Device and Process for Manufacturing a Layered Weighted Yarn

Abstract

A device configured to manufacture a layered weighted yarn includes a formation channel configured to receive a first material and a second material; and a sewing machine including at least one needle, the sewing machine configured to sew a seam on the first material. The formation channel being further configured to receive the first material and form the first material into an outer tube; receive the second material and insert the second material into the outer tube; locate the first material in a position to be sewn by the sewing machine to form the seam on the outer tube; and discharge the outer tube including the first material and the second material inserted into the outer tube as a layered weighted yarn.

What is claimed is: 
     
         1 . A device configured to manufacture a layered weighted yarn comprising:
 a formation channel configured to receive a first material and a second material;   a sewing machine comprising at least one needle, the sewing machine configured to sew a seam on the first material;   an outer tube material delivery system configured to deliver the first material to the formation channel;   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; and   the formation channel being further configured to discharge the outer tube comprising the first material and the second material inserted into the outer tube as a layered weighted yarn.   
     
     
         2 . The device configured to manufacture a layered weighted yarn of  claim 1  wherein the formation channel being further configured to reverse an orientation of the first material. 
     
     
         3 . The device configured to manufacture a layered weighted yarn of  claim 1   wherein the formation channel comprises a first surface structure and a second surface structure configured to form a gap therebetween;   wherein the gap is configured to receive the first material; and   wherein the formation channel comprises 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.   
     
     
         4 . The device configured to manufacture a layered weighted yarn of  claim 1  wherein the formation channel comprises a tubular structure configured to receive the first material and the second material. 
     
     
         5 . The device configured to manufacture a layered weighted yarn of  claim 1   wherein the formation channel comprises a bracket for attachment to the sewing machine; and   wherein the formation channel being attached to the sewing machine by the bracket.   
     
     
         6 . The device configured to manufacture a layered weighted yarn of  claim 1  wherein the outer tube material delivery system comprises a spindle to support the first material. 
     
     
         7 . The device configured to manufacture a layered weighted yarn of  claim 1  wherein the outer tube material delivery system comprises a guide structure to guide the first material to the formation channel. 
     
     
         8 . The device configured to manufacture a layered weighted yarn of  claim 1  wherein the inner layer material delivery system comprises a spindle to support the second material. 
     
     
         9 . The device configured to manufacture a layered weighted yarn of  claim 1  further comprising:
 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; and 
 the racing roller further comprising a lower fabric-engaging roller and an upper fabric-engaging roller. 
 
     
     
         10 . The device configured to manufacture a layered weighted yarn of  claim 1  wherein:
 a length of the layered weighted yarn is configured to be interlooped to form a piece of weighted material; and 
 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. 
 
     
     
         11 . A method of constructing a layered weighted yarn, the method comprising:
 receiving a first material and a second material with a formation channel;   sewing a seam on the first material with a sewing machine comprising at least one needle;   delivering the first material to the formation channel with an outer tube material delivery system;   delivering the second material to the formation channel with an inner layer material delivery system;   receiving the first material from the outer tube material delivery system and forming the first material into an outer tube with the formation channel;   receiving the second material from the inner layer material delivery system and inserting the second material into the outer tube with the formation channel;   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; and   discharging the outer tube comprising the first material and the second material inserted into the outer tube as a layered weighted yarn with the formation channel.   
     
     
         12 . The method of constructing a layered weighted yarn of  claim 11  further comprising reversing an orientation of the first material with the formation channel. 
     
     
         13 . The method of constructing a layered weighted yarn of  claim 11   wherein the formation channel comprises a first surface structure and a second surface structure configured to form a gap therebetween;   wherein the gap is configured to receive the first material; and   wherein the formation channel comprises 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.   
     
     
         14 . The method of constructing a layered weighted yarn of  claim 11  wherein the formation channel comprises a tubular structure configured to receive the first material and the second material. 
     
     
         15 . The method of constructing a layered weighted yarn of  claim 11   wherein the formation channel comprises a bracket for attachment to the sewing machine; and   wherein the formation channel being attached to the sewing machine by the bracket.   
     
     
         16 . The method of constructing a layered weighted yarn of  claim 11  wherein the outer tube material delivery system comprises a spindle to support the first material. 
     
     
         17 . The method of constructing a layered weighted yarn of  claim 11  wherein the outer tube material delivery system comprises a guide structure to guide the first material to the formation channel. 
     
     
         18 . The method of constructing a layered weighted yarn of  claim 11  wherein the inner layer material delivery system comprises a spindle to support the second material. 
     
     
         19 . The method of constructing a layered weighted yarn of  claim 11  further comprising
 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; and 
 the racing roller further comprising a lower fabric-engaging roller and an upper fabric-engaging roller. 
 
     
     
         20 . A method of constructing a weighted material with the layered weighted yarn of  claim 11  comprising:
 interlooping a length of the layered weighted yarn to construct a piece of weighted material, 
 wherein 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.