Patent Publication Number: US-2011047698-A1

Title: Weighted blanket

Description:
TECHNICAL BACKGROUND 
     The disclosure relates generally to blankets. More particularly, the disclosure relates to blankets having weighted filler material. 
     BACKGROUND 
     Autism spectrum disorders affect many children, adolescents, and adults. A number of persons who are affected by autism spectrum disorders also experience difficulties relaxing and sleeping. Sleep difficulties can be caused by various factors, including, for example, serotonin imbalance, insomnia, attention deficit/hyperactivity disorder (ADHD), restless leg syndrome (RLS), and various other geriatric and psychiatric conditions. Other conditions, such as fibromyalgia and Parkinson&#39;s Disease, may also contribute to sleep difficulties. Various interventions have been used to alleviate sleep difficulties in individuals with autism spectrum disorders, such as white noise and melatonin supplements. 
     Weighted blankets have also been used to calm individuals with autism spectrum disorders and help them sleep. Such blankets can be made from a variety of materials and are available in many shapes, sizes, and designs. Weighted blankets apply deep pressure to the individual&#39;s body, helping him or her to relax and inducing sleep. 
     While weighted blankets have been somewhat effective in calming individuals with autism spectrum disorders, conventional designs have been characterized by a number of drawbacks. Some conventional weighted blankets are characterized by uneven weight distribution or uneven pressure points due to, for example, weights that are spaced too far apart. In addition, the craftsmanship of some conventional weighted blankets can result in certain disadvantages. For example, in some cases, the thread that is used to sew the blankets can come loose, particularly when people pick at it. This can cause the filling to fall out of the blanket relatively easily. Wide stitching can also facilitate the filling falling out of the blanket. 
     In addition, in some conventional weighted blankets, the outer covering is only anchored to the blanket along the edges of the blanket. As a result, the outer covering can shift. Over time and with repeated use, the outer covering can become detached from the blanket. Besides damaging the exterior of the blanket, this can cause the filling to fall out of the blanket as well. 
     SUMMARY OF THE DISCLOSURE 
     According to various example embodiments, a weighted blanket includes an inner liner that is filled with weighted filler material and closed to limit movement of the weighted material within the inner liner. In some embodiments, the inner liner is securely sewn within an outer liner to prevent movement of the inner liner within the outer liner, thereby preventing the inner liner from becoming detached from the outer liner. 
     One embodiment is directed to a blanket comprising a weighted material. An inner liner is disposed surrounding the weighted material and closed to limit movement of the weighted material within the inner liner. An outer liner substantially surrounds and is attached to the inner liner. 
     In another embodiment, a blanket includes a liner having a plurality of pockets formed therein. The blanket also includes a plurality of weighted objects. Each weighted object is disposed within a pocket formed in the inner liner and is positioned to apply pressure to a human body when the blanket is in use. 
     Still another embodiment is directed to a method of manufacturing a blanket. A plurality of inner liners are provided. Each inner liner has a first end portion, a second end portion located distally from the first end portion, and a length. For each inner liner, the following steps are performed. The first end portion is closed to form a compartment. A weighted filler material is introduced into the compartment. The second end portion is closed to secure the weighted filler material within the compartment, thereby forming a tube. After these steps are performed for each inner liner, an outer liner is provided. The outer liner surrounds the tubes formed by the inner liners. The tubes formed by the inner liners are attached within the outer liner. 
     Various embodiments may provide certain advantages. For instance, certain embodiments described herein may provide a more even distribution of weighted filler material as compared with conventional weighted blankets. Further, with the inner lining securely attached to the outer lining, product safety is enhanced. In addition, certain embodiments may provide sensory deprivation or stimulation via the sound or absence of sound, depending on the choice of filling material, or via a sensory calming or stimulating experience imparted by the choice of fabric for the outer liner. 
     Additional objects, advantages, and features will become apparent from the following description and the claims that follow, considered in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of an example weighted blanket according to one embodiment. 
         FIG. 2  is a plan view of a tube forming part of the weighted blanket of  FIG. 1 . 
         FIG. 3  is a flow diagram illustrating an example process for manufacturing the blanket of  FIG. 1  according to another embodiment. 
         FIG. 4  is a plan view of another example weighted blanket according to still another embodiment. 
     
    
    
     DESCRIPTION OF VARIOUS EMBODIMENTS 
     According to various embodiments, a weighted blanket includes an inner liner that is filled with weighted filler material and closed to limit movement of the weighted material within the inner liner. In some embodiments, the inner liner is securely sewn within an outer liner to prevent movement of the inner liner within the outer liner, thereby preventing the inner liner from becoming detached from the outer liner. 
     The blanket can be manufactured in a variety of thicknesses and weights and from any of a variety of fabrics and materials. In one embodiment, the weighted filler material is filled in tubes, which are sewn at regular intervals and inserted into an outer liner or covering. The blanket is designed to provide a relatively uniform weight distribution over the body of the user to produce a calming effect similar to a hug. Various aspects of the blanket&#39;s construction, design, sound, fabric choice, feel, and pattern may be designed to create a sense of either calm and harmony or stimulation for people with insomnia, sensory processing disorder, autism spectrum disorders, obsessive-compulsive disorder, or other conditions that can contribute to sleep difficulties. The blanket may also be designed to promote a feeling of calm in people without these disorders. 
     Various embodiments disclosed herein may offer certain advantages relative to known weighted blankets because the weighted material is distributed evenly. In addition, in some embodiments, industrial strength thread is used to sew the inner liner to the outer covering, thus providing a secure attachment that substantially prevents movement of the inner liner within the outer covering, prevents the filler material from escaping, and promotes product safety. The durability of the blanket is also enhanced, such that the blanket is machine washer and dryer safe. 
     While not required, certain embodiments may provide sensory deprivation or stimulation via the sound or absence of sound, depending on the choice of filling material, or via a sensory calming or stimulating experience imparted by the choice of fabric for the outer liner. 
     In the following description, numerous specific details are set forth in order to provide a thorough understanding of various embodiments. It will be apparent to one skilled in the art that some embodiments may be practiced without some or all of these specific details. In other instances, well known components and process steps have not been described in detail. 
     Referring now to the drawings,  FIG. 1  is a plan view of an example weighted blanket  100  according to one embodiment. The weighted blanket  100  includes an outer liner or covering  102 , which is preferably machine washable and dryer safe. The outer covering  102  may be made of a fabric that is chosen for either a sensory limiting or a sensory stimulating effect. For example, the outer covering  102  may consist of one or more layers of natural materials, such as cotton or wool, and/or synthetic materials, such as plastic or TEFLON® brand polytetrafluoroethylene (PTFE). Some materials that provide low sensory stimulation include, for example, polished cotton, fleece, and chenille. By contrast, some materials that provide high sensory stimulation include corduroy and woven plastic. The fabric used for the outer covering  102  may either warm or cool the user&#39;s body. Some fabrics that warm the user&#39;s body include, for example, fleece, polar fleece, and faux fur. Materials that cool the user&#39;s body include, for example, polyester, cotton, and woven plastic. 
     The outer covering  102  may have any of a variety of visual characteristics that are selected for either sensory limitation or sensory stimulation. Some examples include, without limitation, solid colors that provide little visual stimulation, simple repeating patterns, evenly spaced lines, and random patterns that are visually stimulating. Solid colors may have high or low saturation and/or chroma values. Patterns may be symmetrical or asymmetrical. In some embodiments, words, letters, and/or numbers may be employed for stimulation, particularly if the words, letters, and/or numbers are somehow related to one another, e.g., as digits of π (pi). In addition, the outer covering  102  may have fabric, toys, or other materials attached to it for hand manipulation. 
     The outer covering  102  is sewn at regular intervals across either the length of the blanket  100  or the width of the blanket  100 , as shown in  FIG. 1 , to form a number of compartments  104 . The outer covering  102  may be sewn with industrial strength thread, e.g., T-40 strength, to promote durability of the blanket  100 . Preferably, the stitching is close, e.g., performed with a sewing machine thread count dial set at approximately 2.0 to 3.5. It will be appreciated that, while  FIG. 1  depicts nine compartments  104  formed in the outer covering  102 , more or fewer compartments  104  may be formed. 
     A number of inner liners are sewn to form tubes  106  that are inserted in the compartments  104  such that the outer covering  102  at least substantially surrounds the tubes  106 . With the outer covering  102  substantially surrounding the tubes  106 , the tubes  106  may be more securely retained within the blanket  100  as compared with certain conventional weighted blankets, in which the weights are only attached on one side to the blanket surface. The tubes  106  are filled with weighted material (not shown in  FIG. 1 ) and are closed to limit movement of the weighted material within the tubes  106 . For example, the tubes  106  may be sewn closed. A seam allowance portion may be provided at one or both ends of each tube  106 . While not shown in  FIG. 1  and not required, a comfort filling may also be inserted in the compartments  104  between the tubes  106  and the outer covering  102 . The comfort filling may consist of batting or of another layer of the same material used to form the tubes  106 . Non-limiting examples of materials suitable for the comfort filling include PRIMALOFT® brand synthetic insulation, polyester, cotton, hemp, bamboo, and wool. 
     After the tubes  106  are inserted in the compartments  104 , they are attached to the outer covering  102 . For example, the tubes  106  may be sewn to the outer covering  102 . In some embodiments, the seam allowance portions of the tubes  106 , if present, are sewn to the outer covering  102 . 
       FIG. 2  is a plan view of a tube  106  forming part of the weighted blanket  100  of  FIG. 1 . As illustrated in  FIG. 1 , the weighted blanket  100  includes a number of tubes  106 . Each tube  106  is formed from an inner liner material  202 , which can be any of a variety of fabrics or textiles. Preferably, the inner liner material  202  is strong and pliable. Non-limiting examples of suitable materials include muslin, woven plastic, polyester, rayon, and TEFLON® brand polytetrafluoroethylene (PTFE). The inner liner material  202  is closed at one end portion  204  to leave a first seam allowance portion  206  between a seam  208  and an edge  210  of the inner liner material  202 . The first seam allowance portion  206  may measure approximately ½″ between the seam  208  and the edge  210  of the inner liner material  202 . Closing the inner liner material  202  at the end portion  204  forms a compartment in the tube  106 . Pouches or bags of weighted material  212  are introduced into the compartment, with additional seams  214  being sewn at intervals along the length of the tube  206  to define additional compartments to accommodate additional pouches or bags of weighted material  212 . A second end portion  216  of the inner liner material  202  is closed to leave a second seam allowance portion  218  between a seam  220  and an edge  222  of the inner liner material  202 . Like the first seam allowance portion  206 , the second seam allowance portion  218  may also measure approximately ½″ between the seam  220  and the edge  222  of the inner liner material  202 . 
     Any of a variety of materials can be used for the weighted material  212 . For example, the weighted material  212  can consist of plastic beads, pellets, or balls that are designed to be substantially inaudible when they are brought into contact with one another. In other embodiments, by contrast, the weighted material  212  can consist of plastic beads, rocks, metal balls, or other materials that are designed to produce a clinking or cracking sound that is mid- to low-toned. Particular examples of materials that can be used for the weighted material  212  include, without limitation, plastic resin, such as polypropylene or polyethylene, stone, ceramic, and stainless steel. 
     The weighted material  212  can be distributed either uniformly or nonuniformly across compartments. In some embodiments, for example, the bag or pouch in each compartment has the same amount of weighted material  212 . On the other hand, in other embodiments, the weighted material  212  can be of varying sizes and weights so as to produce different pressure points on the user&#39;s body. 
       FIG. 3  is a flow diagram illustrating an example process  300  for manufacturing the weighted blanket  100  of  FIG. 1  according to another embodiment. At a step  302 , the inner liner material  202  is provided. The inner liner material  202  is typically provided as a flat sheet, which is then folded and sewn to form the tube  106 . As a particular non-limiting example, the inner liner material  202  may be provided as a flat sheet measuring approximately 58″ by 9″. The sheet is then folded and sewn along the long edge to form a tube that is approximately 58″ by 4½″. At this point, the tube  106  is open at both ends. For each tube  106  to be made, the end portion  204  of the inner liner material  202  is closed at a step  304 . For example, the end portion  204  may be sewn. In some embodiments, the tube  106  is turned inside out before the end portion  204  is sewn so that the seam along the long edge of the tube  106  is located on the inside of the tube  106 . At a step  306 , the compartment formed by closing the end portion  204  of the inner liner material  202  is filled with weighted material  212 . The compartment is then sewn with another seam  214 . If enough room remains along the length of the tube  106  to form another compartment, another compartment is formed and the process returns to step  306 , at which the newly formed compartment is filled and sewn. 
     The process of filling and sewing compartments continues until there is insufficient room remaining along the length of the tube  106  to form another compartment. At that point, the process continues to a step  308 , at which the end portion  216  of the inner liner material  202  is closed, thereby completing the process of filling one tube  106 . As with the outer covering  102 , the inner liner material  202  is preferably sewn with industrial strength thread using close stitching, e.g., with a sewing machine thread count dial set to approximately 2.0 to 3.5. This stitch length promotes durability and makes it more difficult to pick at the threads, which is a relatively common issue related to persons living with autism spectrum disorders. 
     The above process is performed for each tube  106  to be formed. When all of the tubes  106  have been formed, they are inserted into the compartments  104  formed in the outer covering  102 . The tubes  106  are then attached within the outer covering  102  at a step  310 . By way of example, the seam allowance portions  206  and  218  may be sewn to the outer covering  102 . 
       FIG. 4  is a plan view of another example weighted blanket  400  according to still another embodiment. The weighted blanket  400  includes an outer covering  402  that is made of a strong but lightweight fabric, such as olefin, woven or netted plastic, or TEFLON® brand polytetrafluoroethylene (PTFE) sewn at regular intervals across its length and width so as to form compartments  404  that are substantially square in shape. During the sewing process, a weighted filler  406  is introduced into each compartment  404 . In the embodiment shown in  FIG. 4 , the weighted fillers  406  are implemented as substantially spherical balls formed from metal, plastic, or other man-made materials. Alternatively, rocks or other natural materials can be used. In use, the weighted fillers create pressure points on the body of the user. 
     As demonstrated by the foregoing discussion, various embodiments may provide certain advantages. For instance, certain embodiments described herein may provide a more even distribution of weighted filler material as compared with conventional weighted blankets. Further, with the inner lining securely attached to the outer lining, product safety is enhanced. In addition, certain embodiments may provide sensory deprivation or stimulation via the sound or absence of sound, depending on the choice of filling material, or via a sensory calming or stimulating experience imparted by the choice of fabric for the outer liner. 
     It will be understood by those who practice the embodiments described herein and those skilled in the art that various modifications and improvements may be made without departing from the spirit and scope of the disclosed embodiments. The scope of protection afforded is to be determined solely by the claims and by the breadth of interpretation allowed by law.