METHOD OF MANUFACTURING MECHANORECEPTION STIMULATION FABRIC

Abstract

A method for manufacturing a mechanoreception fabric for incorporation into a garment or item of apparel sets a liquid substrate to a fabric weave to produce a plurality of protuberances in graticulate array and spaced apart across a surface of the fabric. The plurality of protuberances includes pyramidal nodes, each independent and separate from other nodes, not less than 1 mm apart at the base and not more than 5 mm apart at each apex and 1.5 mm in height. Because the nodes are separated and not in contact with each other, the fabric produced is still stretchable and wearable when incorporated into an item of apparel despite the nodes having a hardness of between Shore A 60 and 80.

Claims

1. A method of manufacturing a mechanoreception stimulation fabric comprising the steps of: cutting a mold plate to a general shape appropriate for use in molding an arrangement of a plurality of protuberances upon a garment or item of apparel devised to overlie a targeted receptive field in a user's innervate skin when the protuberances are transferred and affixed to a fabric that is subsequently incorporated or worn as a garment or item of apparel; scoring the mold plate to include a plurality of inverse pyramidal nodes upon a surface thereof, said nodes arranged in an array corresponding to the desired position of the plurality of protuberances upon a completed garment or item of apparel; dispensing controlled volumes of liquid polymer or substrate into the inverse pyramidal nodes in the mold such that the surface of the liquid polymer or substrate is congruent with the surface of the mold without overflowing; heating the mold to a specific temperature for a target time as required to ensure the surface of the liquid polymer or substrate reaches a specific set temperature; placing a fabric blank or item upon a positioning plate corresponding to the shape of the mold such that a targeted surface of the fabric blank or item is caused to directly contact and remain in contact with the mold's surface wherein the liquid polymer or substrate is housed; subjecting the fabric blank or item in contact with the mold to press at a target pressure; cooling the fabric blank and mold so that the mold temperature falls to a desired cooling temperature; and peeling the fabric from the mold when the mold cools to a specific cooling temperature; wherein the plurality of protuberances is affixed to the interior surface of the fabric, each node independent, separate from, and not in contact with any adjacent node, whereby the fabric is stretchable and wearable in generally the same manner as without the nodes affixed thereto.

2. The method of manufacturing a mechanoreception stimulation fabric of claim 1 wherein the liquid polymer or substrate has a Shore A hardness of between 60 and 80 when solidified and affixed to the fabric.

3. The method of manufacturing a mechanoreception stimulation fabric of claim 2 wherein each node is 1.5 mm in height and 2.5 mm by 2.5 mm in length and width at the base.

4. The method of manufacturing a mechanoreception stimulation fabric of claim 3 further comprising the step of adding a color masterbatch to the liquid polymer or substrate previous to dispensing into the mold.

5. The method of manufacturing a mechanoreception stimulation fabric of claim 4 wherein the liquid polymer or substrate is poly vinyl chloride

6. The method of manufacturing a mechanoreception stimulation fabric of claim 5 wherein the step of dispensing controlled volumes of the liquid polymer or substrate into the mold is accomplished by a Computer Numeric Control dispensing machine whereby precise volumes of the polymer or substrate are dispensed into the mold.

6. The method of manufacturing a mechanoreception stimulation fabric of claim 6 wherein the set temperature is in the range of 400° C.

7. The method of manufacturing a mechanoreception stimulation fabric of claim 6 wherein the cooling temperature is 100° C.

8. The method of manufacturing a mechanoreception stimulation fabric of claim 6 wherein the target pressure is 500 kg/cm.sup.2.

9. The method of manufacturing a mechanoreception stimulation fabric of claim 6 wherein the target time is at least two minutes.

10. A method of manufacturing a mechanoreception stimulation fabric comprising the steps of: cutting a mold plate to a general shape appropriate for use in molding an arrangement of a plurality of protuberances upon a garment or item of apparel devised to overlie a targeted receptive field in a user's innervate skin when the protuberances are transferred and affixed to a fabric that is subsequently incorporated or worn as a garment or item of apparel; scoring the mold plate to include a plurality of inverse pyramidal nodes upon a surface thereof, said pyramidal nodes 2.5 mm by 2.5 mm at the opening at the surface of the mold, not more than 1.5 mm deep, and not more than 1 mm apart, said nodes arranged in a graticulate array corresponding to the desired position of the plurality of protuberances upon a completed garment or item of apparel; dispensing controlled volumes of liquid polymer or substrate into the inverse pyramidal nodes in the mold such that the surface of the liquid polymer or substrate is congruent with the surface of the mold without overflowing; heating the mold to a specific temperature of approximately 400° C. for at least two minutes as required to ensure the surface of the liquid polymer or substrate reaches a specific set temperature; placing a fabric blank or item upon a positioning plate corresponding to the shape of the mold such that a targeted surface of the fabric blank or item is caused to directly contact the mold's surface wherein the liquid polymer or substrate is housed; subjecting the fabric blank or item in contact with the mold to a range of pressure of 500 kg/cm.sup.2; cooling the fabric blank and mold so that the mold temperature falls to a desired cooling temperature of approximately 100° C.; and peeling the fabric from the mold when the mold cools to a specific cooling temperature; wherein the plurality of protuberances is affixed to the interior surface of the fabric and arranged not more than 1 mm apart at each base and not more than 5 mm apart at each apex, and wherein each node is independent, separate from, and not in contact with any adjacent node, whereby the fabric is stretchable and wearable in generally the same manner as without the nodes affixed thereto.

11. The method of manufacturing a mechanoreception stimulation fabric of claim 10 wherein the liquid polymer or substrate has a Shore A hardness of between 60 and 80 when solidified and affixed to the fabric.

12. The method of manufacturing a mechanoreception stimulation fabric of claim 11 wherein the liquid polymer or substrate is poly vinyl chloride.

13. The method of manufacturing a mechanoreception stimulation fabric of claim 12 further comprising the step of adding a color masterbatch to the liquid polymer or substrate previous to dispensing into the mold.

14. The method of manufacturing a mechanoreception stimulation fabric of claim 13 wherein the step of dispensing controlled volumes of the liquid polymer or substrate into the mold is accomplished by a Computer Numeric Control dispensing machine whereby precise volumes of the polymer or substrate are dispensed into the mold.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figures

[0019] FIG. 1 is a flow diagram setting forth exemplary steps of the instant method.

DETAILED DESCRIPTION OF THE DRAWINGS

[0020] An example embodiment of the instant method of manufacture of the mechanoreception stimulation fabric is set forth in FIG. 1. A plurality of protuberances, consisting of a plurality of pyramidal nodes, is affixed to a fabric weave of a garment or blank for use as apparel. The exemplary steps as set forth and depicted herein are intended to illustrate an example embodiment of the instant method only, and, in and of themselves, are not intended to be limiting but are provided to breathe life into the accompanying claims.

[0021] Referring now to FIG. 1, a polyvinyl chloride (“PVC”) resin is prepared as a liquid substrate for incorporation into a Computer Numerical Control (“CNC”) machine. In the example method set forth herein, color is added to the substrate by addition of a color masterbatch. The colored substrate is then added to the CNC for precise volumetric dispensation interior to a mold.

[0022] In the example embodiment set forth herein, a mold is presented for receipt of the substrate, said mold rendered in aluminum and having a plurality of pyramid-shaped cavities pressed, scored, or molded into an upper surface thereof. Each of the pyramid-shaped cavities is 2.5 by 2.5 mm at each opening at the upper surface, converging to an acuate apex 1.5 mm deep along a vertical axis into the mold, and spaced 1 mm apart across the upper surface of the mold. Use of the CNC ensures precise volumetric dispensation of the substrate to fill each pyramid-shaped cavity to a volume wherein a surface of the substrate is generally congruent with the upper surface of the mold. Surface tension of the liquid substrate may allow for precise volumetric dispensation to slightly overfill each inverted pyramid, to produce a surface of the injected substrate that is slightly above the upper surface of the mold in some capacity. In either case, however, the substrate is maintained in discrete positions corresponding to the position of each of the pyramid-shaped cavities in conformity with the pyramid shape whereby a square base is fashioned affixed to the fabric.

[0023] The mold itself may be shaped specifically for use with particular fabric blanks for which certain items of apparel are contemplated. For example, a generally oval or obround mold may be configured for use in creating socks. Or the mold may be arranged for creation of a glove, say. Alternatively, the mold may be a parallelepiped or other shaped expanse used for pressing blanks from which multiple and varied items of apparel may be derived. Where the method is used to produce socks, a premade sock may be turned inside-out and inverted and fitted to the mold such that the interior surface of the sock sole is caused to overlie and directly contact the mold.

[0024] Once the substrate has been properly dispensed to fill each of the inverted pyramidal cavities, the mold is baked for two minutes at 400° C. Once removed from the heat, the fabric blank is positioned in contact with the mold in such a manner to accommodate the desired placement of the plurality of protuberances when affixed to the fabric at completion of the present method. The fabric and mold are then subjected to pressure and pressed at 500 kg/cm.sup.2. After pressing, the mold is cooled to 100° C. and thereafter the fabric is separated from the mold. The substrate is solidified and affixed to the fabric presenting a plurality of protuberances consisting of a plurality of pyramidal nodes, each 1.5 mm in height, with a square base dimensioned 2.5 mm by 2.5 mm. Each node is spaced not less than 1 mm between the bases and not more than 5 mm between each apex. In a preferred embodiment disclosed herein, each node has a hardness of Shore A 60 to 80, with a preferred hardness of 75.

[0025] Each node is affixed to the fabric without appreciably impeding the stretchability or wearability of the fabric. Where the fabric produced is a blank, the blank may be used in the production of a garment or apparel. Where the fabric produced is a sock, the sock is prepared for packaging and distribution.