Abstract:
Described herein is a flexible but resilient material comprising a soft outside shell and an internal flexible but resilient support core, as well as a method for constructing such a flexible but resilient material that can have multiple applications, including being used to manufacture an improved shoelace to help young children, individuals who are physically challenged, and/or who have a limiting physical disability.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims priority to U.S. Application 62/321,778 filed on Apr. 13, 2016, the contents of which are herein fully incorporated by reference in its entirety. 
     
    
     FIELD OF THE EMBODIMENTS 
       [0002]    The embodiments of the present invention generally relate to a flexible but resilient material and its application in constructing a shoelace and other materials that are capable of retaining a desired shape to help and facilitate development/maintenance motor skills, and/or compensation for motor skill deficits. 
       BACKGROUND OF THE EMBODIMENTS 
       [0003]    Regular shoelaces are commonly comprised of a soft center core and a tube of braided fabric covered on the periphery of the center core. While flexible, such shoelaces, however, may be problematic to certain wearers (e.g., young children, persons who have physical disabilities, or who are physically challenged) in that they may have a difficult time in tying the shoelace up into a particularly shaped (e.g., a bow) knot and further in tightening the shoelace sufficiently to prevent such a knotted shoelace tie from becoming loose or untied during wearing. Over the years, there have been efforts devoted to constructing an improved shoelace in addressing such problems. 
       REVIEW OF RELATED TECHNOLOGY 
       [0004]    U.S. Pat. No. 8,272,110 pertains to an improved shoelace comprised of a plurality of bendable support elements permanently held within a limp material at each of the two end tips by a sleeve, where the bendable supports can be wires of certain thickness made of copper, steel, aluminum, alloy, or any combination thereof and coated in plastic. 
         [0005]    U.S. Pat. No. 6,729,784 pertains to a method for inhibiting the loosening of knotted ties, e.g., shoelaces, by applying to the ties a waxy compound comprising a waxy ingredient effective to inhibit the ties from becoming untied. 
         [0006]    U.S. Pat. No. 5,209,667 pertains to a shoelace for use by young children or the handicapped, which facilitates tying of a bow by providing a moderately stiff end portion; the stiff end portion can retain a loop shape when a pair of spaced locations on the stiff end portion are temporarily fastened together as by a pair of Velcro® retainers. The shoelace is formed of a flexible shoelace core with first and second opposite end portions, and with the first end portion penetrated by a solidified, originally-liquid stiffening material. 
         [0007]    None of the art described above addresses all of the issues that the present invention does. Accordingly, there is a long-felt need for an improved shoelace that can be used easily by children, and persons who are physically challenged and/or with physical disabilities, to tie their shoes. There is also a need for an improved shoelace that does not contain metals or other materials that may pose potential hazards. 
       SUMMARY OF THE EMBODIMENTS 
       [0008]    An embodiment of the present invention relates to a length of a flexible but resilient material comprising: an outside shell and an inner sheath encasing a bendable support assembly, which comprises at least one bendable support element comprising a support element core coated with a wax coating compound. Here, the bendable support assembly is encased in said sheath, which is, in turn, encased in said outside shell. A pre-selected length of said flexible but resilient material comprises a first end and a second end, each of which may be capped by an end-cap. 
         [0009]    Another embodiment of the present invention relates to a length of a flexible but resilient material comprising: an outside shell and an inner sheath encasing a bendable support assembly, which comprises more than one bendable support element that may be arranged in various ways, such as, with an even-spacing among them, or having a center support element core that is surrounded by multiple support element cores with an even-spacing, etc. and said bendable support assembly is coated with said wax compound. Multiple, rather than a single, support element core can provide increased strength and rigidity. Here again, the bendable support assembly is encased in said sheath, which is, in turn, encased in said outside shell. A pre-selected length of said flexible, but resilient material comprises a first end and a second end, each of which is capped by an end-cap. 
         [0010]    Alternatively in both of the above embodiments, said bendable support assembly encased in said sheath is first encased in an adhesive film sleeve and the resulting encased assembly is, further in turn, encased in said outside shell. The adhesive film sleeve can be made of a plant based or synthetic resin compound with the adhesive on one or both of the faces of a removable plastic or paper backsheet. 
         [0011]    In both of the above embodiments, said bendable support element core may be made of a soft and flexible material selected from the group consisting of, but not limited to, wool, cotton, acrylic, fabric, and/or any combination thereof, said sheath is made of a material of, but not limited to, wool, cotton, acrylic, synthetic fabric, satin, silk, cloth, paper products of different types comprising: single or multiple ply paper, laminated paper, crepe paper, self-sticking paper and/or any combination thereof while said outside shell may be made of a limp material selected from the group consisting of, but not limited to, wool, cotton, synthetic fabric, cloth, suede, nylon, leather, and/or any combination thereof. 
         [0012]    Yet another embodiment of the present invention relates to a shoelace made of a pre-selected length of a flexible but resilient material comprising: an outside shell; an adhesive film sleeve, a sheath; a bendable support assembly, which comprises at least one bendable support element comprising a support element core coated with a wax coating compound, or more than one bendable support element, that is arranged to have a center support element core with multiple surrounding support element cores and the entire said bendable support assembly is coated with said wax compound. Here, the bendable support assembly is encased in said sheath, which is, in turn, encased in said adhesive film sleeve, which is, in turn, encased in said outside shell. 
         [0013]    According to this embodiment, the bendable support element core is made of a soft and flexible material selected from the group consisting of, but not limited to, wool, cotton, acrylic, fabric, and/or any combination thereof, while said sheath is a material made of, but not limited to, wool, cotton, acrylic, synthetic fabric, satin, silk, cloth, paper and/or any combination thereof and said adhesive film sleeve can be made of a plant based or synthetic resin compound with the adhesive on one or both of the faces of a removable plastic or paper backsheet and wherein said outside shell is made of a limp material selected from the group consisting of, but not limited to, wool, cotton, acrylic, synthetic fabric, satin, silk, cloth, nylon, leather, and/or any combination thereof. A pre-selected length of said flexible but resilient material comprises a first end and a second end and each of said ends is secured by a plastic end-cap tubing or metal/plastic aglet, or by crimping. 
         [0014]    Further another embodiment of the present invention relates to a method of manufacturing a shoelace made of a pre-selected length of a flexible but resilient material with an outside shell and an internal bendable support core comprising: i) providing an internal support core by coating at least one bendable support element core with microcrystalline wax compound using a dipping method, wherein when more than one support element core is present, arranging them with an even-spacing or first arranging the cores such that one core is in the center and then arranging the remaining cores to surround the center core with an even-spacing and making the entire support core assembly coated with microcrystalline wax compound; ii) constructing a sheath in close proximity around (i.e., encasing) said core, said sheath extending along said length of said core, said sheath having an outer surface for contact within an adhesive film sleeve, wherein said sheath is constructed after the wax coating is hardened; iii) wrapping the sheath encasing the internal support core with the adhesive film sleeve, which can be made of a plant based or synthetic resin compound with the adhesive on one or both of the faces of a removable plastic or paper backsheet; iv) wrapping the adhesive film sleeve encasing the internal support assembly with an outside shell made of limp material; v) cutting the resulting shoelace made of said flexible but resilient material of said desired shape into a pre-selected length; vi) securing each of the two ends of said resulting shoelace made of said flexible but resilient material of said desired shape and length with a plastic end-cap tubing or metal/plastic aglet, or with a plastic end-cap. 
         [0015]    It is an object of at least one embodiment of the present invention to provide a method of helping young children, the physically challenged or individuals who have physical disabilities in easily tying their shoelaces. 
         [0016]    It is another object of at least one embodiment of the present invention to provide a method for constructing a flexible but resilient material that can have multiple applications. 
         [0017]    It is another object of at least one embodiment of the present invention to provide a microcrystalline wax compound that can help to form and maintain the shape and appearance of a shoelace knot. 
         [0018]    It is another object of at least one embodiment of the present invention to provide a shoelace with a flexible but resilient core assembly/sheath/adhesive film/outside shell structure, wherein the flexible but resilient core assembly comprises one or more bendable support core elements and the entire said bendable support assembly is coated with a microcrystalline wax compound. 
         [0019]    It is another object of at least one embodiment of the present invention to provide a material that it is inexpensive and easy to use. 
         [0020]    It is another object of at least one embodiment of the present invention to provide a material that can have multiple potential applications in various fields. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1A  shows a cross-sectional view of an embodiment of the invention. 
           [0022]      FIG. 1B  shows a cut-away view of a part of an embodiment of the invention. 
           [0023]      FIG. 2A  shows a cross-sectional view of another embodiment of the invention. 
           [0024]      FIG. 2B  shows a cut-away view of a part of another embodiment of the invention. 
           [0025]      FIG. 3A  shows a cross-sectional view of yet another embodiment of the invention. 
           [0026]      FIG. 3B  shows a cut-away view of a part of yet another embodiment of the invention. 
           [0027]      FIG. 4  shows a perspective view of an embodiment of the invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0028]    The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals. 
         [0029]    Reference will now be made in detail to each embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto. 
         [0030]    Referring now to  FIGS. 1A and 1B ,  FIG. 1A  illustrates a cross-sectional view of a preferred embodiment  100  of the present invention of a length of a flexible but resilient material comprising: a bendable support assembly, which comprises at least one bendable support element comprising a support element core  101  coated with a wax coating compound  103 . This bendable support assembly is encased in a sheath  105 , which is, in turn, encased in an adhesive film sleeve  109 , which is, further in turn, encased in an outside shell  107 .  FIG. 1B  illustrates a cut-away view (along the length) of the same preferred embodiment  100 . A pre-selected length of said flexible but resilient material comprises a first end and a second end and each of said ends is crimped, capped by a plastic end-cap tubing or metal/plastic aglet. 
         [0031]    Referring now to  FIGS. 2A and 2B ,  FIG. 2A  illustrates a cross-sectional view of another preferred embodiment  200  of the present invention of a length of a flexible but resilient material comprising: a bendable support assembly, which comprises more than one bendable support element that is arranged to have a center support element core with multiple surrounding support element cores  201  and said bendable support assembly is coated with said wax compound  203 . Multiple, rather than a single, support elements are preferable because their combination provides increased strength and rigidity. This bendable support assembly is encased in a sheath  205 , which is, in turn, may be encased in an adhesive film sleeve  109  (see  FIG. 1 ), which is, further in turn, encased in an outside shell  207 .  FIG. 2B  illustrates a cut-away view (along the length) of the same preferred embodiments  200 . A pre-selected length of said flexible but resilient material comprises a first end and a second end and each of said ends is crimped, capped by a plastic end-cap tubing or metal/plastic aglet. 
         [0032]    Referring now to  FIGS. 3A and 3B ,  FIG. 3A  illustrates a cross-sectional view of yet another preferred embodiment  300  of the present invention of a length of a flexible but resilient material comprising: a bendable support assembly, which comprises more than one bendable support element arranged to have said multiple support element cores  301  evenly spaced to each other and said bendable support assembly is coated with said wax compound  303 . Multiple, rather than a single, support elements are preferable because their combination provides increased strength and rigidity. This bendable support assembly is encased in a sheath  305 , which, in turn, may be encased in an adhesive film sleeve  109  (see  FIG. 1 ), which is, further in turn, encased in an outside shell  307 .  FIG. 3B  illustrates a cut-away view (along the length) of the same preferred embodiments  300 . A pre-selected length of said flexible but resilient material comprises a first end and a second end and each of said ends is crimped, capped by a plastic end-cap tubing or metal/plastic aglet. 
         [0033]    Turning now to  FIG. 4 , there is a perspective view of yet another preferred embodiment  400  of the present invention of a shoelace  401  made of a pre-selected length of a flexible but resilient material comprising: an outside shell; an adhesive film sleeve; a sheath; a bendable support assembly, which comprises at least one bendable support element comprising a support element core coated with a wax coating compound, or more than one bendable support element, that may be arranged in various ways, such as, with an even-spacing among them, or having a center support element core that is surrounded by multiple support element cores with an even-spacing, etc. and said bendable support assembly is coated with said wax compound. Here, the bendable support assembly is encased in said sheath, which in turn may be encased in an adhesive film sleeve, which is, further in turn encased in said outside shell. A pre-selected length of said flexible but resilient material comprises a first end and a second end and each of said ends is secured by a plastic end-cap tubing  403 , or metal/plastic aglet, or by crimping. 
         [0034]    A variety of materials are contemplated as being suitable for constructing all of the above-mentioned embodiments. For example, said bendable support element core may be made of a soft and flexible material selected from the group consisting of, but not limited to, wool, cotton, acrylic, fabric, and/or any combination thereof, while said sheath may be a material made of, but not limited to wool, cotton, acrylic, synthetic fabric, satin, silk, cloth, paper products of different types comprising: single or multiple ply paper, laminated paper, crepe paper, self-sticking paper and/or any combination thereof. Additionally, it is contemplated that the outside shell may be made of a limp material selected from the group consisting of, but not limited to, wool, cotton, synthetic fabric, cloth, suede, nylon, leather, and/or any combination thereof, i.e., materials typically utilized in constructing a shoelace. 
         [0035]    The cross section of the shoelace according to the preferred embodiment shown in  FIG. 4  is either cylindrical or rectangular in shape, wherein the wax compound coating the support element core is a microcrystalline wax of laminating or food grade and wax adhesive compound. The composition of such microcrystalline wax compound contains a waxy ingredient that is naturally occurring or synthetic. The thickness of said microcrystalline wax compound coating on the bendable support element core is about 0.1 to about 10 millimeters and about 5 to about 30 percent by weight based on the total combined weight of the bendable support element. 
         [0036]    Yet another preferred embodiment of the present invention relates to a method of manufacturing a shoelace made of a pre-selected length of a flexible but resilient material with an outside shell and an internal bendable support core comprising: i) providing an internal support core by coating at least one bendable support element core with microcrystalline wax compound using a dipping method, wherein when more than one support element core is present, arranging them with an even-spacing or first arranging the cores such that one core is in the center and then arranging the remaining cores to surround the center core with an even-spacing and making the entire support core assembly coated with a microcrystalline wax compound; ii) constructing a sheath in close proximity around (i.e., encasing) said core, said sheath extending along said length of said core, said sheath having an outer surface for contact within an adhesive film sleeve, wherein said sheath is constructed after the wax coating is hardened; iii) wrapping the sheath encasing the internal support core with the adhesive film sleeve, which can be made of a plant based or synthetic resin compound with the adhesive on one or both of the faces of a removable plastic or paper backsheet; iv) threading the adhesive film sleeve encasing the internal support assembly through a hollow tubular outside shell made of limp material; v) cutting the resulting shoelace made of said flexible but resilient material of said desired shape into a pre-selected length; v) securing each of the two ends of said resulting shoelace made of said flexible but resilient material of said desired shape and length with a plastic end-cap tubing or metal/plastic aglet. 
       Example 
       [0037]    In the example described below, the following components, materials and manufacturing procedural steps, as summarized in the Table, were used, unless otherwise noted: 
         [0000]    
       
         
               
             
               
               
               
               
             
           
               
                   
               
               
                 Method Utilized To Manufacture One Small Batch of Laces Comprising of about 5 Units 
               
             
          
           
               
                   
                   
                 Specifications/ 
                   
               
               
                 Components 
                 Material/Makeup 
                 Quantity 
                 Procedure 
               
               
                   
               
               
                 Internal Bendable 
                 5 strands of cotton/acrylic  
                 Each measuring about  
                 1. Cut yarn to 45 inches in length 
               
               
                 Support 
                 blend yarn 
                 ¼ inch wide and 45 
                   
               
               
                 Core/Element 
                   
                 inches long 
                   
               
               
                 Waxy Compound 
                 1. Microcrystalline wax  
                 A total of 2 ounces/60 
                 2. Melt wax pastilles and wax 
               
               
                   
                 pastilles 
                 grams was used per  
                 adhesive additive at a temperature 
               
               
                   
                   
                 batch 
                 of about 85 degrees F 
               
               
                   
                   
                   
                 3. Rest yarn in microcrystalline bath 
               
               
                   
                   
                   
                 for at least 5 minutes 
               
               
                   
                 2. Wax adhesive 
                 .5 ounces 
                 4. Remove strands and allow to dry  
               
               
                   
                   
                   
                 on a nonstick surface for at least 10 
               
               
                   
                   
                   
                 minutes until solid and assembly 
               
               
                   
                   
                   
                 comes to a temperature near or at 
               
               
                   
                   
                   
                 room temperature 
               
               
                 Inner Sheath 
                 5 pieces of Polyester blend  
                 Each measuring 3/8 of  
                 5. Cut ribbon or paper to 45 inches in 
               
               
                   
                 ribbon or crepe paper 
                 an inch wide and 45 
                 length 
               
               
                   
                   
                 inches long 
                 6. Press along the length of the 
               
               
                   
                   
                   
                 support assembly to adhere 
               
               
                 Adhesive layer 
                 5 strips of fabric adhesive 
                 Each measuring 3/8 of  
                 7. Cut adhesive strip to 45 inches in 
               
               
                   
                   
                 an inch wide and 45 
                 length 
               
               
                   
                   
                 inches long 
                 8. Press along the length of the 
               
               
                   
                   
                   
                 support assembly to adhere 
               
               
                 Outer Shell 
                 5 polyester blend outer  
                 Each measuring 1/4  
                 9. Support assembly covered in sheath 
               
               
                   
                 shells/hollow shoelace strings 
                 inch in wide and 45  
                 and/or adhesive is threaded through 
               
               
                   
                   
                 inches long 
                 tubular hollow outer shell 
               
               
                 End-cap/Securing 
                 1. 10 metal aglets 
                 Each piece measures  
                 10. Affix aglets to both ends of each 
               
               
                 Element 
                   
                 about 1 inch in length 
                 completed lace using a crimping tool 
               
               
                   
                   
                   
                 Or 
               
               
                   
                 2. 10 pieces of 
                 Each piece measuring  
                 10. Cut heat shrink tubing to 1 inch in 
               
               
                   
                 polyolefin heat 
                 about 1 inch in length 
                 length and slide over ends 
               
               
                   
                 shrink tubing 
                 and 3/16 of an inch in  
                 11. Heat to shrink tubing resulting in a 
               
               
                   
                   
                 diameter 
                 close wrapping effect around 
               
               
                   
                   
                   
                 assembly ends 
               
               
                   
               
             
          
         
       
     
         [0038]    As described in the table above, the present invention, in some embodiments, may be manufactured by first using an internal bendable support/core element that is made of a strand of cotton/acrylic blend yarn that measures about ¼ of an inch wide and about 45 inches long. 
         [0039]    The yarn may then coated by a waxy compound by placing it in a warm wax bath made of microcrystalline pastilles measuring at least 12 grams in weight and 0.5 ounces of a wax adhesive additive and melted at a temperature of 85 degrees Fahrenheit. 
         [0040]    After soaking for at least 5 minutes, the yarn may be removed and allowed to dry for at least 10 minutes to a temperature near or at room temperature until it forms the solid support assembly. The solid wax coated support assembly is then covered by an inner sheath made of a polyester blend fabric measuring about ⅜ of an inch wide and about 45 inches long that is pressed along the length of the solid support assembly until it adheres. Alternative materials for the inner sheath include paper products of different types comprising: single or multiple ply paper, laminated paper, crepe paper, self-sticking paper. 
         [0041]    The assembly with its affixed inner sheath may then be encased by an adhesive film sleeve, which may then be further encased by an outer shell made of a hollow, tubular, braided polyester fabric blend measuring about ½ of an inch in diameter and about 45 inches in length. The ends of the resulting flexible, resilient embodiment may then be finally secured by slipping on an end cap made of a cylindrical piece of polyolefin tubing measuring about 1 inch in length and about 3/16 of an inch in diameter that is heated until it shrinks to about half of its original diameter, resulting in a close wrapping effect around the assembly&#39;s ends or by crimping metal aglets measuring about 1 inch in length around the assembly&#39;s ends. 
         [0042]    The many elements of the present invention make it unique in the field. The novelty is illustrated by the various options for nearly every aspect of the invention that allow it to be used in a variety of additional embodiments and further by adding or deleting several core units and affixing them between different types of fabrics/materials. 
         [0043]    In one such embodiment to be used in garments and/or under garments, the material of the present invention can be used to replace drawstrings, ties, or wire found in various products including, but not limited to, hoodies, jackets, corset/waist trainers, scrub uniform pants, bras, men&#39;s ties/bows, drawstring backpack, etc. 
         [0044]    In another such embodiment, the material of the present invention can be used to manufacture hair ties, or the substructures/components/supports used in common items including, but not limited to, bag handles, brims of hats, etc. 
         [0045]    In yet another such embodiment, the material of the present invention can be used to replace the string/ties/rope used in the following skill building activities, including, but not limited to, boy scouts knot tying, weaving mats, string used in a stringing bead set for children, knot tying games, shoelace tying books, etc. 
         [0046]    In still another such embodiment, the material of the present invention can be used to form a core panel in the following products for special needs children, including, but not limited to, weighted vests, weighted blankets, weighted bean bags, yoga mats, etc. 
         [0047]    Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.