of FIG. 4, according to an aspect of the disclosure.

FIG. 6A is a partial back side perspective view the formation channel of FIG. 4, according to an aspect of the disclosure.

FIG. 6B is a back side perspective view the formation channel of FIG. 4, according to an aspect of the disclosure.

FIG. 7A is a schematic of the movement of materials in the formation channel of FIG. 4, according to an aspect of the disclosure.

FIG. 7B illustrates the movement of materials in the formation channel of FIG. 7A.

FIG. 7C illustrates the movement of materials in the formation channel of FIG. 7A.

FIG. 8 is a perspective top view of an outer tube material delivery system, according to an aspect of the disclosure.

FIG. 9 is a perspective bottom view of an outer tube material delivery system of FIG. 8, according to an aspect of the disclosure.

FIG. 10 is a perspective view of an inner layer material delivery system, according to an aspect of the disclosure.

FIG. 11 is a perspective view of a racing roller, according to an aspect of the disclosure.

FIG. 12 is a top view of a weighted material comprising a layered weighted yarn that is interlooped, according to an aspect of the disclosure.

FIG. 13 is a side view of a layered weighted yarn that can be interlooped to construct the weighted material of FIG. 12, according to an aspect of the disclosure.

FIG. 14 is a cross-sectional view of the layered weighted yarn of FIG. 2 taken across line III-III, according to an aspect of the disclosure.

FIG. 15 is a perspective view of the layered weighted yarn of FIG. 13, according to an aspect of the disclosure.

FIGS. 16A, 16B, 16C, 16D, and 16E show exemplary details of forming inner layers by folding an inner sheet, according to an aspect of the disclosure.

FIGS. 17A, 17B, and 17C show exemplary details of constructing a layered weighted yarn, according to an aspect of the disclosure.

FIGS. 18A, 18B, and 18C show exemplary details of constructing a layered weighted yarn, according to an aspect of the disclosure.

FIG. 19A is a perspective view of a layered weighted yarn being knit to construct a piece of weighted material, according to an aspect of the disclosure.

FIG. 19B is a perspective view of a layered weighted yarn being crocheted to construct a piece of weighted material, according to an aspect of the disclosure.

FIG. 20 is a top view of a piece of weighted material that is constructed by knitting layered weighted yarn, according to an aspect of the disclosure.

FIG. 21 is a flowchart of an exemplary method of constructing a piece of weighted material, according to an aspect of the disclosure.

Throughout the drawings, identical reference characters and descriptions indicate similar, but not necessarily identical, elements. While the exemplary aspects described herein are susceptible to various modifications and alternative forms, specific aspects have been shown by way of example in the drawings and will be described in detail herein. The exemplary aspects described herein, however, are not intended to be limited to the particular forms disclosed. Rather, the disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims.

DETAILED DESCRIPTION OF EXEMPLARY ASPECTS

The disclosure is generally directed to a device and process to manufacture a layered weighted yarn for a weighted material. In one aspect, the weighted material can be used as a blanket to provide a person with deep pressure therapy, without the need for weights or components.
FIG. 1 is a perspective view of a device to manufacture a layered weighted yarn for a weighted material, according to an aspect of the disclosure.
In particular, FIG. 1 illustrates a device 900 configured to manufacture a material such as a layered weighted yarn 100 for a weighted material as described herein. Exemplary details of the layered weighted yarn 100 are illustrated in FIG. 13 and the associated description thereof described herein. The device 900 may include a sewing machine 400, a racing roller 500, a formation channel 800, an outer tube material delivery system 600, an inner layer material delivery system 700, and the like.
The outer tube material delivery system 600 may deliver a first material 602 to the formation channel 800 for forming an outer tube 10 for the layered weighted yarn 100.
The inner layer material delivery system 700 may deliver a second material 702 to the formation channel 800 for inserting a plurality of inner layers 18 into the layered weighted yarn 100. In one aspect, the inner layer material delivery system 700 may deliver a plurality of portions of the second material 702 to the formation channel 800 for inserting a plurality of the inner layers 18 into the outer tube 10 of the layered weighted yarn 100. In one aspect, the inner layer material delivery system 700 may deliver 1-8 portions of fabric, 1-5 portions of fabric, 2-8 portions of fabric, or 2-5 portions of fabric.
In one aspect, the formation channel 800 may receive the first material 602 for producing the outer tube 10 from the outer tube material delivery system 600. The formation channel 800 may guide and form the first material 602 for producing the outer tube 10 from the outer tube material delivery system 600 into a tubular shape. Thereafter, the formation channel 800 may position the first material 602 for the sewing machine 400 to sew a seam 24 to connect sides of the first material 602 to form the outer tube 10. Accordingly, the formation channel 800 forms the outer tube 10 by sewing the seam 24 to connect sides of the first material 602 resulting in a tubular shape construction of the outer tube 10.
The formation channel 800 may receive the second material 702 from the inner layer material delivery system 700 and may insert the second material 702 as the plurality of inner layers 18 into the outer tube 10 to form the layered weighted yarn 100. In one aspect, the second material 702 may include 1-8 portions of fabric, 1-5 portions of fabric, 2-8 portions of fabric, or 2-5 portions of fabric.
The sewing machine 400 may be configured to hold the formation channel 800 while the formation channel 800 guides and forms the first material 602 for producing the outer tube 10 from the outer tube material delivery system 600 into a tubular shape and the sewing machine 400 may sew a seam 24 to connect the sides of the first material 602 to form the outer tube 10. As noted above, the sewing machine 400 sews the seam 24 to connect the sides of the first material 602 to form the outer tube 10. Thereafter, the formation channel 800 reverses the orientation of the outer tube 10 while the formation channel 800 receives and pulls the second material 702 from the inner layer material delivery system 700 for inserting the second material 702 as the plurality of inner layers 18 into the outer tube 10 to form the layered weighted yarn 100.
The racing roller 500 may be configured to receive the layered weighted yarn 100 after the sewing machine 400 has sewn the seam 24 to connect the sides of the first material 602 to form the outer tube 10, the formation channel 800 has reversed the orientation of the outer tube 10 to place the seam 24 within the outer tube 10, and the formation channel 800 has inserted the plurality of inner layers 18 into the outer tube 10 to form the layered weighted yarn 100. The racing roller 500 may be configured to advance and/or move the first material 602 and the second material 702 through the sewing machine 400. In one aspect, the racing roller 500 may be configured to advance and/or move the first material 602 and the second material 702 through the sewing machine 400 by advancing the layered weighted yarn 100. In one aspect, the racing roller 500 may be configured to advance and/or move the first material 602 and the second material 702 through the sewing machine 400 by advancing the layered weighted yarn 100 with rollers that are driven by a motor as described below. In one aspect, the motor is the only motor operating to move the first material 602 and the second material 702 through the sewing machine 400.
Details of exemplary implementations and operational functionality of the sewing machine 400, the racing roller 500, the formation channel 800, the outer tube material delivery system 600, the inner layer material delivery system 700, and the like will be described in greater detail below.
FIG. 2 is a partial perspective view of the device of FIG. 1, according to an aspect of the disclosure; and
FIG. 3A is a partial perspective view of the device of FIG. 1, according to an aspect of the disclosure.
In particular, FIG. 2 illustrates the first material 602 entering into the formation channel 800 as described above. The formation channel 800 may include an attachment bracket 802. The attachment bracket 802 may be configured for attachment to the sewing machine 400. In one aspect, the attachment bracket 802 may include apertures for receiving one or more mechanical fasteners 414 for attachment of the formation channel 800 to the sewing machine 400.
FIG. 3A illustrates the second material 702 entering into the formation channel 800 as described above. FIG. 3A further illustrates a guide structure 402 configured to guide the second material 702 into the formation channel 800. In this regard, the guide structure 402 may receive the second material 702 from the inner layer material delivery system 700 and direct the second material 702 into the formation channel 800. The guide structure 402 may be implemented using any type of structure to guide fabric material such as the second material 702. In one aspect, the guide structure 402 may be a guide pin. In one aspect the guide pin may be a metallic structure attached to the sewing machine 400. In one aspect, the guide structure 402 may be a guide pin having a length of 6 cm. (centimeters)-16 cm., 8 cm.-14 cm., or 9 cm.-12 cm.
FIG. 3B is a partial perspective view of the device of FIG. 1, according to an aspect of the disclosure.
In particular, FIG. 3B illustrates the second material 702 entering into the formation channel 800 as described above. FIG. 3B further illustrates the first material 602 entering the formation channel 800 from the outer tube material delivery system 600. The formation channel 800 may form a half-rounded shape of the first material 602 to form the outer tube 10 formation of the outer tube 10 (outside fabric layer) of the layered weighted yarn 100. The converging shape of the formation channel 800 forms the outer tube 10 while the sewing aperture 816 (open area) allows the stitching needle of the sewing machine 400 to connect both fabric ends or sides into the outer tube 10, while the second material 702 is pulled into the formation channel 800 in parallel in a loose tube shape (no connection or stitching to the outside tube).
As further described below, the first material 602 may be pulled into position 602-3 by the formation channel 800. In particular, the first material 602 now forms an outer tube 10 and movement of the outer tube 10 into the formation channel 800 reverses the orientation of the outer tube 10. Accordingly, the seam 24 and its associated loose edges formed by the sewing machine 400 are now located within the outer tube 10.
Additionally, the second material 702 may be introduced at position 702-1 and may be inserted into the outer tube 10 as the outer tube 10 enters the formation channel 800. In particular, once the second material 702 is introduced at position 702-1, it may thereafter be drawn into the formation channel 800 and the outer tube 10.
FIG. 3C is a partial perspective view of the device of FIG. 1, according to an aspect of the disclosure.
In particular, as further described below, FIG. 3C illustrates the first material 602 within the formation channel 800. Additionally, FIG. 3C shows a sewing aperture 816 as well as the at least one needle 406 operating to form the seam 24 on the first material 602.
Returning to FIG. 2, FIG. 2 further illustrates the first material 602 entering the formation channel 800 from the outer tube material delivery system 600. The outer tube material delivery system 600 may further include a guide structure 608. In this regard, the guide structure 608 may receive the first material 602 from the outer tube material delivery system 600 and direct the first material 602 into the formation channel 800. The guide structure 608 may be implemented using any type of structure to guide fabric material such as the first material 602. Moreover, the guide structure 608 may be configured to straighten the first material 602 before it enters the formation channel 800. In one aspect, the guide structure 608 may be a guide pin. In one aspect, the guide structure 608 may be a pair of guide pins. In one aspect, the guide structure 608 may be a pair of metallic guide pins. In one aspect, the guide structure 608 may be attached to the outer tube material delivery system 600.
While the first material 602 and the second material 702 are located within the formation channel 800, the sewing machine 400 may sew the seam 24 to connect the sides of the first material 602 to form the outer tube 10. Thereafter, the outer tube 10 with the second material 702 forming the plurality of inner layers 18 may exit the formation channel 800 as the layered weighted yarn 100 as illustrated in FIG. 2.
FIG. 4 is a bottom side perspective view of a formation channel, according to an aspect of the disclosure.
FIG. 5A is a perspective front side view of the formation channel of FIG. 4, according to an aspect of the disclosure.
FIG. 5B is a front side perspective view of the formation channel of FIG. 4, according to an aspect of the disclosure.
FIG. 6A is a partial back side perspective view the formation channel of FIG. 4, according to an aspect of the disclosure.
FIG. 6B is a back side perspective view the formation channel of FIG. 4, according to an aspect of the disclosure.
In particular, FIG. 4 illustrates the formation channel 800. The formation channel 800 may have a first end 810 configured to receive the first material 602. The formation channel 800 further includes a first surface structure 804 that receives the first material 602. The formation channel 800 may further include a second surface structure 806. The first surface structure 804 and the second surface structure 806 may be arranged to form a gap 820 (as shown in FIG. 5A and FIG. 5B) therebetween so that the first material 602 may travel toward a second end 830 of the formation channel 800 through the gap 820. In one aspect, the formation channel 800 may have a length 840 as illustrated in FIG. 4 of 6 cm. to 20 cm., 8 cm. to 18 cm., 10 cm. to 16 cm., or 12 cm. to 14 cm. In one aspect, the formation channel 800 may have a width 850 as illustrated in FIG. 5 of 2 cm. to 10 cm., 4 cm. to 8 cm., or 6 cm. to 7 cm.
The formation channel 800 may further include a slot 812 as illustrated in FIG. 6A and FIG. 6B in communication with the gap 820 formed between the first surface structure 804 and the second surface structure 806. The slot 812 may allow the first material 602 to travel out the formation channel 800.
With reference to FIG. 6A in FIG. 6B, the formation channel 800 may further include a tubular structure 814. The slot 812 may extend substantially around the tubular structure 814. This construction allows the first material 602 to travel out the formation channel 800 through the slot 812. In this regard, the tubular structure 814 may be attached to the second surface structure 806 adjacent the sewing aperture 816 in order to form the slot 812 around the tubular structure 814. In one aspect, the tubular structure 814 may be attached to the second surface structure 806 adjacent a sewing aperture 816 at a single location. In one aspect, the tubular structure 814 may be attached to the second surface structure 806 adjacent a sewing aperture 816 at a single location by welding. In one aspect, the tubular structure 814 may form a second inside tube.
Additionally, the formation channel 800 may include the sewing aperture 816 as illustrated in FIG. 4. The sewing aperture 816 may allow the sewing machine 400 to sew the seam 24 to connect the sides of the first material 602 to form the outer tube 10 while it travels through the formation channel 800 and, in particular, the slot 812. In particular, the slot 812 may guide the first material 602 to locate the sides of the first material 602 adjacent the sewing aperture 816 for sewing the seam 24 by the sewing machine 400.
With reference to FIG. 6B, the tubular structure 814 may include an aperture 822 that is configured to receive the outer tube 10 after it has exited the slot 812. The movement of the outer tube 10 into the aperture 822 of the tubular structure 814 reverses the orientation of the outer tube 10. Accordingly, the seam 24 formed by the sewing machine 400 is now located within the outer tube 10. In this regard, reversing the orientation of the outer tube 10 moves the seam 24 and its associated edges inside the outer tube 10 while receiving the second material 702 (inner layers 18). In one aspect, the tubular structure 814 forms a separate inner formation channel inside the formation channel 800. The tubular structure 814 reverses the outer tube 10 after it has been sewn together. Thereafter, the tubular structure 814 moves the seam 24 inside and receives the second material 702 (inner layers 18) forming the layered weighted yarn 100. Additionally, the tubular structure 814 may be configured such that the tubular structure 814 (inner channel) may separate the process of stitching the seam 24 from the process of finishing the layered weighted yarn 100 to prevent the layered weighted yarn 100 from being double stitched. Additionally, as illustrated in FIG. 6B, the tubular structure 814 may be structurally separated from the sewing aperture 816.
In one or more aspects, the first material 602 may be configured and/or adapted to have different sizes to form an outer tube 10 with a different size. In one aspect, the first material 602 may be configured and/or adapted to be larger to form an outer tube 10 with a larger size to form a heavier layered weighted yarn 100. In one aspect, the first material 602 may be configured and/or adapted to be smaller to form an outer tube 10 with a smaller size to form a lighter layered weighted yarn 100.
In one or more aspects, the formation channel 800 and/or the tubular structure 814 may be configured and/or adapted to have different sizes to form an outer tube 10 with a different size. In one aspect, the formation channel 800 and/or the tubular structure 814 may be configured and/or adapted to be larger to form an outer tube 10 with a larger size to form a heavier layered weighted yarn 100. In one aspect, the formation channel 800 and/or the tubular structure 814 may be configured and/or adapted to be smaller to form an outer tube 10 with a smaller size to form a lighter layered weighted yarn 100.
The formation channel 800 may be constructed of any number of types of materials including metallic materials, synthetic materials, and the like. In one aspect, the formation channel 800 may be a metallic structure. In one aspect, the first surface structure 804 and the second surface structure 806 may be formed of a single sheet of the metallic material shaped as illustrated in FIGS. 4, 5A, and 5B. In one aspect, the ends of the single sheet of metallic material may be connected adjacent the gap 820 as illustrated in FIG. 5A. In one aspect, the ends of the single sheet of metallic material may be connected by welding.
In one aspect, the sewing aperture 816 may be formed in the first surface structure 804 and/or the second surface structure 806. In one aspect, the sewing aperture 816 may have a circular structural opening allowing the at least one needle 406 to form the seam 24.
In one aspect, the tubular structure 814 may be an oval shaped cross-sectional shape tube. Other shapes including circular are contemplated as well. In one aspect, the tubular structure 814 may be a metallic structure. In one aspect, the tubular structure 814 may be connected at a single location to the first surface structure 804 and/or the second surface structure 806. In one aspect, the tubular structure 814 may be connected at a single location to the first surface structure 804 and/or the second surface structure 806 by welding. In one aspect, the tubular structure 814 may include an additional feature adjacent the aperture 822 configured to provide a smooth surface for the materials entering the aperture 822. In one aspect, the additional feature is a metallic band.
In one aspect, the attachment bracket 802 may be a metallic structure. In one aspect the attachment bracket may be attached to a surface of the first surface structure 804 and/or the second surface structure 806. In one aspect, the attachment bracket may be attached to a first surface of the first surface structure 804 and/or the second surface structure 806; and the tubular structure 814 may be connected at a single location to the first surface structure 804 and/or the second surface structure 806 opposite the first surface.
FIG. 7A is a schematic of the movement of materials in the formation channel of FIG. 4, according to an aspect of the disclosure.
In particular, as discussed in greater detail below, the first material 602 (Outside fabric layer) may be pulled through the first surface structure 804, the second surface structure 806, and the gap 820 (outside division) of the formation channel 800. The first surface structure 804, the second surface structure 806, and the gap 820 (outside division) of the formation channel 800 forms a half-rounded shape of the first material 602 to form the outer tube 10 formation of the outer tube 10 (outside fabric layer) of the layered weighted yarn 100. The converging shape of the formation channel 800 forms the outer tube 10 while the sewing aperture 816 (circular open area) allows the at least one needle 406 of the sewing machine 400 to connect both fabric ends or sides into the outer tube 10, while the second material 702/plurality of inner layers 18 (inside fabric layers) are pulled into the formation channel 800 in parallel in a loose tube shape (no connection or stitching to the outside tube). The formation channel 800 then reverses the outer tube 10 (fabric tube) so that the seam 24 (stitched fabric connection) is inside the layered weighted yarn 100.
More specifically, as shown in FIG. 7, the first material 602 may be initially located at position 602-1 in the formation channel 800 on the first end 810. In this regard, the first material 602 located at position 602-1 in the formation channel 800 may be located on the first surface structure 804. The first material 602 located at position 602-1 in the formation channel 800 on the first end 810 may initially be generally flat with a slight curvature.
Next, the first material 602 may be pulled into position 602-2 in the formation channel 800 through the gap 820. In this regard, the first material 602 located at position 602-2 is guided by the first surface structure 804 and the second surface structure 806 to start to form a tubular configuration. In particular, the formation channel 800 may have a converging shape that manipulates the first material 602 to form the tubular configuration.
Next, the first material 602 may be pulled into position 602-3 in the formation channel 800 while traveling into the slot 812. In this regard, the first material 602 located at position 602-3 may be further guided by the first surface structure 804, the second surface structure 806, and the slot 812 to complete the manipulation of the first material 602 into the tubular configuration. In particular, the formation channel 800 at position 602-3 is further converged to urge the first material 602 into the tubular configuration. Additionally, the first material 602 at position 602-3 presents the sides of the first material 602 to the sewing aperture 816. At this time, the sewing machine 400 may sew the seam 24 to connect the sides of the first material 602 to form the outer tube 10 while it travels through the slot 812. In particular, the sewing machine 400 may sew the seam 24 to connect the sides through the sewing aperture 816.
Next, the first material 602 may be pulled into position 602-4 in the formation channel 800 while exiting the slot 812. In this regard, the first material 602 located at position 602-4 is guided by the slot 812 and the tubular structure 814 out of the slot 812. Thereafter, the first material 602 may be pulled into position 602-4 in the formation channel 800 and guided into the aperture 822. In particular, the first material 602 now forms the outer tube 10 and movement of the outer tube 10 into the aperture 822 of the tubular structure 814 reverses the orientation of the outer tube 10. Accordingly, the seam 24 and its associated loose edges formed by the sewing machine 400 are now located within the outer tube 10.
While the first material 602 is pulled into position 602-4 in the formation channel 800 and enters the tubular structure 814, the second material 702 may be introduced at position 702-1 such that it is inserted into the outer tube 10 as the outer tube 10 enters the tubular structure 814. In particular, once the second material 702 is introduced at position 702-1, it may thereafter be drawn into the tubular structure 814. Accordingly, the second material 702 that forms the plurality of inner layers 18 may be pulled into the outer tube 10 to form the layered weighted yarn 100. Accordingly, as described above, the first material 602 may be sewed first to form the seam 24 as well as the outer tube 10, then the first material 602 that now forms the outer tube 10 may be reversed.
Finally, the first material 602 may be pulled into position 602-5 and the second material 702 may be pulled into position 702-2 and accordingly the tubular structure 814 and/or the formation channel 800 releases the combined structure of the first material 602, now forming the outer tube 10, and the second material 702, now forming the inner layers 18, as the layered weighted yarn 100.
FIG. 7B illustrates the movement of materials in the formation channel of FIG. 7A.
FIG. 7C illustrates the movement of materials in the formation channel of FIG. 7A.
In particular, FIG. 7B illustrates the first material 602 pulled into position 602-3 as it exits the formation channel 800. As described above, the first material 602 now forms the outer tube 10 and movement of the outer tube 10 into the tubular structure 814 (hidden by the fabric) reverses the orientation of the outer tube 10. Accordingly, the seam 24 and its associated loose edges formed by the sewing machine 400 are now located within the outer tube 10. While the first material 602 enters the tubular structure 814 (hidden by the fabric), the second material 702 may be introduced at position 702-1 such that it is inserted into the outer tube 10 as the outer tube 10 enters the tubular structure 814.
FIG. 7C illustrates the movement the first material 602 moving into position 602-4 by the formation channel 800. In particular, the first material 602 is shown extended from formation channel 800 for ease of understanding. In this regard, the first material 602 now forms the outer tube 10 and movement of the outer tube 10 into the aperture 822 of the tubular structure 814 reverses the orientation of the outer tube 10 as it moves from position 602-3 to position 602-4.
The sewing machine 400 may be configured as an industrial sewing machine, or the like and may have any known construction. In one aspect, the sewing machine 400 may be implemented as a Yamato Model VFS2503-8 high-speed flatbed interlock stitch machine with top feeder (manufactured by Yamato Sewing Machine Mfg. Co., Ltd., Osaka, Japan) or an equivalent sewing machine having one or more commensurate capabilities.
In one aspect, with reference to FIG. 2, the sewing machine 400 may include a throat plate 404 provided on the upper surface of a sewing machine bed. The sewing machine 400 may include at least one needle 406 configured to be movable vertically reciprocally and supported on an arm 408 disposed above the throat plate 404. A needle location of the at least one needle 406 may be formed in the throat plate 404.
In operation, the sewing machine 400 may form the seam 24 by sewing when rotation of the sewing machine 400 is started. As the sewing machine 400 is rotated, the first material 602 is fed in the sewing direction along the upper surface of the throat plate 404 through the formation channel 800 in response to the operation of the racing roller 500. Then, when the first material 602 reaches the needle location, the at least one needle 406 and a looper (not shown) cooperate to form a stitch utilizing thread that forms the seam 24.
The sewing machine 400 may further include supports for sewing rolls for thread stitching, a handwheel for manual operation, one or more pulleys, belts, a power controller, and a motor (rated for operation at 100 watts-700 watts) for providing rotational movement of the sewing machine 400 and/or the racing roller 500, and other features not described for brevity, but known to those of ordinary skill in the art. In one aspect, the sewing machine 400 may not include the motor; and the motor may be implemented by the racing roller 500.
FIG. 8 is a perspective top view of an outer tube material delivery system, according to an aspect of the disclosure; and
FIG. 9 is a perspective bottom view of an outer tube material delivery system of FIG. 8, according to an aspect of the disclosure.
In particular, FIG. 8 illustrates exemplary details of the outer tube material delivery system 600. The outer tube material delivery system 600 may include a support surface 604 that may be configured to support the first material 602. In one aspect, the support surface 604 may be configured to support a roll of the first material 602. The support surface 604 may include a circular synthetic flat surface configured to allow the first material 602 to unwind and be delivered to the formation channel 800. In one aspect, the support surface 604 may be a static support plate. In one aspect, the support surface 604 may have a diameter of 20 cm. to 40 cm., 24 cm. to 36 cm., 28 cm. to 34 cm., or 29 cm. to 31 cm.
The outer tube material delivery system 600 may include a spindle 606 that may be attached to the support surface 604. The spindle 606 may be received in a tube portion of the roll of the first material 602. The outer tube material delivery system 600 may include the guide structure 608 and may include a support structure for supporting the guide structure 608. The support structure may include a first connector 614 extending from the outer tube material delivery system 600 as well as a second connector 612 configured to connect the first connector 614 to the guide structure 608. In one aspect, the guide structure 608 may have a length of 4 cm. to 10 cm., 5 cm. to 9 cm., or 6 cm. to 8 cm. In one aspect, the first connector 614 and the second connector 612 may rigidly support the guide structure 608. In one aspect, the first connector 614 may be a rod, a metal rod, or the like. In one aspect, the first connector 614 may have a length of 10 cm. to 30 cm., 12 cm. to 28 cm., 14 cm. to 26 cm., 18 cm. to 24 cm., or 19 cm. to 23 cm.
With reference to FIG. 9, the support surface 604 may be supported on a support rod 616 with a connection portion attached to the support surface 604. The support rod 616 may be supported by an attachment bracket 618. The attachment bracket 618 may be configured to attach to a flat surface with one or more clamping components. The connection portion may additionally connect and support the first connector 614. In other aspects, the outer tube material delivery system 600 may simply be a source of the first material 602.
FIG. 10 is a perspective view of an inner layer material delivery system, according to an aspect of the disclosure.
In particular, FIG. 10 illustrates the inner layer material delivery system 700. The inner layer material delivery system 700 may include a spindle 704 to support the second material 702. In one aspect, the spindle 704 may support a plurality of rolls of the second material 702. In one aspect, the spindle 704 may be received in a tube portion of a roll of the second material 702. In one aspect, the spindle 704 may be received in tube portions of a multiple number of rolls of the second material 702. In one aspect, the inner layer material delivery system 700 may support 1-6 rolls of the second material 702, 2-6 rolls of the second material 702, or 2-4 rolls of the second material 702. In one aspect, the inner layer material delivery system 700 may simply be a source of the second material 702.
FIG. 11 is a perspective view of a racing roller, according to an aspect of the disclosure.
The racing roller 500 may be configured as a puller configured to operate with a sewing machine or an industrial sewing machine and may have any known construction. In particular, FIG. 11 illustrates the racing roller 500. The racing roller 500 may be mounted in alignment with the sewing machine 400 so that the layered weighted yarn 100 that is being sewn by the sewing machine 400 may be engaged between a lower fabric-engaging roller 502 and an upper fabric-engaging roller 504. The lower fabric-engaging roller 502 and the upper fabric-engaging roller 504 may be biased toward one another to grip and apply tension on the layered weighted yarn 100. The lower fabric-engaging roller 502 and the upper fabric-engaging roller 504 may have a fabric-engaging surface for engaging the layered weighted yarn 100 to prevent slipping, as the rollers are rotated to withdraw the layered weighted yarn 100 at the desired linear velocity from the sewing machine 400.
The lower fabric-engaging roller 502 and the upper fabric-engaging roller 504 may each be securely fastened to a shaft and may be supported in pivotable brackets, each of which may be cantilever mounted to pivot. The lower fabric-engaging roller 502 and the upper fabric-engaging roller 504 may be implemented as rubber rollers.
The racing roller 500 may be configured to be adjusted to apply the desired tension on the layered weighted yarn 100 through compression of the lower fabric-engaging roller 502 and the upper fabric-engaging roller 504. A handle 506 may be configured to control a position of the lower fabric-engaging roller 502 and the upper fabric-engaging roller 504 into and out of engagement. In one aspect, when the handle 506 is rotated in a first direction the lower fabric-engaging roller 502 and the upper fabric-engaging roller 504 may separate from each other. In one aspect, when the handle 506 is rotated in a second direction the lower fabric-engaging roller 502 and the upper fabric-engaging roller 504 may engage each other.
The racing roller 500 may include a driving belt 508 that may be mounted and driven by the motor (not shown) and may be connected to a driven pulley. In operation, the driving belt 508 may rotate a pulley which in turn will rotate the lower fabric-engaging roller 502 and/or the upper fabric-engaging roller 504, which may be spaced apart to apply the appropriate tension to the layered weighted yarn 100 being withdrawn from the sewing machine 400. The racing roller 500 may include a threaded distance controller 510, tension adjustment devices 512, and the like.
The layered weighted yarn 100 manufactured by the device 900 described by the disclosure may be used for any type of desired product. In one aspect, the layered weighted yarn 100 may be utilized in a weighted material 200 as described in further detail below.
As used herein, the terms “providing deep pressure therapy,” “bringing about deep pressure therapy,” “effectuating deep pressure therapy” and/or terms similar thereto, refer to effectively causing deep pressure therapy (also known as deep pressure stimulation, deep touch pressure, etc.) in a person as herein described. More particularly, the terms “providing deep pressure therapy,” “bringing about deep pressure therapy,” “effectuating deep pressure therapy” and/or terms similar thereto, refer to physically contacting an individual to effectively cause the individual's nervous system activity to switch from being dominated by their sympathetic nervous system to being dominated by their parasympathetic nervous system.
An individual's autonomic nervous system (ANS) receives information from the individual's body and environment, and in response thereto, sends signals out to regulate the individual's body and organs. The ANS may include the sympathetic system, the parasympathetic system, and/or other systems, which work together to help the individual physiologically respond in accordance with the information the ANS receives.
The sympathetic nervous system may often be referred to as the “alert” or “fight or flight” response that is elicited during stressful situations, emergency situations, and/or like situations. The parasympathetic nervous system, on the other hand, is responsible for regulating involuntary functions, such as heart rate, blood pressure, and/or the like and stimulating the digestive tract. It brings a sense of calm, peace, and/or the like to the mind and body. When the parasympathetic nervous system takes over, an individual's heart rate may slow, muscles may relax, circulation may improve, and/or the like. When deep pressure is correctly applied, it may relax the nervous system, causing the body to switch from running its sympathetic nervous system to its parasympathetic nervous system.
Deep touch pressure may also alter the person's hormone levels by decreasing their level of cortisol (which causes anxiety and/or other negative physiological effects) while increasing their levels of serotonin and dopamine (which help with mood regulation, relaxation, and/or other positive physiological effects). In other words, the disclosed deep touch pressure provided by the disclosed implementations may reduce anxiety and/or other negative physiological effects; and may provide positive mood regulation, relaxation, and/or other positive physiological effects.
The further disclosed systems and methods include integrating the layered weighted yarn 100 into a weighted material 200 that provides a person with tactile sensory input, which provides proprioceptive input to the individual's body. The weighted material 200 is configured such that when it is administered as a blanket to cover an individual's body, it brings about deep pressure therapy (DPT), thus causing the individual's parasympathetic system to increase, their sympathetic system to decrease, and/or other beneficial responses.
FIG. 12 is a top view of a weighted material comprising a layered weighted yarn that is interlooped, according to an aspect of the disclosure.
In particular, FIG. 1 is a top view of a piece of the weighted material 200 that includes the layered weighted yarn 100 that may be manufactured utilizing the device 900 described herein and that is interlooped (e.g., knit, crocheted, etc.). In one aspect, the layered weighted yarn 100 that is interlooped may have a knitted construction. In one aspect, the layered weighted yarn 100 that is interlooped may have a crocheted construction. The construction of the layered weighted yarn 100, together with the interlooping thereof, provides a weighted material 200 that is sufficiently heavy to provide deep pressure therapy (DPT) to a person without the need for additional weights. The weighted material 200 is configured so that the interlooped configuration of the layered weighted yarn 100 (e.g., one layer of the interlooped configuration of the layered weighted yarn 100), by itself and without any added weights or components, brings about deep pressure therapy (DPT) in an individual, when the weighted material 200 is employed as a blanket over the individual.
As will be described in further detail below, the disclosed weighted material 200 can be employed as a deep pressure therapy (DPT) blanket that provides many advantageous that are not provided by conventional deep pressure therapy (DPT) blankets. For example, the disclosed weighted material 200 includes the layered weighted yarn 100 that may be manufactured utilizing the device 900 described herein and that is interlooped in a pattern that creates small openings at the crossing of the loops. This allows for even airflow through the blanket, thus providing desirable breathability, and helping to regulate the person's body temperature.
The interlooping of the layered weighted yarn 100 may create heavy knots at the cross-sections of the loops. This pattern of heavy knots, in turn, creates a pattern of pressure regions on the individual when the weighted material 200 configured as a blanket and is placed over them. This provides a highly effective deep pressure therapy blanket.
Also, the disclosed weighted material 200 offers even weight distribution. The layered weighted yarn 100 may be evenly interlooped (e.g., knit, crochet) in equally sized, enmeshed loops, which distributes the weight substantially equally and/or evenly across the structure of the weighted material 200. The layered weighted yarn 100 is sufficiently heavy and is fixated through the wide-looped pattern.
Thus, unlike conventional deep pressure therapy (DPT) blankets, the weight does not shift throughout the structure of the weighted material 200 when the weighted material 200 moves. This is highly advantageous, as continuously maintaining an even weight distribution across the individual is imperative to the efficacy of deep pressure therapy (DPT).
Also, the disclosed weighted material 200 provides improved body-contouring abilities. The stretchability of the interlooped configuration of the layered weighted yarn 100 may take a natural body contouring shape and can adapt to each individual body shape, thus creating a direct and increased surface area for the weight to apply gentle and even pressure across the body. Several other benefits and advantageous may be recognized as well.
FIG. 12 further shows an aspect of a weighted material 200 that is constructed by interlooping the layered weighted yarn 100 through a knitting technique. Additionally or alternatively, other suitable techniques of interlooping the layered weighted yarn 100 (e.g., crocheting, looping, knitting, hand-knitting etc.) may be implemented to form the weighted material 200 while remaining within the scope of this disclosure. For example, FIG. 19B show a piece of the weighted material 200 that is constructed by interlooping the layered weighted yarn 100 through a crocheting technique.
The piece of the weighted material 200 shown in FIG. 12 can be utilized as a blanket, for example, for covering a large percentage (e.g., a majority) of a person's body when the person is lying down. In some aspects, a blanket comprising only a single layer of the weighted material 200 provides sufficient weight to effectuate deep pressure therapy on the person. For example, the weighted material 200 may have a length, width, and height; and the layered weighted yarn 100 may have a longitudinal length and a diameter perpendicular thereto. The height of the weighted material 200 may be equal to the diameter of the layered weighted yarn 100. In other words, the weighted material 200 may consist of only a single layer of the interlooped configuration of the layered weighted yarn 100 that is sufficiently weighted to effectuate deep pressure therapy (DPT) when placed over the person's body.
FIG. 13 is a side view of a layered weighted yarn that can be interlooped to construct the weighted material of FIG. 1, according to an aspect of the disclosure; FIG. 14 is a cross-sectional view of the layered weighted yarn of FIG. 13 taken across line III-Ill, according to an aspect of the disclosure; and FIG. 15 is a perspective view of the layered weighted yarn of FIG. 13, according to an aspect of the disclosure.
In particular, FIGS. 13-15 are side, cross-sectional, and perspective views of a length of the layered weighted yarn 100 that may be manufactured utilizing the device 900 described herein, according to an aspect of the disclosure. The term yarn, as used herein, refers to a continuous strand of material that can be manipulated (e.g., interlooped) to form a fabric. The layered weighted yarn 100 may be interlooped to provide a piece of weighted material, for example, the piece of the weighted material 200 shown in FIG. 12. The layered weighted yarn 100 comprises the outer tube 10 and the plurality of inner layers 18 (18 a, 18 b, 18 c) that may be manufactured utilizing the device 900 described herein. The outer tube 10 and the inner layers 18 may be made from textile material, further details of which are provided below with reference to FIGS. 14 and 15. The outer tube 10 extends longitudinally from a first end 12 to a second end 14. While FIG. 13 shows an aspect in which the first end 12 and second end 14 are separated from one another, in other aspects, the length of the layered weighted yarn 100 may comprise a loop, in which the first end 12 and the second end 14 are connected to each other.
The outer tube 10 defines a conduit 16 that extends longitudinally therethrough, from the first end 12 to the second end 14. A plurality of inner layers 18 of material are disposed within the conduit 16 and extend longitudinally from the first end 12 to the second end 14.
The inner layers 18 may be formed by folding at least one inner sheet of the inner layer 18 about at least one fold axis extending substantially longitudinally from the first end 12 to the second end 14. The inner layers 18 may be configured to provide equal weight distribution along a longitudinal length 20 of the layered weighted yarn 100. The inner sheets of the inner layers 18 may be folded longitudinally in any suitable configuration. One or more of the inner sheets of the inner layers 18 may be folded about its respective fold axis a plurality of rotations to provide a coil shape. In some aspects, the inner sheet of the inner layers 18 may be folded about a plurality of fold axes, each of plurality of fold axes may extend longitudinally. The inner layers 18 may include any suitable number of folded inner sheets of the inner layers 18. For example, one to twenty folded inner sheets of the inner layers 18, one to sixteen folded inner sheets of the inner layers 18, one to twelve folded inner sheets of the inner layers 18, one to eight folded inner sheets of the inner layers 18, one to four folded inner sheets of the inner layers 18, two to twenty folded inner sheets of the inner layers 18, two to sixteen folded inner sheets of the inner layers 18, two to twelve folded inner sheets of the inner layers 18, two to eight folded inner sheets of the inner layers 18, or two to four folded inner sheets of the inner layers 18.
As shown in FIGS. 14 and 15, the inner sheet of the inner layer 18 is folded onto itself into one or more coiled or otherwise folded configuration(s). As further shown in FIGS. 14 and 15, the plurality of inner sheets of the inner layers 18 can each be folded in various fold arrangements. For example, FIG. 14 shows an inner sheet of the inner layer 18 a that is folded about one respective fold axis in a plurality of rotations to provide a coil shape. FIG. 14 also shows an inner sheet of the inner layer 18 b that is folded about two respective fold axes in a plurality of rotations to provide two coil shapes. The fold arrangements shown and described herein are exemplary, and the inner layers 18 may include any suitable fold arrangement while remaining within the scope of this disclosure.
The fold axis may extend substantially longitudinally along the longitudinal length 20 from the first end 12 to the second end 14, so that the inner sheet of the inner layer 18 may be folded onto itself lengthwise. The fold axis, however, does not need to be entirely straight or parallel to the longitudinal axis of the layered weighted yarn 100. For example, the folded inner sheet of the inner layer 18 may be twisted, squished, and/or the like along the length of the layered weighted yarn 100.
The plurality of inner layers 18 may extend uninterrupted along the longitudinal length 20 of the layered weighted yarn 100. For example, the at least one folded inner sheet of the inner layers 18 may be uninterrupted along the longitudinal length 20 (e.g., extending uninterrupted from the first end 12 to the second end 14 of the layered weighted yarn 100). This may provide a layered weighted yarn 100 having a substantially homogeneous weight distribution along its length, which in turn may provide a weighted material 200 that has a substantially homogeneous weight distribution across its surface. The plurality of inner layers 18 may be disposed within the conduit 16 and fill the conduit 16 or hollow portion of the outer tube 10 by any suitable proportion. For example, the folded inner sheets of the inner layers 18 may take up 50-99% of the volume of the conduit 16. For example, the folded inner sheets of the inner layers 18 may take up 75-99% of the volume of the conduit 16. For example, the folded inner sheets of the inner layers 18 may take up 85-95% of the volume of the conduit 16. For example, the folded inner sheets of the inner layers 18 may take up to about 50% of the volume of the conduit 16. For example, the folded inner sheets of the inner layers 18 may take up to about 70% of the volume of the conduit 16. For example, the folded inner sheets of the inner layers 18 may take up to about 90% of the volume of the conduit 16. The inner layers 18 may be configured to take up enough volume within the conduit to provide sufficient weight, while allowing for sufficient air flow to flow through the layered weighted yarn 100.
The outer tube 10 and the inner layers 18 may be made of any suitable textile materials, for example, spun fibers, woven fibers, and/or the like. The outer tube 10 and/or the inner layers 18 may be made from cotton, for example, organic cotton. In one aspect, the organic cotton may be entirely 100% organic cotton. The outer tube 10 and/or the inner layers 18 may include a material that demonstrates high stretching properties, such as elastane, to facilitate interlooping of the layered weighted yarn 100.
In some aspects, the outer tube 10 may be made of a cotton-elastane mix, and the inner layers 18 may be made almost entirely (e.g., entirely) of cotton. In one aspect, the organic cotton may be entirely 100% organic cotton. This construction provides a layered weighted yarn 100 that demonstrates sufficient stretchability (from the elastane material in the outer tube 10) to facilitate interlooping of the layered weighted yarn 100 and body contouring of the weighted material 200, while also maintaining sufficient rigidity to provide steady weight distribution of the weighted material 200 configured as a blanket. In one aspect, these characteristics may be a result of the cotton material in the outer tube 10 and/or the cotton material of the inner layers 18.
The weighted material 200 may have any suitable dimensions to be employed as a blanket over a person laying down to bring about deep pressure therapy (DPT). For example, the weighted material 200 may have a length between 40 and 90 inches, between 50 and 80 inches, or between 65 and 75 inches. The weighted material 200 may have a width between 25 and 80 inches, between 35 and 70 inches, or between 45 and 55 inches.
In some aspects, a length of the layered weighted yarn 100 is between 100 and 300 meters in length, between 200 and 300 meters in length, between 225 and 300 meters in length, or between 225 and 275 meters in length.
In some aspects, the weighted material 200 is about 48 inches wide, 72 inches long, and 2 inches high (thick), and is made of a length of the layered weighted yarn 100 having an interlooped configuration that is about 250 meters long and that has a diameter of about 2 inches.
The weighted material 200 may be configured to weigh between 5 lb. and 45 lb., between 7 lb. and 40 lb., or between 10 and 35 lb. The weighted material 200 may weigh between 10% and 20% of a person's body weight, and the weighted material 200 may be configured to bring about deep pressure therapy (DPT) for a person weighing between, for example, 35 lb. and 400 lb. In some aspects, the piece of the weighted material 200 has dimensions of about 48×72×2 inches, weighs between 20 and 35 lb., and is constructed from a length of interlooped layer yarn that is about 250 meters long and has a diameter of about 2 inches.
The layered weighted yarn 100 may have a diameter between 1 and 5 inches. For example, the layered weighted yarn 100 may have a diameter between 1.5 and 3 inches. In some aspects, the layered weighted yarn 100 has a diameter of about 2 inches. In some aspects, the plurality of inner layers 18 comprise folded inner sheets that have a length that is substantially the same as the length of the hollow portion of the outer tube 10, and the inner sheets of the inner layers 18 have a width that is greater than the diameter of the hollow portion of the outer tube 10.
FIGS. 16A, 16B, 16C, 16D, and 16E show exemplary details of forming inner layers by folding an inner sheet, according to an aspect of the disclosure.
In particular, FIGS. 16A-16E show a schematic representation of forming the inner layers 18 by folding an inner sheet of the inner layer 18, according to an aspect of the disclosure. FIG. 16A shows an inner sheet of the inner layer 18 that is in a substantially flat configuration. The inner sheet of the inner layer 18 shown in FIG. 16A may be formed of a larger configuration of the inner sheet of the inner layer 18 that is folded along one or more fold lines to provide the substantially flat configuration shown in FIG. 16A.
FIGS. 16B and 16C show the inner sheet of the inner layer 18 of FIG. 16A as it is being rolled along the longitudinally extending fold axis 22. FIG. 16D shows the inner sheet of the inner layer 18 of FIGS. 16A-16C that is rolled along the longitudinally extending fold axis 22. FIG. 16E shows the inner sheet of the inner layer 18 a of FIGS. 16A-16D, together with additional inner sheets of the inner layers 18 b, 18 c that are each folded along their respective longitudinally extending fold axes. The inner sheets of the inner layers 18 can be arranged within the hollow portion of the outer tube 10 to form the layered weighted yarn 100.
FIGS. 17A, 17B, and 17C show exemplary details of constructing a layered weighted yarn, according to an aspect of the disclosure.
In particular, FIGS. 17A-17C show a schematic representation of constructing a layered weighted yarn 100, according to an aspect of the disclosure. FIG. 17A shows the outer tube 10 that is arranged as a sheet (e.g., sheet of fabric) before it is rolled into the hollow portion of the outer tube 10. Also shown in FIG. 17A is the at least one folded inner layer 18 as it is being arranged on top of a sheet of the outer tube 10. FIG. 17B shows the at least one folded inner layer 18 disposed on the outer tube 10, and the outer tube 10 being rolled into the hollow portion of the outer tube 10. FIG. 17C shows the hollow portion of the outer tube 10 rolled around the plurality of inner layers 18 to form the layered weighted yarn 100. The outer tube 10 may be attached at a seam 24 by any suitable means (e.g., stitching, adhesion, friction, hook-and-loop, etc.) to secure the hollow portion of the outer tube 10. In one aspect, the outer tube 10 may be attached at a seam 24 by that the device 900 described herein. In one aspect, the outer tube 10 may be attached at the seam 24 by stitching. In one aspect, the outer tube 10 may be attached at the seam 24 by adhesion. In one aspect, the outer tube 10 may be attached at the seam 24 by friction. In one aspect, the outer tube 10 may be attached at the seam 24 by hook-and-loop. The hollow portion of the outer tube 10 may be attached to itself the first end 12 and the second end 14 to close the conduit 16.
FIGS. 18A, 18B, and 18C show exemplary details of constructing a layered weighted yarn, according to an aspect of the disclosure.
In particular, FIGS. 18A-18C show a schematic representation of constructing a layered weighted yarn 100, according to an aspect of the disclosure. FIG. 18A shows the outer tube 10 that is hollow, with conduit 16 extending longitudinally therethrough. In some aspects, the outer tube 10 is formed by rolling an outer layer sheet and securing it at a seam into a tube shape (e.g., by attaching the rolled sheet by suitable means (e.g., stitching, adhesion, friction, hook-and-loop, etc.) similarly to the seam 24 shown in FIG. 17C. In some aspects, the outer tube 10 is formed as a seamless tubular structure. For example, the outer tube 10 may be formed by interlocking fibers to form the tubular configuration. FIG. 18B shows the plurality of inner layers 18 being inserted into the conduit 16 of the hollow portion of the outer tube 10. FIG. 18C shows the plurality of inner layers 18 that are arranged inside the hollow portion of the outer tube 10 to provide the layered weighted yarn 100. The hollow portion of the outer tube 10 may be attached to itself at the first end 12 and the second end 14 to close the conduit 16.
In some aspects, the plurality of inner layers 18 may be attached together by any suitable means to maintain, for example, the folded configuration. For example, the at least one folded inner sheets of the inner layers 18 may be stitched and/or adhered to itself. Additionally or alternatively, the plurality of inner layers 18 may be attached to at least a portion of the inner tubular wall of the hollow portion of the outer tube 10 by any suitable means. For example, the at least one folded inner sheet of the inner layer 18 may be attached to the inner tubular wall of the hollow portion of the outer tube 10 by way of stitching, adhesion (e.g., glue), friction, hook-and-loop, etc.
FIG. 19A is a perspective view of a layered weighted yarn being knit to construct a piece of weighted material, according to an aspect of the disclosure.
FIG. 20 is a top view of a piece of weighted material that is constructed by knitting layered weighted yarn, according to an aspect of the disclosure.
FIG. 19A is a perspective view of a layered weighted yarn 100 that is being knit to construct a piece of the weighted material 200, according to an aspect of the disclosure. FIG. 20 is a top view of a piece of the weighted material 200 that is constructed by knitting the layered weighted yarn 100 (e.g., as shown in FIG. 19A), according to an aspect of the disclosure. The layered weighted yarn 100 may be knit using a pair of knitting needles 300. The knitting may be performed manually by a user and/or using an automated machine. The knitting may comprise intermeshing loops of the layered weighted yarn 100 in a number of consecutive rows. As each row progresses, a newly generated loop may be pulled through one or more loops from the prior row, creating a dense pattern.
FIG. 19B is a perspective view of a layered weighted yarn being crocheted to construct a piece of weighted material, according to an aspect of the disclosure.
In particular, FIG. 19B is a perspective view of a strand of the layered weighted yarn 100 being crocheted to construct a piece of the weighted material 200, according to an aspect of the disclosure. The layered weighted yarn 100 may be crocheted using a pair of crocheting needles 450, as shown. The crocheting may be performed manually by a user and/or using an automated machine. The crocheting may comprise intermeshing loops of the layered weighted yarn 100 in a number of consecutive rows.
As shown in FIGS. 19A and 19B, the weighted material 200 comprises layered weighted yarn 100 that is interlooped in a pattern that creates small openings at the crossing of the loops. This allows for even airflow through the blanket, thus providing desirable breathability and helping to regulate the individual's body temperature. The interlooping of the layered weighted yarn 100 (e.g., knitting as shown in FIG. 19A, crocheting as shown in FIG. 19B), together with the construction of the layered weighted yarn 100, creates a piece of the weighted material 200 that is dense enough to provide deep pressure therapy (DPT) for a person. For example, the piece of the weighted material 200 can have dimensions, of about 48×72×2 inches and can weigh between 20 and 35 lb. The interlooped configuration of the weighted material 200 is both sufficiently wide-looped and dense to effectuate deep pressure therapy (DPT), while also providing superior breathability, even and continuous weight distribution, and natural body contouring capabilities.
In one aspect, the interlooped configuration of the weighted material 200 comprises substantially a textile material. In one aspect, the interlooped configuration of the weighted material 200 comprises substantially a fabric material. In one aspect, the interlooped configuration of the weighted material 200 comprises substantially a fiber material. In one aspect, the interlooped configuration of the weighted material 200 comprises substantially a cotton material.
In one aspect, the interlooped configuration of the weighted material 200 comprises 90%-100% by weight of a textile material. In one aspect, the interlooped configuration of the weighted material 200 comprises 90%-100% by weight of a fabric material. In one aspect, the interlooped configuration of the weighted material 200 comprises 90%-100% by weight of a fiber material. In one aspect, the interlooped configuration of the weighted material 200 comprises 90%-100% by weight of a cotton material.
In one aspect, the interlooped configuration of the weighted material 200 entirely includes a textile material. In one aspect, the interlooped configuration of the weighted material 200 entirely includes a fabric material. In one aspect, the interlooped configuration of the weighted material 200 entirely includes a fiber material. In one aspect, the interlooped configuration of the weighted material 200 entirely includes a cotton material.
The interlooping of the layered weighted yarn 100 creates heavy knots at the cross-sections of the loops. This pattern of heavy knots, in turn, creates a pattern of pressure regions on the individual when the weighted material 200 configured as a blanket and is placed over them. This provides a highly effective deep pressure therapy (DPT) blanket.
FIGS. 19A and 19B show formation of a single layer of interlooped configuration of the layered weighted yarn 100. For example, the thickness of the weighted material 200 is equal to the diameter of the layered weighted yarn 100. In some aspects, the layered weighted yarn 100 is sufficiently heavy, and the layered weighted yarn 100 is interlooped such that only a single layer of the interlooped configuration of the layered weighted yarn 100 creates a piece of the weighted material 200 that, when employed as a blanket over a person, brings about deep pressure therapy (DPT) to the person.
FIG. 21 is a flowchart of an exemplary method of constructing a piece of weighted material, according to an aspect of the disclosure.
In particular, FIG. 21 is a flowchart of a method 1000 of constructing a piece of weighted material 200, according to an aspect of the disclosure. In steps 1002-1008, a layered weighted yarn 100 is constructed. At step 1002, an outer tube 10 is provided. The outer tube 10 includes a conduit 16 extending therethrough in a longitudinal direction. At steps 1004 and 1006, an inner sheet is provided and folded around a fold axis, which extends in a longitudinal direction. At step 1008, the folded inner sheet is arranged within the conduit 16, such that the folded inner sheet extends longitudinally within the conduit 16.
In one aspect, the steps 1002-1008 of constructing the layered weighted yarn 100 are performed by the device 900 utilizing the sewing machine 400, the racing roller 500, the formation channel 800, the outer tube material delivery system 600, the inner layer material delivery system 700, and the like as described herein. In one aspect, the steps 1002-1008 of constructing the layered weighted yarn 100 are performed by the device 900 receiving a first material 602 and a second material 702 with a formation channel 800; sewing a seam 24 on the first material 602 with a sewing machine 400 comprising at least one needle 406; delivering the first material 602 to the formation channel 800 with an outer tube material delivery system 600; delivering the second material 702 to the formation channel 800 with an inner layer material delivery system 700; receiving the first material 602 from the outer tube material delivery system 600 and forming the first material 602 into an outer tube 10 with the formation channel 800; reversing an orientation of the first material 602 with the formation channel 800; receiving the second material 702 from the inner layer material delivery system 700 and inserting the second material 702 into the outer tube 10 with the formation channel 800; locating the first material 602 in a position to be sewn by the sewing machine 400 to form the seam 24 on the outer tube 10 with the formation channel 800; and discharging the outer tube 10 comprising the first material 602 and the second material 702 inserted into the outer tube 10 as a layered weighted yarn 100 with the formation channel 800.
At step 1010, the constructed layered weighted yarn is interlooped to construct the weighted material 200 or piece of deep pressure therapy (DPT) material.
The weighted material 200 of FIG. 12 is employed as a blanket over a person's body (e.g., a majority of the person's body). The weighted material 200 and configured as a blanket and may be configured to provide sufficient air circulation through the weighted material 200 configured as a blanket to regulate the body temperature of the person. For example, the weighted material 200 configured as a blanket may be configured to provide 18-26% air flow therethrough (e.g., from the air above the weighted material 200 configured as a blanket to the person laying beneath the weighted material 200 configured as a blanket).
The weighted material 200 may have beneficial air flow qualities that may be provided by the interlooping of the layered weighted yarn 100 (allowing air to circulate around the layered weighted yarn 100) as well as the construction of the layered weighted yarn 100 (allowing air to circulate through the layered weighted yarn 100). For example, as described above with reference to FIGS. 19A and 19B, the weighted material 200 may be created by an interlooped pattern that creates small openings at the crossing of the loops, and between the loops of layered weighted yarn 100. Thus, air flow may travel from the top and to the bottom of the weighted material 200 through the small openings (the air flowing around the layered weighted yarn 100). Also, the layered weighted yarn 100 may be configured to allow air to circulate through the yarn itself. For example, the configuration of the hollow portion of the outer tube 10 and the plurality of the inner layers 18 provide empty spaces within the conduit 16. Air is thus allowed to circulate along the empty spaces and through the conduit 16 (the air flowing through the layered weighted yarn 100). In addition to providing superior air circulation, the construction of the weighted material 200 also provides well-balanced moisture and heat transfer capabilities.
The layered weighted yarn 100 may be configured to have a substantially homogenous weight and density along its longitudinal length 20. This provides many advantages over strands of material that comprise bunched up filler material. For example, the bunched up filler material creates inconsistent weight distribution, which greatly impairs even weight distribution of the weighted blanket. The layered weighted yarn 100, however, is configured to maintain weight distribution through the interlooping of the layered weighted yarn 100 and the movement and use of the weighted material 200 configured as a blanket.
While the outer tube 10 and inner layers 18 are shown and described as being separate components, in some aspects, the outer tube 10 and at least one of the inner layers 18 are integrally formed. In some aspects, the inner layers 18 are attached (e.g., at a seam along the longitudinal length 20 of the layered weighted yarn 100), so the outer periphery of the attached inner layers 18 forms the outer construction of the yarn (e.g., without a separate outer tube 10).
While this disclosure describes using the piece of the weighted material 200 to provide deep pressure therapy (DPT), it should be well understood that the weighted material 200 may be used for other purposes, in addition to or as an alternate to deep pressure therapy (DPT). Also, while the disclosure describes employing the piece of the weighted material 200 as a blanket to lay over an individual, it should be well understood that the weighted material 200 may be employed in other suitable ways. Further, while this disclosure describes laying the weighted material 200 over a person, it should be well understood that the weighted material 200 may be laid over other suitable kinds of animals to provide them with deep pressure therapy (DPT).
The preceding description has been provided to enable others skilled in the art to best utilize various aspects of the exemplary aspects disclosed herein. This exemplary description is not intended to be exhaustive or to be limited to any precise form disclosed. Many modifications and variations are possible without departing from the spirit and scope of the disclosure. The aspects disclosed herein should be considered in all respects illustrative and not restrictive. Reference should be made to the appended claims and their equivalents in determining the scope of the disclosure.
Unless otherwise noted, the terms “connected to” and “coupled to” (and their derivatives), as used in the specification and claims, are to be construed as permitting both direct and indirect (i.e., via other elements or components) connection. In addition, the terms “a” or “an,” as used in the specification and claims, are to be construed as meaning “at least one of.” Finally, for ease of use, the terms “including” and “having” (and their derivatives), as used in the specification and claims, are interchangeable with and have the same meaning as the word “comprising.”
It will be understood that when an element such as a layer or region is referred to as being “on” or extending “onto” another element, it can be directly on or extend directly onto the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or extending “directly onto” another element, there are no intervening elements present. It will also be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.
Relative terms such as “below” or “above” or “upper” or “lower” or “top” or “bottom” may be used herein to describe a relationship of one element, layer or region to another element, layer or region as illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.
While the disclosure has been described in terms of exemplary aspects, those skilled in the art will recognize that the disclosure can be practiced with modifications in the spirit and scope of the appended claims. These examples given above are merely illustrative and are not meant to be an exhaustive list of all possible designs, aspects, applications or modifications of the disclosure.
In the drawings and specification, there have been disclosed typical aspects of the disclosure and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the disclosure being set forth in the following claims.

Claims

What is claimed is:

1. A device configured to manufacture a layered weighted yarn comprising:

a formation channel configured to receive a first material and a second material;

a sewing machine comprising at least one needle, the sewing machine configured to sew a seam on the first material;

an outer tube material delivery system configured to deliver the first material to the formation channel;

an inner layer material delivery system configured to deliver the second material to the formation channel;

the formation channel being further configured to receive the first material from the outer tube material delivery system and form the first material into an outer tube;

the formation channel being further configured to receive the second material from the inner layer material delivery system and insert the second material into the outer tube;

the formation channel being further configured to locate the first material in a position to be sewn by the sewing machine to form the seam on the outer tube; and

the formation channel being further configured to discharge the outer tube comprising the first material and the second material inserted into the outer tube as a layered weighted yarn.

2. The device configured to manufacture a layered weighted yarn of claim 1 wherein the formation channel being further configured to reverse an orientation of the first material.

3. The device configured to manufacture a layered weighted yarn of claim 1

wherein the formation channel comprises a first surface structure and a second surface structure configured to form a gap therebetween;

wherein the gap is configured to receive the first material; and

wherein the formation channel comprises a sewing aperture being configured to locate the first material in the position to be sewn by the sewing machine to form the seam on the outer tube.

4. The device configured to manufacture a layered weighted yarn of claim 1 wherein the formation channel comprises a tubular structure configured to receive the first material and the second material.

5. The device configured to manufacture a layered weighted yarn of claim 1

wherein the formation channel comprises a bracket for attachment to the sewing machine; and

wherein the formation channel being attached to the sewing machine by the bracket.

6. The device configured to manufacture a layered weighted yarn of claim 1 wherein the outer tube material delivery system comprises a spindle to support the first material.

7. The device configured to manufacture a layered weighted yarn of claim 1 wherein the outer tube material delivery system comprises a guide structure to guide the first material to the formation channel.

8. The device configured to manufacture a layered weighted yarn of claim 1 wherein the inner layer material delivery system comprises a spindle to support the second material.

9. The device configured to manufacture a layered weighted yarn of claim 1 further comprising:

a racing roller configured to engage the layered weighted yarn and advance the first material and the second material through the formation channel and the sewing machine; and

the racing roller further comprising a lower fabric-engaging roller and an upper fabric-engaging roller.

10. The device configured to manufacture a layered weighted yarn of claim 1 wherein:

a length of the layered weighted yarn is configured to be interlooped to form a piece of weighted material; and

the piece of weighted material, by itself, is configured and sufficiently weighted to effectuate deep pressure therapy to a person as a deep pressure therapy blanket when placed over a person's body.

11. A method of constructing a layered weighted yarn, the method comprising:

receiving a first material and a second material with a formation channel;

sewing a seam on the first material with a sewing machine comprising at least one needle;

delivering the first material to the formation channel with an outer tube material delivery system;

delivering the second material to the formation channel with an inner layer material delivery system;

receiving the first material from the outer tube material delivery system and forming the first material into an outer tube with the formation channel;

receiving the second material from the inner layer material delivery system and inserting the second material into the outer tube with the formation channel;

locating the first material in a position to be sewn by the sewing machine to form the seam on the outer tube with the formation channel; and

discharging the outer tube comprising the first material and the second material inserted into the outer tube as a layered weighted yarn with the formation channel.

12. The method of constructing a layered weighted yarn of claim 11 further comprising reversing an orientation of the first material with the formation channel.

13. The method of constructing a layered weighted yarn of claim 11

wherein the gap is configured to receive the first material; and

14. The method of constructing a layered weighted yarn of claim 11 wherein the formation channel comprises a tubular structure configured to receive the first material and the second material.

15. The method of constructing a layered weighted yarn of claim 11

16. The method of constructing a layered weighted yarn of claim 11 wherein the outer tube material delivery system comprises a spindle to support the first material.

17. The method of constructing a layered weighted yarn of claim 11 wherein the outer tube material delivery system comprises a guide structure to guide the first material to the formation channel.

18. The method of constructing a layered weighted yarn of claim 11 wherein the inner layer material delivery system comprises a spindle to support the second material.

19. The method of constructing a layered weighted yarn of claim 11 further comprising

20. A method of constructing a weighted material with the layered weighted yarn of claim 11 comprising:

interlooping a length of the layered weighted yarn to construct a piece of weighted material,

wherein the piece of weighted material, by itself, is configured and sufficiently weighted to effectuate deep pressure therapy to a person as a deep pressure therapy blanket when placed over a person's body.