Method for manufacturing a metal insert for a collar device

Abstract

A method of manufacturing a metallic spring insert for use in a collar device is provided. The method comprises providing a flat, metallic blank unit, rolling the flat, metallic blank unit into a collar-shaped metallic unit, and stress relieving the collar-shaped metallic unit to form the metallic spring insert. The metallic spring is inserted into a collar device so as to be encased or inserted into a collar device to be worn on a user's neck and is configured to effect a mild compression of the user's jugular veins in order to reduce a risk of brain injury by concussive force.

What is claimed: 
     
         1 . A method of making a metallic spring insert for use in a collar device, comprising:
 providing a flat, metallic blank unit,   rolling the flat, metallic blank unit into a collar-shaped metallic unit, and   stress relieving the collar-shaped metallic unit to form the metallic spring insert.   
     
     
         2 . The method according to  claim 1 , wherein the flat, metallic blank unit has a curved shape including a first end section and a second end section each having a curvature of a first direction, and a center section in between the first end section and the second end section having a curvature of a second direction. 
     
     
         3 . The method according to  claim 2 , further comprising, prior to said providing a flat, metallic blank unit, laser cutting a plurality of flat, metallic blank units from a metallic sheet, each of the plurality of flat, metallic blank units uniformly having the curved shape. 
     
     
         4 . The method according to  claim 1 , wherein the flat, metallic blank unit is made from 301 stainless steel and has a thickness of between approximately 0.025 inches and 0.032 inches. 
     
     
         5 . The method according to  claim 1 , further comprising: prior to said rolling the flat, metallic blank unit into the collar-shaped metallic unit, inspecting the metallic blank unit to confirm that the metallic blank unit is within one or more size parameters, the one or more size parameters comprising one or more of a length, width and thickness of the metallic blank unit. 
     
     
         6 . The method according to  claim 2 , further comprising: prior to said rolling the flat, metallic blank unit into the collar-shaped metallic unit, labeling the flat, metallic blank unit with one or more of a size indicator or a lot identification number. 
     
     
         7 . The method according to  claim 1 , wherein rolling the flat, metallic blank unit into the collar-shaped metallic unit is performed by an industrial rolling machine configured to receive an input of the one or more predetermined parameters corresponding to one or more intended attributes of the collar-shaped metallic unit and configured to execute a rolling program that is configured to roll the flat, metallic blank unit to a rolled, collar shape according to the input one or more predetermined parameters. 
     
     
         8 . The method according to  claim 7 , wherein the one or more predetermined parameters comprise one or more of:
 a diameter of the collar-shaped metallic unit,   a width of a gap between a first end and a second end of the collar-shaped metallic unit,   a vertical distance between a bottom-most tip of the first end and a bottom-most tip of the second end of the collar-shaped metallic unit, and   a surface profile.   
     
     
         9 . The method according to  claim 1 , wherein said stress relieving the collar-shaped metallic unit to form the metallic spring insert comprises:
 placing the collar-shaped metallic unit into a stress relief container, and   subjecting the collar-shaped metallic unit to a predetermined temperature for a predetermined length of time.   
     
     
         10 . The method according to  claim 9 , wherein the stress relief container comprises an aluminum ring having dimensions configured to correspond to dimensions of the collar-shaped metallic unit, and configured to constrain the collar-shaped metallic unit while it is subjected to the predetermined temperature for the predetermined length of time. 
     
     
         11 . The method according to  claim 10 , wherein the predetermined temperature is between 600° F. and 650° F. and the predetermined length of time is between 30 and 90 minutes. 
     
     
         12 . The method according to  claim 10 , wherein the predetermined temperature is approximately 650° F. and the predetermined length of time is approximately 90 minutes. 
     
     
         13 . The method according to  claim 9 , wherein said stress relieving the collar-shaped metallic unit to form the metallic spring insert further comprises:
 after completion of the predetermined amount of time, removing the metallic spring insert from the stress relief container and cooling the metallic spring insert.   
     
     
         14 . The method according to  claim 1 , further comprising:
 inspecting the metallic spring insert to determine that the metallic spring insert meets one or more required characteristics after being stress relieved, the one or more required characteristics comprising one or more of a width of a gap between a first end and a second end of the metallic spring insert, a vertical distance between a bottom-most tip of the first end and a bottom-most tip of the second end of the metallic spring insert, a surface profile and tensile strength,   wherein said inspecting is performed by one or more of a calibrated tensile testing apparatus, a hoop gauge or a pin gauge.   
     
     
         15 . The method according to  claim 14 , further comprising:
 performing a load test on the metallic spring insert using a spring force measurement device to determine if the metallic spring insert meets a predetermined load requirement.   
     
     
         16 . The method according to  claim 1 , wherein the metallic spring insert is configured to be inserted into a collar device to be worn on a user's neck and is configured to effect a mild compression of the user's jugular veins in order to reduce a risk of brain injury by concussive force. 
     
     
         17 . The method according to  claim 1 , wherein the flat, metallic blank unit has a length between approximately and 150 and 400 millimeters. 
     
     
         18 . The method according to  claim 8 , wherein the diameter of the collar-shaped metallic unit is between approximately 60 and 150 millimeters. 
     
     
         19 . The method according to  claim 8 , wherein the width of the gap between the first end and the second end of the collar-shaped metallic unit is between approximately 10 and 30 millimeters. 
     
     
         20 . The method according to  claim 8 , wherein the vertical distance between the bottom-most tip of the first end and the bottom-most tip of the second end of the collar-shaped metallic unit is between approximately 0 and 1.25 millimeters.