Patent Application
20210071322
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.
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.
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.
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.
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.
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.
In particular,
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.
In particular,
In particular,
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.
In particular, as further described below,
Returning to
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
In particular,
The formation channel 800 may further include a slot 812 as illustrated in
With reference to
Additionally, the formation channel 800 may include the sewing aperture 816 as illustrated in
With reference to
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
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.
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
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.
In particular,
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
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.
In particular,
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
In particular,
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,
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.
In particular,
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.
The piece of the weighted material 200 shown in
In particular,
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
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.
In particular,
In particular,
In particular,
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.
In particular,
As shown in
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.
In particular,
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
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
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.
