HK1155046A - Comfort pillow - Google Patents

Description

Comfortable pillow

The present application is a divisional application of the invention application with application number 03811907.2 filed on 23/5/2003.

Technical Field

The present invention relates to a pillow or cushion, and more particularly, to a pillow or cushion for treating diseases.

Background

The neck of a person in a supine or side lying position is often not in line with the spine of the person. It is common to support a person's neck with one or more pillows such that the neck is at an angle defined by the deflected height of the one or more pillows, which is generally not coplanar with the spine. The deflected height of the pillow is closely related to its flexure resistance, which is typically provided via a fill material disposed within the cloth cover. Conventional padding materials include feather, cotton or synthetic padding.

Disclosure of Invention

To provide a pillow construction that is more likely to properly align the user's neck and spine, the present invention provides a pillow having multiple foam components.

One embodiment of the invention includes a pillow having a viscoelastic sleeve defining a cavity and a filling material disposed within the cavity.

Another embodiment of the invention includes a pillow having outer layers and a filler material comprised of granulated viscoelastic foam disposed between the outer layers.

Yet another embodiment of the present invention includes a pillow having an outer layer of reinforcing fabric, an intermediate layer of viscoelastic foam, and a filler material of granulated viscoelastic foam disposed between the intermediate layer.

The invention also includes a method for manufacturing a pillow. The method comprises the following steps: providing a viscoelastic sleeve defining a cavity, inserting a filler material into the cavity, and sealing the sleeve to retain the filler material within the cavity.

The viscoelastic foam responds to changes in temperature such that body heat conforms the shape of the pillow to the body curve, thereby providing comfort and support to the body. This allows the pillow shape to more closely follow the contours of the human body and promotes better alignment of the neck and spine when a person is in a supine or side lying position.

Preferably, a cover encloses the pillow and it follows the shape of the pillow. The cover is removable, washable and has a resealable slot through which the pillow can be inserted or removed. This slot extends across the edge of the pillow and is preferably opened and closed by means of a zipper.

Brief description of the drawings

FIG. 1 is a perspective view showing a pillow embodying the present invention;

FIG. 2 is an exploded schematic view of the pillow of FIG. 1;

fig. 3 is a partial cross-sectional view of the pillow of fig. 1.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Description of The Preferred Embodiment

Fig. 1-3 illustrate a pillow 10 of the present invention having a cushion structure constructed of multiple layers of material 10. The pillow 10 includes a filler material 14 disposed between layers of viscoelastic foam 18. The viscoelastic foam layer 18 possesses a particular thermal sensitivity that conforms the pillow 10 to the shape of the portion of the person's body that contacts the pillow 10. The viscoelastic foam layer 18 has a lower stiffness or hardness at higher temperatures than at lower temperatures. In contrast, the filling material of conventional pillows typically has a constant stiffness with respect to temperature changes. The body heat of the person acts to soften the portion of the pillow 10 that is in contact with the person while the portion of the pillow 10 that is not in contact with the person remains relatively stiff. As a result, the pillow 10 embodying the present invention is more comfortable than conventional pillows by matching the body shape of each user.

In one embodiment of the invention, the filler material 14 is in the form of pellets or chips, and the viscoelastic foam has a viscosity of about 85kg/m³The density of (c). However, for an average weight pillow 10, a suitable density for the viscoelastic foam filler material 14 may be, for example, from about 30 to about 140kg/m³In the meantime. Further, for a lightweight pillow 10, a suitable density for the viscoelastic foam filler material 14 can be, for example, less than about 40kg/m³. Similarly, for a heavy-weight pillow 10, a suitable density for the viscoelastic foam filler material 14 may be, for example, greater than about 130kg/m³. Alternatively, the granulated viscoelastic foam used as the filler material 14 can have any density depending on the desired characteristics of the pillow 10. In addition, a suitable viscoelastic foam filling material 14 possesses an indentation load deflection or "ILD" of 65% and a maximum 10% rebound between a load of 100 and 500N according to the test procedures performed using the ASTM-D-1564 standard.

The particulate filler material 14 may be comprised of recycled, virgin or discarded viscoelastic material. The granular packing material 14 may be comprised of pieces of a nominal length, or the granular packing material 14 may be comprised of pieces of varying lengths. For example, the granular packing material 14 may have a nominal length of about 1.3 cm. The particulate filler material 14 may also have a length that varies between about 0.6cm and about 2 cm. The granular filling material 14 can be as short as 0.3cm and as long as 4cm, or the filling material 14 can have any length depending on the desired characteristics of the pillow 10. According to a preferred embodiment of the invention, the granular filling material 14 consists of 16-20% pieces having a length greater than 2cm, 38-42% pieces having a length between 12cm and 38-42% pieces having a length less than 1 cm. Significant cost savings and waste reduction can be achieved by using discarded or recycled filler material 14 instead of unused filler material 14. The viscoelastic foam used as the filler material 14 is made of a polyurethane foam material, however, the filler material 14 may be made of any other viscoelastic polymeric material that exhibits similar thermal sensitivity.

The composition of the filler material 14 can be varied to alter the characteristics of the pillow 10 and the cost of the pillow 10. In another embodiment of the invention, the filler material 14 is a combination of granulated viscoelastic foam and a fibrous material. The fibrous material may be made of any type of fabric, such as organic (cotton) or synthetic fabric, which tends to be less expensive than viscoelastic foam. In one embodiment of the invention, the fibrous material has about 1g/cm³The density of (c). However, for an average weight pillow 10, a suitable density for the fibrous material may be, for example, 0.1-2g/m³. Further, for a lightweight pillow 10, a suitable density of the fibrous material can be, for example, less than about 0.3g/m³. Similarly, for a heavy weight pillow 10, a suitable density of the fibrous material can be, for example, greater than about 1.8g/m³. Alternatively, the fibrous material used in combination with the granulated viscoelastic foam into the filler material 14 can have any density depending on the desired characteristics of the pillow 10.

In a preferred embodiment of the present invention, the filler material 14 comprises about 50% fibrous material, while the other components comprise granulated viscoelastic foam. However, for an average price pillow 10, a suitable range of fiber material within the filler material 14 can be, for example, between about 20% and about 80%. Further, for a more expensive pillow 10, a suitable range of fiber material within the filler material 14 can be, for example, less than about 30% of the filler material 14. Similarly, for a less expensive pillow 10, a suitable range of fiber material within the filler material 14 can be, for example, greater than about 70% of the filler material 14.

In yet another embodiment of the present invention, the filler material 14 is a composition of granulated viscoelastic foam and polystyrene balls, which tend to be less expensive than viscoelastic foam. The filler material 14 of such embodiments can also comprise organic or synthetic fiber materials, depending on the desired characteristics of the pillow 10. The polystyrene balls may consist of balls of a nominal diameter, or the polystyrene balls may consist of balls of varying diameters. For example, polystyrene spheres may have a nominal diameter of about 5 mm. The polystyrene spheres may also have a diameter varying between about 1mm and about 10 mm. The polystyrene balls can also be as short as 0.5mm in diameter and as long as 20mm in diameter, or the polystyrene balls can have any diameter depending on the desired characteristics of the pillow 10.

In a preferred embodiment of the invention, the filler material 14 comprises about 50% polystyrene spheres, and the other components comprise granulated viscoelastic foam. However, for an average price pillow 10, a suitable range of polystyrene balls within the filler material 14 can be, for example, between about 20% and about 80%. Further, for a more expensive pillow 10, a suitable range of polystyrene balls within the filler material 14 can be, for example, less than about 30% of the filler material 14. Similarly, for a less expensive pillow 10, a suitable range of polystyrene balls within the filler material 14 can be, for example, greater than about 70% of the filler material 14.

In another embodiment of the present invention, the filler material may comprise a granulated high elasticity ("HE") foam in addition to the granulated viscoelastic foam. HE foam tends to be less expensive than viscoelastic foam, thereby resulting in a potentially less expensive pillow 10. The filler material may be comprised of any of the individual fillers described above, or any combination of the fillers described above. Optionally, the filler material 14 may also comprise any conventional material, such as feathers, granulated cotton, cotton fibers, and the like. In one embodiment of the present invention, the filler material 14 comprisesA density of about 35kg/m³HE foam of (1). However, for an average weight pillow 10, a suitable density for the HE foam may be, for example, from about 20 to about 50kg/m³In the meantime. Further, for a lightweight pillow 10, a suitable density for the HE foam can be, for example, less than about 25kg/m³. Similarly, for a heavy weight pillow 10, a suitable density for the HE foam can be, for example, greater than about 45kg/m³. Alternatively, the HE foam used in the filler material 14 can have any density depending on the desired characteristics of the pillow 10.

The granulated HE foam may be comprised of pieces of a nominal length, or the granulated HE foam may be comprised of pieces of varying lengths. For example, the granulated HE foam may have a nominal length of about 1.3 cm. The granulated HE foam may also have a length that varies between about 0.6cm and about 2 cm. The granulated HE foam can be as short as 0.3cm and as long as 4cm, or the granulated HE foam can have any length depending on the desired characteristics of the pillow 10. In a preferred embodiment of the invention, the granulated HE foam consists of 16-20% pieces having a length of more than 2cm, 38-42% pieces having a length of between 1 and 2cm and 38-42% pieces having a length of less than 1 cm.

In a preferred embodiment of the invention, the filler material 14 comprises about 50% granulated HE foam, while the other components comprise granulated viscoelastic foam. However, for an average price pillow 10, a suitable range of granulated HE foam in the filler material 14 is, for example, 20% -80%. Further, for more expensive pillows 10, a suitable range of granulated HE foam in the filler material 14 can be, for example, less than about 30% of the filler material 14. Similarly, for a less expensive pillow 10, a suitable range of granulated HE foam within the filler material 14 can be, for example, greater than about 70% of the filler material 14.

As previously described, the filler material 14 is disposed between the layers of viscoelastic foam 18. In one embodiment of the present invention, the viscoelastic foam layer 18 has a thickness of about 85kg/m³The density of (c). However, for an average weight pillow 10, a suitable density for the viscoelastic foam layer 18 may be, for example, from about 30 to about 140kg/m³In the meantime. Further, for a lightweight pillow 10, a suitable density for the viscoelastic foam layer 18 can be, for example, less than about 40kg/m³. Similarly, for a heavy weight pillow 10, a suitable density for the viscoelastic foam layer 18 can be, for example, greater than about 130kg/m³. Alternatively, the viscoelastic foam layer 18 can have any density depending on the desired characteristics of the pillow 10.

The layer of viscoelastic foam 18 is preferably about 10mm thick and has a thermal sensitivity similar to the granulated viscoelastic foam of the filler material 14. Similarly, for an average weight pillow 10, a suitable thickness for the viscoelastic foam layer 18 may be, for example, between about 5mm and 15 mm. However, for a lightweight pillow 10, a suitable thickness for the viscoelastic foam layer 18 can be, for example, less than about 7 mm. Further, for a heavy weight pillow 10, a suitable thickness for the viscoelastic foam layer 18 can be, for example, greater than about 13 mm. The viscoelastic foam layer 18 is made of a polyurethane foam material, however, the viscoelastic foam layer 18 may be made of any other viscoelastic polymeric material that exhibits similar thermal sensitivity.

The overall stiffness or hardness of the pillow 10 is dependent upon the stiffness of the individual viscoelastic foam layers 18 and the filler material 14. Thus, the overall stiffness or hardness of the pillow 10 can be affected by varying the stiffness of the individual viscoelastic foam layers 18 and/or the filler material 14.

As shown in fig. 1-3, a reinforcing fabric layer 22 is provided on the outside of the viscoelastic foam layer 18. The reinforcing fabric layer 22 acts as a tie to the stitches 26, which stitches 26 secure the reinforcing fabric layer 22 to the viscoelastic foam layer 18. Without the reinforcing fabric layer 22, the viscoelastic foam layer 18, which is durable without the reinforcing fabric layer 22, would have to anchor the stitches 26 directly to secure the filler material 14 between the viscoelastic foam layers 18. In a pillow (not shown) having this configuration, the viscoelastic foam layer 18 is likely to tear near the stitches 26 as a result of daily use of the pillow. Furthermore, if the viscoelastic foam layer 18 is torn, the filler material 14 will spill out. The reinforcing fabric layer 22 thus provides a measure of durability to the pillow 10. Preferably, the reinforcing fabric layer 22 is made of a durable material, such as a cotton/polyester blend.

A cover 30 wraps and encloses the pillow 10 and follows the shape of the pillow 10. The outer cover 30 is preferably made of a durable and washable fabric material, such as a cotton/polyester blend. As shown in fig. 1, a slot 34 extends through the cover 30 along the edge of the cover. The pillow 10 can be inserted into the cover 30 via the slot 34. The pillow 10 can also be removed from the cover 30 via the slot 34 to facilitate cleaning of the cover 30. The slot 34 is resealable to enclose the cover 30 around the pillow 10 and to open the cover 30 for removal of the pillow 10. A latching device is used to open and close the slot 34. In the preferred embodiment, the closure means is a zipper 38, but the closure means may also include snaps, buttons, hook and loop fasteners, overlapping flaps, ties, or other similar fasteners.

During manufacture, the viscoelastic foam layer 18 is sewn to the reinforcing fabric layer 22 to form a sleeve or sock having an open end, where the viscoelastic foam layer 18 forms the inner layer of the sock and the reinforcing fabric layer 22 forms the outer layer of the sock. The filler material 14 is then inserted through the open end of the liner until the desired amount of filler material 14 is present in the liner. The open end is then sewn to enclose the filler material 14 within the liner and define a pillow 10. The pillow 10 is then inserted into the cover 30 and the cover 30 is enclosed by the zipper 38.

Claims (28)

1. A pillow, comprising:

a viscoelastic sleeve defining a cavity; and

a filler material disposed within the cavity.

2. The pillow of claim 1 wherein said insert comprises

A first viscoelastic layer; and

a second viscoelastic layer, the first and second viscoelastic layers being joined together to form the cavity therebetween,

wherein the filler material is disposed between the first and second viscoelastic layers.

3. The pillow of claim 2, wherein the first viscoelastic layer and the second viscoelastic layer have a thickness of between about 5mm and 15 mm.

4. The pillow of claim 3, wherein the first viscoelastic layer and the second viscoelastic layer have a thickness of about 10 mm.

5. The pillow of claim 2, wherein the first viscoelastic layer and the second viscoelastic layer have a viscosity of about 30kg/m³To about 140kg/m³The density of (d) in between.

6. The pillow of claim 5, wherein the first viscoelastic layer and the second viscoelastic layer have a viscosity of about 85kg/m³The density of (c).

7. The pillow of claim 2, further comprising

A first fabric layer overlying the first viscoelastic layer; and

a second fabric layer covering the second viscoelastic layer.

8. The pillow of claim 7 wherein said first and second fabric layers are attached to said first and second viscoelastic layers, respectively.

9. The pillow of claim 8 wherein said first and second fabric layers are stitched to said first and second viscoelastic layers, respectively.

10. The pillow of claim 1, further comprising a cover enclosing the viscoelastic sleeve, the cover having a resealable seam.

11. The pillow of claim 1, wherein the filler material comprises granulated viscoelastic foam.

12. The pillow of claim 11, wherein the granulated viscoelastic foam has a foam density of about 30kg/m³To about 140kg/m³The density of (d) in between.

13. The pillow of claim 12, wherein the granulated viscoelastic foam has a density of about 85kg/m³The density of (c).

14. The pillow of claim 11, wherein the granulated viscoelastic foam has a nominal length of between about 0.6cm and about 2 cm.

15. The pillow of claim 14, wherein the granulated viscoelastic foam has a nominal length of about 1.3 cm.

16. The pillow of claim 11, wherein approximately 16% to 20% of the granulated viscoelastic foam has a length greater than about 2 cm.

17. The pillow of claim 11, wherein approximately 38% to 42% of the granulated viscoelastic foam has a length of between about 1cm to about 2 cm.

18. The pillow of claim 11, wherein approximately 38% to 42% of the granulated viscoelastic foam has a length less than about 1 cm.

19. The pillow of claim 1, wherein the filler material comprises granulated viscoelastic foam and polystyrene balls.

20. The pillow of claim 1 wherein said filler material comprises granulated viscoelastic foam and granulated high resilience foam.

21. A method for manufacturing a pillow, the method comprising:

providing a viscoelastic sleeve defining a cavity;

filling a filler material into the cavity; and

encapsulating the liner to retain the filler material within the cavity.

22. The method of claim 21, further comprising

Placing the first viscoelastic layer on top of the second viscoelastic layer;

joining a portion of the first viscoelastic layer with a portion of the second viscoelastic layer to form the sleeve containing the filler material; and

joining the remainder of the first viscoelastic layer with the remainder of the second viscoelastic layer to encapsulate the sleeve and retain the filler material within the cavity.

23. The method of claim 22, further comprising

Covering the first viscoelastic layer with a first fabric layer; and

covering the second viscoelastic layer with a second fabric layer.

24. The method of claim 23, further comprising

Connecting the first fabric layer and the first viscoelastic layer; and

connecting the second fabric layer and the second viscoelastic layer.

25. The method of claim 20, further comprising

Inserting said viscoelastic sleeve into a housing via a resealable seam; and

sealing the slot to secure the viscoelastic sleeve within the enclosure.

26. The method of claim 20, further comprising shredding the viscoelastic material into individual pieces to form the filler material.

27. A method for manufacturing a pillow, the method comprising:

providing at least two opposing layers of viscoelastic foam and at least two layers of reinforcing fabric covering the opposing layers of viscoelastic foam;

sewing together said viscoelastic foam layer and said reinforcing fabric layer to form a covering having an open end, said viscoelastic foam layer forming inner layers of said covering and said reinforcing fabric layer forming outer layers of said covering;

injecting a filler material through the open end of the liner cap; and

sewing the open ends of the liner covers together to close the liner and secure the filler material therein.

28. The method of claim 27, wherein the two opposing viscoelastic foam layers comprise a first viscoelastic layer and a second viscoelastic layer and the two opposing fabric layers comprise a first fabric layer and a second fabric layer, the method further comprising

Placing the first viscoelastic layer on top of the second viscoelastic layer;

covering the first viscoelastic layer with a first fabric layer; and

covering the second viscoelastic layer with a second fabric layer.