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

1-14. (canceled):

15. A method for stimulating cutaneous receptors in glabrous skin of a person, comprising: contacting cutaneous receptors in glabrous skin of a person with a somatosensation and proprioceptor stimulation surface comprising a plurality of protuberances which are projected upwardly from the stimulation surface and which are configured to stimulate cutaneous receptors in the glabrous skin of the person when pressed in contact with the glabrous skin of the person, wherein said protuberances comprise an acute apex; a medial portion; and a base; and wherein said protuberances are not more than 1 mm apart between bases, have a Shore hardness of approximately 30 A or harder, have a pyramidal shape, and are not more than 5 mm apart between apices.

16. The method of claim 15, wherein cutaneous receptors in the glabrous skin of a foot of the person are stimulated.

17. The method of claim 15, wherein cutaneous receptors in the glabrous skin of a hand of the person are stimulated.

18. The method of claim 15, wherein the stimulation surface is in the form of an insole.

19. The method of claim 15, wherein the stimulation surface is in the form of a mat.

20. The method of claim 15, wherein the stimulation surface is in the form of a flooring material insole.

21. The method of claim 16, wherein the stimulation surface is in the form of an insole.

22. The method of claim 16, wherein the stimulation surface is in the form of a mat.

23. The method of claim 16, wherein the stimulation surface is in the form of a flooring material insole.

24. The method of claim 15, wherein said protuberances have a Shore hardness of approximately 30 A to 70A.

25. The method of claim 15, wherein said protuberances are 3.5 mm apart between apices.

26. The method of claim 24, wherein said protuberances are 3.5 mm apart between apices.

27. The method of claim 16, wherein said protuberances have a Shore hardness of approximately 30 A to 70A.

28. The method of claim 16, wherein said protuberances are 3.5 mm apart between apices.

29. The method of claim 27, wherein said protuberances are 3.5 mm apart between apices.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 is a flow diagram setting forth exemplary steps of the instant method.

DETAILED DESCRIPTION OF THE DRAWINGS

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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.