Patent Application
20160338514
The present disclosure relates generally to comfort pillows. In particular, pillows constructed out of various types of foam that can be adjusted for height and firmness are described.
Known pillows are not entirely satisfactory for the range of applications in which they are employed. For example, existing pillows made from duck or goose down, while often being preferable in terms of comfort, have a tendency to flatten over the course of use, despite repeated fluffing. This flattening can result in an awkward head angle and less-than-optimal sleep for the user. Moreover, down pillows are unsuitable for some people who have an allergy to the associated dander. Existing foam pillows, while mitigating issues of allergies and flattening, often are relatively firm when compared to a down pillow and can have a tendency to trap heat, and thus are less comfortable to use compared to a down pillow. In addition, conventional pillows are not easily adjustable for height. This can discourage a user from bringing his or her pillow along while traveling where the firmness and quality of provided bedding is unknown, potentially resulting in poorer sleep quality.
Thus, there exists a need for foam pillows that improve upon and advance the design of known pillows. Examples of new and useful foam pillows relevant to the needs existing in the field are discussed below.
The present disclosure is directed to an improved foam pillow. A pillow constructed from multiple foam layers is disclosed, with one or more of the layers including multiple channels designed to reduce the firmness of the layer, as well as enhance cooling air flow through the pillow, thereby increasing comfort to the user and preferably approximating the feel of a down pillow. By using channels in at least one layer to adjust the pillow's firmness in combination with careful selection of foam type for each layer, the improved foam pillow can be tailored to a wide variety of user preferences for comfort and cooling.
In some examples, the improved foam pillow includes a top layer made of memory foam with the second layer made of lower cost low density foam, to enable a cost savings. At least the second layer has channels for firmness adjustment and cooling. Additional layers can be optionally added to adjust the overall pillow height without substantially altering the pillow's firmness. The shape and number of the channels can be varied to achieve different firmness levels and comfort feels.
In still further examples, the top and second layers can be combined into a single unified layer, preferably made of memory foam, and including a series of channels through the center to adjust for desired firmness and enhance cooling.
The disclosed improved foam pillows will become better understood through review of the following detailed description in conjunction with the figures. The detailed description and figures provide merely examples of the various inventions described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered without departing from the scope of the inventions described herein. Many variations are contemplated for different applications and design considerations; however, for the sake of brevity, each and every contemplated variation is not individually described in the following detailed description.
Throughout the following detailed description, examples of various improved foam pillows are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in each example. Instead, the use of related feature names will cue the reader that the feature with a related feature name may be similar to the related feature in an example explained previously. Features specific to a given example will be described in that particular example. The reader should understand that a given feature need not be the same or similar to the specific portrayal of a related feature in any given figure or example.
The disclosed improved foam pillow comprises a multiple-layer system, with one or more of the foam layers specially cut to adjust the firmness of the pillow as a whole, while enhancing airflow through the pillow and associated cooling. These improvements allow the pillow to better approximate the feel of a down pillow, while avoiding the problems with long-term flattening and providing a pillow that is usable by people otherwise allergic to down. Furthermore, by employing a layered system, the height of the pillow can be easily adjusted to accommodate a variety of users and bedding scenarios without significantly affecting the pillow's overall feel. Moreover, by changing layers the pillow's feel can be altered to suit different users, or changing needs of a user.
With reference to
First top foam layer 110 is preferably manufactured from viscoelastic polyurethane foam, commonly referred to as memory foam, which is an open-cell type of foam that temporarily molds to user's contours, and is commonly used in bedding applications. Because of these properties, it is ideal for use in the top layer, the top surface of which directly cradles the user, providing initial comfort that approximates that of a down pillow. This foam is typically formed into the desired shape by injection molding. Alternatively, the top foam layer 110 can be constructed from other types of malleable synthetic or natural foam such as latex, gel cushioning, or any foam or other material now known or later devised that provides cradling properties for a user. First top foam layer 110 can optionally have a plurality of vertical channels 137, with each channel having an opening on the top and bottom surfaces of the first top foam layer 110. This enables air to flow through the first top foam layer 110 and, in conjunction with channels 130 that are located on the top surface of the middle second foam layer 120 (described below), enhances cooling air flow through the pillow. Preferably the vertical channels 137 are arranged so that at least some or all of the openings of each of the vertical channels 137 on the bottom surface of first top foam layer 110 are positioned over one of the channels 130, facilitating air flow between the vertical channels 137 and channels 130.
In the example shown in
Channels 130 are cut into the top surface of second foam layer 120 to both adjust the firmness of second foam layer 120, and to optionally enhance air flow through the pillow, so as to reduce the trapping of body heat by the pillow, thereby enhancing the user's comfort. The depth, number, and shape of the channels 130 can be varied to increase or decrease the desired firmness of the pillow and effective cooling. Deeper channels 130 that are kept relatively narrow will tend to increase cooling while not substantially reducing pillow firmness, while wider and deeper channels 130 can decrease firmness while increasing cooling. Conversely, shallower channels 130 will reduce effective cooling while not substantially altering pillow firmness. The positioning of channels 130 preferably is coordinated with the position of vertical channels 137, if present on the first top foam layer 110. The width, depth, and number of channels 130 selected also depend upon the types of foam employed for first top foam layer 110 and second foam layer 120. Where firmer, denser foams are utilized, the depth, width, and number of channels 130 employed will need to be increased to reduce overall firmness of pillow 100. Conversely, use of less dense foams with greater give will require fewer and shallower/narrower channels 130. By careful selection of the types of foam utilized as well as the shape and number of channels 130 employed, pillow 100 can be tailored to a wide variety of feels and firmness levels depending on user preference.
As can be seen in
Shown in
It will be appreciated that the layered construction of pillow 100 allows for the swapping of top foam layer 110 or second foam layer 120 for layers constructed from different foam types, or with different configurations of channels 130. For top foam layer 110, the layer can additionally be swapped for a layer that either possesses or lacks channels 135. By swapping layers, pillow 100 can be adjusted over time for changing user needs, or layers can be replaced as they may wear out without the need for complete pillow replacement.
Turning attention to
As can be seen in
Top foam layer 410, similar to top foam layer 110, is preferably constructed from memory foam, with the channels 420 implemented during the molding process. However, top foam layer 410 can also be constructed from other types of malleable synthetic or natural foam such as latex, gel cushioning, or any foam or other material now known or later devised that provides cradling properties for a user. Bottom foam layers 430 correspond in implementation and function to bottom foam layers 140 previously described.
The disclosure above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in a particular form, the specific embodiments disclosed and illustrated above are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed above and inherent to those skilled in the art pertaining to such inventions. Where the disclosure or subsequently filed claims recite “a” element, “a first” element, or any such equivalent term, the disclosure or claims should be understood to incorporate one or more such elements, neither requiring nor excluding two or more such elements.
Applicant(s) reserves the right to submit claims directed to combinations and subcombinations of the disclosed inventions that are believed to be novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of those claims or presentation of new claims in the present application or in a related application. Such amended or new claims, whether they are directed to the same invention or a different invention and whether they are different, broader, narrower or equal in scope to the original claims, are to be considered within the subject matter of the inventions described herein.
