BLANKET AND METHOD OF MANUFACTURE THEREOF

Abstract

An example blanket includes: a yarn having a predefined length based on a target size of the blanket, wherein the yarn is interlaced to form the blanket, the yarn comprising: an outer layer comprising a first layer of fabric forming a tube, the outer layer having the predefined length and defining a fixed diameter of the tube and a fixed interior capacity of the tube based on the fixed diameter; and an inner layer comprising a second layer of fabric, having the predefined length and a width selected based on a target pressure to be applied over the target size of the blanket, wherein the inner layer is disposed in the tube to fill a portion of the fixed interior capacity of the tube.

Claims

1. A blanket comprising: a yarn having a predefined length based on a target size of the blanket, wherein the yarn is interlaced to form the blanket, the yarn comprising: an outer layer comprising a first layer of fabric forming a tube, the outer layer having the predefined length and defining a fixed diameter of the tube and a fixed interior capacity of the tube based on the fixed diameter; and an inner layer comprising a second layer of fabric, having the predefined length and a width selected based on a target pressure to be applied over the target size of the blanket, wherein the inner layer is disposed in the tube to fill a portion of the fixed interior capacity of the tube.

2. The blanket of claim 1, wherein the inner layer comprises a single fabric sheet.

3. The blanket of claim 1, wherein the inner layer fills less than a maximum of the fixed interior capacity of the tube.

4. The blanket of claim 1, wherein a ratio of the width of the inner layer to a perimeter of the tube is greater than about 1.

5. The blanket of claim 1, wherein a ratio of the width of the inner layer to a perimeter of the tube is greater than about 0.75.

6. The blanket of claim 1, wherein the inner layer further has a weight selected to optimize a ratio of the width of the inner layer to a perimeter of the tube.

7. The blanket of claim 1, wherein the width of the inner layer is selected to achieve a target weight for the blanket.

8. The blanket of claim 1, wherein the inner layer is rolled along the predefined length.

9. A method of manufacturing a blanket, the method comprising: selecting a target size of the blanket and predefining a length of yarn to be interlaced to form the blanket based on the target size; providing an outer layer having the predefined length and forming a tube to define an interior capacity; selecting a width for an inner layer based on a target pressure to be applied over the target size of the blanket; providing the inner layer having the predefined length and the selected width; inserting the inner layer into the outer layer to fill at least a portion of the interior capacity, wherein the outer layer filled with the inner layer defines the yarn; and interlacing the yarn to form the blanket.

10. The method of claim 9, wherein the inner layer comprises a single fabric sheet.

11. The method of claim 9, wherein the inner layer fills less than a maximum of the interior capacity of the tube.

12. The method of claim 9, wherein a ratio of the width of the inner layer to a perimeter of the tube is greater than about 1.

13. The method of claim 9, wherein a ratio of the width of the inner layer to a perimeter of the tube is greater than about 0.75.

14. The method of claim 9, wherein the inner layer further has a weight selected to optimize a ratio of the width of the inner layer to a perimeter of the tube.

15. The method of claim 9, wherein the width of the inner layer is selected to achieve a target weight for the blanket.

16. The method of claim 9, wherein the inner layer is rolled along the predefined length.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0007] Implementations are described with reference to the following figures, in which:

[0008] FIG. 1 depicts an example blanket in accordance with the present disclosure;

[0009] FIGS. 2A and 2B depict schematic cross-sectional and partial perspective views of an example double layered yarn for the example blanket of FIG. 1;

[0010] FIGS. 3A and 3B depict schematic diagrams of example yarn for the example blanket of FIG. 1;

[0011] FIG. 4 depicts a schematic cross-sectional view of an example yarn for the example blanket of FIG. 1 in another configuration;

[0012] FIG. 5 depicts a side view of an example yarn for the example blanket of FIG. 1;

[0013] FIG. 6 depicts an example method of manufacture of a blanket in accordance with the present disclosure;

[0014] FIGS. 7A-E depict schematic diagrams of an example performance of block 620 of the method of FIG. 6.

DETAILED DESCRIPTION

[0015] To achieve a more environmentally-friendly weighted blanket, crocheted or knitted blankets can be an attractive alternative. Such weighted blankets are generally made by cutting the fabric roll into into approximately 6- to 8-inch-wide strips, which are then placed on a spool holder, with the strips of fabric acting like yarn. The fabric strip is then handwoven using the crochet method. A primary problem with this method is that it is expensive to produce since the amount of material required is greater.

[0016] Some knitted weighted blankets are formed from double layered yarn, which has an outer layer and an inner layer (formed of the 6- to 8-inch-wide strips) to fill the outer layer. The inner layer preferably substantially fills the outer layer to its maximum capacity in order to create a full look. However, in such examples, to vary the weight of the overall blanket, the length of the yarn may be varied to maintain the full look of the yarn. This solution achieves variations in weight, however does not allow for variations in pressure of the blanket, since the greater weight is spread over a corresponding larger or smaller area, after interlacing the yarn to form the blanket.

[0017] Accordingly, the present disclosure provides a blanket which varies the width of the inner layer to achieve the target pressure for the target size of the blanket. FIG. 1 depicts an example blanket 100 in accordance with the present specification. The blanket 100 is formed of a yarn 104 which is interlaced to form the blanket 100. For example, the yarn 104 may be a single length of yarn which is self-interlaced (e.g., knitted, crochet, woven, etc.) to form the blanket 100. In other examples, the yarn 104 may include more than one length of yarn which are interlaced to form the blanket 100. The yarn 104 and/or the blanket 100 may be referred to herein as being knitted, however, it will be understood that any suitable fiber arts techniques are also contemplated.

[0018] The yarn 104 has a predefined length based on a target size of the blanket 100. In particular, the predefined length of the yarn 104 may be selected to achieve the target size of the blanket 100 when the yarn 104 is knitted, based on the amount of yarn used for the selected knitting (or other weaving) technique.

[0019] The yarn 104 is a double-layered yarn to increase the weight of the blanket 100. In particular, referring to FIG. 2A, a cross-sectional view of the yarn 104 is depicted. FIG. 2B depicts a perspective view of the yarn 104 including the cross-section. As can be seen, the yarn 104 includes an outer layer 200 and an inner layer 204.

[0020] The outer layer 200 is a first layer of fabric forming a tube or sheath extending longitudinally along the predefined length of the yarn 104. The outer layer 200 may thus be substantially circular or elliptical in cross-sectional shape. The outer layer 200 has a fixed diameter which defines an interior capacity 208 of the outer layer 200. For example, the outer layer 200 may be a sheet of fabric which is sewn together at its longitudinal edges 212-1 and 212-2 to form a seam 216 which extends longitudinally along the predefined length of the yarn 104 (depicted in FIG. 3A). Preferably, after sewing the seam 216 to form the tube, the outer layer 200 may be inverted so that the seam 216 and the edges 212-1, 212-2 are contained in the interior capacity 208 of the outer layer 200.

[0021] In other examples, the outer layer 200 may have its edges 212-1, 212-2 secured together with adhesive, hook and loop fasteners, buttons, or other suitable fasteners. The outer layer 200 may similarly be inverted so that the fasteners are contained in the interior capacity 208 of the outer layer 200. In still further examples, the outer layer 200 may be formed of two sheets of fabric which are fastened together at two edges, as depicted in FIG. 3B, which may be subsequently inverted, or the outer layer 200 may be a seamless tube of fabric. In still further examples, the yarn 104 may simply be woven or interlaced in such a manner that the outer layer 200 covers the inner layer 204.

[0022] The outer layer 200 preferably has a fixed diameter and a fixed interior capacity 208 irrespective of the target size of the blanket 100. This allows the blankets 100 to have an aesthetic consistency, since the yarn 104 is consistently formed from the outer layer 200 having a consistent fixed diameter. For example, the cross-sectional diameter may be a fixed value between about 0.25 inches to about 6 inches. Preferably, the cross-sectional diameter may be a fixed value between about 1 inch to about 2 inches.

[0023] The outer layer 200 thus provides a perimeter wall for holding the inner layer 204. That is, the outer layer 200 covers the inner layer 204 when the yarn 104 is knitted, crocheted or woven. Accordingly, the outer layer 200 may be selected to achieve a certain aesthetic look or a certain tactile feel. The outer layer 200 may be made of natural fibers, regenerated synthetic, other natural materials, combinations of the above, or the like. For example, the outer layer 200 may be formed of cotton, linen, hemp, bamboo, viscose, modal, combinations of the above, and the like. In some examples, the material may include amounts of synthetic fibers such as spandex. In some examples, various types of synthetic material may be used, such as velvet, velour, fleece, chiffon, lace, polyester, and the like. The outer layer 200 may include 2-ply, 3-ply, 4-ply or other materials.

[0024] The inner layer 204 is a second layer of fabric extending longitudinally along the predefined length of the yarn 104. The inner layer 204 is disposed in the tube and fills at least a portion of the interior capacity 208 of the outer layer 200. Generally, the inner layer 204 increases the overall weight of the blanket 100 to provide deep pressure therapy when the blanket 100 is placed over a user's body. For example, the inner layer 204 may be selected to vary its weight according to a desired target pressure to be applied over the target size of the blanket 100, as will be described further herein.

[0025] The inner layer 204 has a length equal to the predefined length of the yarn 104 and a width selected based on a target pressure to be applied over the target size of the blanket 100. For example, when the inner layer 204 is wider, the weight of the inner layer 204 is increased, and hence, when the yarn 104 is interlaced to form the blanket 100, the blanket 100 will have a greater pressure (i.e., weight per area) than an equivalent blanket 100 with a thinner inner layer 204. In particular, since the yarn 104 has the predefined length, equivalent blankets 100 will be the same size (i.e., since the predefined length of yarn forms a blanket 100 of the target size), and hence the increase or decrease in weight of the inner layer 204 based on its width will increase the pressure of the blanket 100. Accordingly, in order to achieve the target pressure to be applied over the target size of the blanket 100, the width of the inner layer 204 may be selected to achieve a target weight for the blanket 100.

[0026] As will be appreciated, by varying the width of the inner layer 204 based on the target pressure to be applied over the target size of the blanket 100, the overall volume of the inner layer 204 may also change. That is, a thinner inner layer 204 may occupy less space in the interior capacity 208 than a wider inner layer 204. In other words, the appearance of the yarn 104 (i.e., its fullness) and thus the blanket 100 may depend at least in part on a ratio of the width of the inner layer 204 to the width (i.e., the perimeter) of the outer layer 200.

[0027] Preferably, the ratio of the width of the inner layer 204 to the perimeter of the outer layer 200 is greater than about 2, however in other examples, the ratio may be about 1 or about 0.75. As will be appreciated, the ratio of the width of the inner layer 204 to the perimeter of the outer layer 200 may depend on the target pressure to be applied over the target size of the blanket 100.

[0028] When the yarn 104 has a smaller ratio of the width of the inner layer 204 to the perimeter of the outer layer 200, the yarn 104 may appear more ribbon-like or flatter in appearance, rather than circular in appearance. To improve the circular appearance of the yarn 104 when the inner layer 204 occupies less than the maximum of the fixed interior capacity 208 of the outer layer 200, the inner layer 204 may be rolled longitudinally along the predefined length to provide for a more substantially circular shape, as depicted in the example cross section shown in FIG. 4. In other examples, the inner layer 204 may simply be inserted in any form within the interior capacity 208, as depicted in FIG. 2A. As will be appreciated, the diameter of the yarn 104 may be fixed based on an expected maximum weight at which the blanket 100 may be manufactured, wherein the inner layer 204 substantially fills the interior capacity 208 at the expected maximum weight. The diameter may then be fixed for blankets 100 manufactured at a lower weight to provide consistency in the yarn 104 across blankets 100 of differing target weights and/or target pressures.

[0029] The inner layer 204 may be made of plain virgin or recycled synthetic material, such as polyester, polyamide, elastane, or the like, or various natural fibers, regenerated synthetic, or other natural materials, combinations thereof, and the like, selected to reduce costs or optimize the selection of the weight. For example, for a lighter target pressure, the material of the inner layer 204 may be selected to be a lighter material so that the selected width of the inner layer 204 is wider to achieve the target pressure, thereby increasing the ratio of the width of the inner layer 204 to the perimeter of the outer layer 200 and thus increasing the fullness of the interior capacity 208 of the outer layer 200. That is, in some examples, the inner layer 204 may have a selected width and material to optimize the target pressure to be applied over the target size of the blanket 100. In still further examples, other parameters of the inner layer 204 may also be varied to optimize the target pressure to be applied over the target size of the blanket 100.

[0030] In other examples, the inner layer 204 may include foam, feather, polyether flakes, yarn, wool, fiber, vinyl, nylon, spun yarn, thread, fleece, cord, cord yarn, rope, and the like.

[0031] As will be appreciated, the flexibility of having separate materials for the inner layer 204 and the outer layer 200 may reduce costs. In particular, the inner layer 204 may be selected to optimize the weight of the blanket 100 while the outer layer 200 may be selected to optimize the appearance and feel of the blanket 100. Thus, for example the outer layer 200 may be lighter than the inner layer 204 (e.g., selected to reduce pilling) without negatively affecting the overall pressure applied by the blanket 100, since the inner layer 204 may be similarly selected to accommodate the variance in weight of the outer layer 200.

[0032] Preferably, the inner layer 204 is a single fabric sheet. This may allow the inner layer 204 to be easily inserted into the interior capacity 208 of the outer layer 200 since only a single sheet is to be inserted, rather than multiple sheets, which may cause bunching during manufacture and/or use as the sheets move against one another. Further preferably, in some examples, the inner layer 204 may be securely fastened to the outer layer 200 (e.g., by sewing, buttons, hook and loop fasteners or the like) to reduce movement of the inner layer 204 within the outer layer 200.

[0033] FIG. 5 depicts a partial view of the yarn 104 with the outer layer 200 inverted to conceal the seam 216 and the edges 212-1, 212-2 and with the inner layer 204 partially extending from opening 500 for illustrative purposes.

[0034] FIG. 6 depicts an example method 600 of manufacturing a blanket. The method 600 will be described in conjunction with the manufacture of the blanket 100, however this is non-limiting.

[0035] At block 605, a target size of the blanket 100 is selected. In view of the target size of the blanket 100 and the manner of interlacing the yarn 104, a length of the yarn 104 is defined.

[0036] At block 610, the outer layer 200 having the length defined at block 605 is provided. In some examples, the provision of the outer layer 200 may include providing a sheet of fabric and sewing or otherwise fastening the edges 212-1, 212-2 to form a tube from the outer layer 200.

[0037] At block 615, a target pressure to be applied over the target size of the blanket is selected. In view of the target pressure, a width of the inner layer 204 is selected. The width of the inner layer 200 may further be selected according to the weight (e.g., based on grams per square meter) of the inner layer 200. The inner layer having the predefined length and the selected width may then be provided.

[0038] At block 620, the inner layer 204 is inserted into the outer layer 200 to fill at least a portion of the interior capacity 208 of the outer layer 200.

[0039] For example, referring to FIG. 7A-7E, example schematic diagrams of filling the outer layer 200 with the inner layer 204 are depicted.

[0040] In FIG. 7A, the outer layer 200 may be placed on the exterior of a hollow pipe (not shown). In particular, the outer layer 200 may be placed on the hollow pipe in its inverted state (i.e., with the seam 216 exposed). In FIG. 7B, a wire 700 may be extended through the hollow pipe from one end to the other. In FIG. 7C, the inner layer 204 is attached to the wire 700. Additionally, the outer layer 200 may be attached to the wire 700. In FIG. 7D, the wire 700 is pulled back through the hollow pipe, and therefore pulls the inner layer 204 and the outer layer 200 through the hollow pipe. The outer layer 200 may therefore retract from the outside of the hollow pipe as it is pulled through the inside of the hollow pipe by the wire 700. In FIG. 7E, the outer layer 200 has been inverted and the inner layer 204 is disposed in the interior capacity 208 of the outer layer 200 to form the yarn 104.

[0041] In other examples, other manners of filling the outer layer 200 with the inner layer 204 are contemplated. For example, the inner layer 204 may be rolled along its length (i.e., longitudinally) prior to being inserted into the outer layer 200.

[0042] Returning to FIG. 6, at block 625, having created the yarn 104 having an appropriate length and weight to achieve the target pressure over the target size of the blanket 100, the yarn 104 is interlaced to form the blanket 100.

[0043] As described above, a blanket and method of manufacture thereof use a double layered yarn with the inner layer having its width selected to achieve a target pressure for the target size of the blanket. The inner layer may therefore fill only a portion of the interior capacity of the outer layer, resulting in a flatter or ribbon-like yarn, however this may be mitigated by varying other parameters of the inner layer, such as its weight to maintain a higher ratio of the width of the inner layer to the perimeter of the outer layer to maintain a fuller appearance.

[0044] In some examples, the yarn may be combined with other sizes (e.g., having different diameters) of yarn, or other materials, such as yarn, wool, fiber, vinyl, nylon, spun yarn, thread, fleece, cord, cord yarn, rope, and the like, to form the blanket and to provide different visual aesthetics for the blanket. In such examples, the width and/or other parameters (e.g., weight of the material) of the inner layer may be selected in view of the additional materials forming the blanket.

[0045] In other examples, the outer layer may be omitted entirely, and the inner layer may be selected to have a sufficient weight to achieve the target pressure for the blanket.

[0046] Thus, knitted weighted blankets may be provided to have consistent sizes, while accommodating the desired target pressure for the size of blanket.

[0047] The scope of the claims should not be limited by the embodiments set forth in the above examples but should be given the broadest interpretation consistent with the description as a whole.