Patent Application
20240398139
A pillow provides support for a user during rest and may be formed from a single piece of deformable material or a quantity of filling. Both may be formed from a foam or microfiber material. Some people are warmer sleepers and prefer to sleep without heavy warm bedding. Pillows are a key part of any bedding and provide a major role in creating a comfortable sleeping environment. Bedding providers are constantly seeking ways to provide products that create a sleep experience tailored to sleep preferences.
An example pillow according to an exemplary embodiment of this disclosure includes, among other possible things a case defining an inner cavity and a closeable opening providing access to the inner cavity and a filler material disposed within the inner cavity. The filler material includes a predefined amount of microfibers intermixed with a plurality of defined geometric shaped foam elements that define open spaces for an increased airflow through the pillow.
Although the different examples have the specific components shown in the illustrations, embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.
These and other features disclosed herein can be best understood from the following specification and drawings, the following of which is a brief description.
Referring to
The example pillow 20 includes the selectively closeable opening 38 that provides access to the inner cavity 26 for adjustment to the amount of filler material 24. The closeable opening may have use zippers 54, 56, as shown, buttons or any other fastener to hold close the opening 38. Adjustment to the amount of filler material 24 enables a user to tailor the firmness of the pillow 20 to personal preferences.
Referring to
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The example skewed block element 30 includes a height 58, width 62, and depth 60 that are substantially the same with a tolerance included that accounts for manufacturing variations. The sides of the skewed block 30 are not necessarily parallel to each other nor exact straight lines. The term skewed as utilized in this disclosure, describes a non-symmetric shape with sides that may not be parallel nor perpendicular to each other. Instead, the skewed block may have curved, angled, non-flat sides that are not symmetric but that generally define a block. In one disclosed example embodiment, the height 58, width 62 and depth 60 of the skewed block element 30 are approximately ½ inch+/−0.11 inch (1.5 cm+/−3 mm), however other sizes could be utilized and are within the contemplation of this disclosure.
Referring to
The cross-shaped foam element 32 includes a height 64, width 66, and thickness 68. Each of cross portion 74 includes a width 70 and a length 72. The width 70 and length 72 of each cross portion 74 is substantially the same. The cross-shape is shown with straight lines and perpendicular corners; however, the resulting foam element is not a precise structure as cutting of the foam elements results in irregular sides and surfaces due to variations of the manufacturing process within acceptable tolerances. Accordingly, the example cross-shape foam element may be non-symmetrical and include non-straight sides and surfaces and remain within the contemplation and scope of this disclosure. In one disclosed example embodiment, the height 64 and width 66 of the cross-shaped foam element 32 is approximately 0.82 inch (2.1 cm). The width of the cross portions are around 0.25 inches (0.7 cm). The thickness 68 of the example cross-shaped foam element 32 is about 0.63 inches (1.6 cm). All of the example dimensions are subject to variations in manufacture that may be within a tolerance of around +/−0.11 inch (+/−3 mm). Although an example dimensional embodiment is provided by way of example, other sizes are within the contemplation and scope of this disclosure.
The example disclosed shaped foam elements 30, 32 are formed from a Visco polyurethane foam material. The microfiber fill material 34 is formed from polyester material formed into fibers that are finer than one denier with a diameter of less than 10 micrometers. Although materials are disclosed by way of example for shaped foam elements 30, 32 and the microfiber fill material 34, other materials could be utilized and are within the scope and contemplation of this disclosure.
The foam filling 24 is made up of a combination of one of the shaped elements 30, 32 and loose randomly shaped microfiber filling material 34. Although the example skewed block element 30 and the cross-shaped elements 32 are shown by way of example of the defined geometric shaped elements other defined geometric shapes may be utilized and are within the contemplation and scope of this disclosure. In this disclosure, the term defined geometric shape is used in reference to a shape that is purposely formed and not a shape that is the result of random processes.
The defined geometric shaped elements 30, 32 are configured such that the shapes do not interlock or combine into a solid mass as they gather within the inner cavity 26 of the pillow 20. Instead, the defined shaped elements 30, 32 are shaped such that they create spaces therebetween when gathered and packed to together.
The defined geometric shapes 30, 32 resists interlocking and define randomly arranged open spaces therebetween. Rather than a uniform material orientation or stacking together, the shaped elements 30, 32 resists interlocking and the formation of tightly packed clusters. Instead, when the shaped elements 30, 32 are grouped together, spaces are generated that provide an improved airflow. Moreover, the microfiber fill material 34 intermixes between the shaped elements 30, 32 and further prevent tight contact and stacking to maintain open spaces for air flow.
Referring to
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Prior art filing material would include a substantially uniform overall density that defined how air may flow through the pillow. Compression of the filling material during use would have a substantial effect on this density and the amount of airflow through the pillow.
The disclosed example filling material 24 includes the shaped elements 30, 32 that maintains a greater portion of the open spaces 36 when compressed during use. Even when compressed, some portion of the open spaces 36 defined between the shaped elements 30, 32 remain. Moreover, the spacing is maintained while still providing the desired support for the user. The open spaces provide for a substantially greater airflow that provides a perceived dryer and cooler experience as compared to traditional pillow configurations.
Referring to
An airflow through the filing material is measured utilizing a testing apparatus schematically shown and indicated at 40. The apparatus 40 includes an inlet 42 that is seated against a portion of the pillow 20. The pillow 20 is filled with a predefined quantity of filling material 24. A pump 46 generates a vacuum measured by a vacuum gauge 45. The vacuum draws inlet air 50 into and through the pillow 20 and out through an inlet 42. The amount of vacuum is predefined to provide a constant for comparison purposes. A flow meter 44 measures an outlet flow 48. Once the outlet flow 48 stabilizes, an airflow measurement is obtained. In one disclosed example, the outlet flow 48 was allowed to stabilize for around 5 minutes.
In one disclosed example embodiment, testing is conducted according to ASTM D3574-Part G and utilizes a testing device 40 that draws with an inlet 42 opening that is approximately 6 inches in diameter. A load of approximately 10 pounds is exerted to push the inlet 42 against a surface of the pillow 20. In one example the A suction rate of approximately 0.5 inches is used to draw the airflow 50 through the pillow 20.
The airflow 48 is indicative of the cooling properties provided by the example filling material. The greater the airflow 48, the better moisture dissipation and less heat that may remain within the filling. The less heat and moisture retained, the cooler the perceived environment experienced by a user of the pillow.
The example filling material 24 includes a plurality of at least one of the shaped elements 30, 32. In one example embodiment, only one of the shaped elements 30, 32 are provided in the filling material 24. In another example embodiment, the cross-shaped element 32 is provided along with the microfiber fill material 34. In still another example embodiment, the skewed block element 30 is utilized with the microfiber fill material 34.
In any of the example embodiments, the example pillow 20 provides a substantially cooler experience for a user. In one disclosed example, the filling material 24, including a plurality of at least one of the shaped elements 30, 32 provides a pillow that is approximately 1.5 more flow and breathability than conventional filling without defined geometric shapes. The cooler experience can be quantified as relating to the airflow 48 measurements obtained utilizing the testing apparatus 40 and the process for testing described above.
The volume of the filling material is predefined to provide a constant for comparison purposes. In one disclosed embodiment, a density of filling material 24 provided within the pillow 20 during testing is between 3.4 lb/ft3 and 6.0 lb/ft3. In another disclosed example embodiment, the density of the filling material is between 4.0 lb/ft3 and 5.3 lb/ft3.
In one disclosed example embodiment, under a vacuum with a suction rate of approximately 0.5 inches water, the airflow is between of 5.00 and 8.00 CFM (ft3/minute). In another example embodiment, for the same vacuum, the airflow is between 6.00 and 7.50 CFM (ft3/minute). In still another example embodiment, the airflow rate through the example pillow is about 7.25 CFM. The example airflow ranges are indicative of a cooler, dryer perceived sleeping experience as compared to traditional solid or foam filled pillows.
The disclosed example airflow ranges through the filling material are provided by the spacings generated by the defined geometric shaped foam elements 30, 32. The example airflow ranges are indicative of a cooler, dryer perceived sleeping experience as compared to traditional solid or foam filled pillows.
Although the different non-limiting embodiments are illustrated as having specific components or steps, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments.
It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure.
Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. For that reason, the following claims should be studied to determine the scope and content of this disclosure.
