Patent Application
20180305199
Embodiments of the disclosure relate generally to pillows, and to methods of making pillows. More particularly, embodiments of the present disclosure relate to pillows that include a gelatinous elastomer cushion having deformable wall members, and to methods of making and using such pillows.
Pillows are used to support the head and neck while sleeping or lying down. Pillows typically consist of a fabric envelope, referred to as a “pillowcase,” which contains a soft cushioning material. The soft cushioning material typically comprises synthetic or natural fiber material, down feathers, or a synthetic foam material.
The inventor of the present invention has also previously invented various cushioning materials and cushions that include gelatinous elastomer materials. For example, the following patents disclose various gelatinous elastomer cushions: U.S. Pat. No. 5,749,111 issued May 12, 1998 to Pearce, U.S. Pat. No. 6,026,527 issued Feb. 22, 2000 to Pearce, U.S. Pat. No. 6,413,458 issued Jul. 2, 2002 to Pearce, and U.S. Pat. No. 8,919,750 issued Dec. 30, 2014 to Pearce et al., the disclosures of which are hereby incorporated herein in their entireties by this reference.
In some embodiments, a pillow comprises a first pillow cushion defining a first major surface of the pillow, a second pillow cushion coupled thereto at an interface, and a pillow cover enclosing the first and second pillow cushions. The first pillow cushion consists essentially of a gelatinous elastomer and defines a first major surface of the pillow. The first pillow cushion is sized and configured to support a head and neck of a person using the pillow. The first pillow cushion comprises deformable wall members extending between the first major surface and the interface. The deformable wall members are located and configured to define voids therebetween such that the deformable wall members may be displaced into adjacent voids upon deformation of the deformable wall members. The deformable wall members configured to buckle when a pressure applied to the first major surface of the first pillow cushion, in a direction perpendicular to the first major surface, exceeds a threshold pressure level. The second pillow cushion defines a second major surface of the pillow opposite the first major surface. The second pillow cushion has a material composition different from the first pillow cushion.
In other embodiments, a method of fabricating a pillow comprises forming a first pillow cushion consisting essentially of a gelatinous elastomer. The first pillow cushion is sized and configured to support a head and neck of a person using the first pillow cushion. The first pillow cushion comprises deformable wall members located and configured to define voids therebetween such that the deformable wall members may be displaced into adjacent voids upon deformation of the deformable wall members. Ends of the deformable wall members define a first major surface of the pillow. The deformable wall members are configured to buckle when a pressure applied to the first major surface of the pillow first cushion, in a direction perpendicular to the first major surface, exceeds a threshold pressure level. The method further comprises coupling the first pillow cushion to a second pillow cushion. The second pillow cushion defines a second major surface of the pillow opposite the first major surface of the pillow. The second pillow cushion has a material composition different from the first pillow cushion. A pillow cover encloses the first pillow cushion and the second pillow cushion.
While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present invention, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments when read in conjunction with the accompanying drawings, in which:
As used herein, the term “elastomeric polymer” means and includes a polymer capable of recovering its original size and shape after deformation. In other words, an elastomeric polymer is a polymer having elastic or viscoelastic properties. Elastomeric polymers may also be referred to as “elastomers” in the art. Elastomeric polymers include, without limitation, homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units).
The illustrations presented herein are not actual views of any particular pillow, pillow cushion, pillow insert, or pillow cover, but are merely idealized representations employed to describe embodiments of the present disclosure. Elements common between figures may retain the same numerical designation.
The pillow cushion 102 consists essentially of a gelatinous elastomer (also referred to in the art as “elastomer gels,” “gelatinous elastomers,” or simply “gels”). In some embodiments, the pillow cushion 102 may comprise 90% by weight or more, 95% by weight or more, 98% by weight or more, or even 100% by weight gelatinous elastomer. Gelatinous elastomers are elastomeric materials, which may include elastomeric polymers or mixtures of elastomeric polymers and plasticizers (and optionally other materials such as pigments, fillers, antioxidants, etc.). Gelatinous elastomers are elastic (i.e., capable of recovering size and shape after deformation).
For example, the gelatinous elastomer of the pillow cushion 102 may comprise a mixture of an elastomeric block copolymer and a plasticizer. As used herein, the term “elastomeric block copolymer” means and includes an elastomeric polymer having groups or blocks of homopolymers linked together, such as A-B diblock copolymers and A-B-A triblock copolymers. A-B diblock copolymers have two distinct blocks of homopolymers. A-B-A triblock copolymers have two blocks of a single homopolymer (A) each linked to a single block of a different homopolymer (B). As used herein, the term “plasticizer” means and includes a substance added to another material (e.g., an elastomeric polymer) to increase a workability of the material. For example, a plasticizer may increase the flexibility, softness, or extensibility of the material. Plasticizers include, without limitation, hydrocarbon fluids, such as mineral oils. Hydrocarbon plasticizers may be aromatic or aliphatic.
As non-limiting examples, the pillow cushion 102 may comprise a gelatinous elastomer as described in U.S. Pat. No. 5,994,450, issued Nov. 30, 1999, and titled “Gelatinous Elastomer and Methods of Making and Using the Same and Articles Made Therefrom”; U.S. Pat. No. 7,964,664, issued Jun. 21, 2011, and titled “Gel with Wide Distribution of MW in Mid-Block”; and U.S. Pat. No. 4,369,284, issued Jan. 18, 1983, and titled “Thermoplastic Elastomer Gelatinous Compositions”; the disclosures of each of which are incorporated herein in their entirety by this reference.
The elastomeric block polymer of the gelatinous elastomer may be an A-B-A triblock copolymer such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), or styrene ethylene propylene styrene (SEEPS). For example, A-B-A triblock copolymers commercially available from Kuraray America, Inc., of Houston, Tex., under the trade name SEPTON® 4055, and from Kraton Polymers, LLC, of Houston, Tex., under the trade names KRATON® E1830, KRATON® G1650, and KRATON® G1651 may be employed in the gelatinous elastomer. In these examples, the “A” blocks are styrene. The “B” block may be rubber (e.g., butadiene, isoprene, etc.) or hydrogenated rubber (e.g., ethylene/propylene or ethylene/butylene or ethylene/ethylene/propylene) capable of being plasticized with mineral oil or other hydrocarbon fluids. The gelatinous elastomer may include elastomeric polymers other than styrene-based copolymers, such as non-styrenic elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers or that are multi-component thermoset elastomers. Other elastomeric polymers that may be employed include polymers that are derivatives of these families of synthetic rubber polymers, or that exhibit similar physical properties to such synthetic rubber polymers.
The gelatinous elastomer may include one or more plasticizers, such as hydrocarbon fluids. For example, elastomeric materials may include aromatic-free food-grade white paraffinic mineral oils, such as those sold by Sonneborn, Inc., of Mahwah, N.J., under the trade names BLANDOL® and CARNATION®.
As one particular non-limiting example, the gelatinous elastomer of the pillow cushion 102 may include a melt-blend of one part by weight of a styrene-ethylene-ethylene-propylene-styrene (SEEPS) elastomeric triblock copolymer (e.g., SEPTON® 4055) with four parts by weight of a 70-weight straight-cut white paraffinic mineral oil (e.g., CARNATION® white mineral oil) and, optionally, pigments, antioxidants, and/or other additives.
The gelatinous elastomer may include one or more fillers (e.g., lightweight microspheres). Fillers may affect thermal properties, density, processing, etc., of the elastomeric material. For example, hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may decrease the thermal conductivity of the elastomeric material by acting as an insulator because such hollow microspheres (e.g., hollow glass microspheres or hollow acrylic microspheres) may have lower thermal conductivity than the plasticizer or the polymer.
The gelatinous elastomer may also include antioxidants. Antioxidants may reduce the effects of thermal degradation during processing or may improve long-term stability. Antioxidants include, for example, pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate), commercially available as IRGANOX® 1010, from BASF Corp., of Iselin, N.J. or as EVERNOX®-10, from Everspring Chemical, of Taichung, Taiwan; octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, commercially available as IRGANOX® 1076, from BASF Corp. or as EVERNOX® 76, from Everspring Chemical; and tris(2,4-di-tert-butylphenyl)phosphite, commercially available as IRGAFOS® 168, from BASF Corp. or as EVERFOS® 168, from Everspring Chemical. One or more antioxidants may be combined in a single formulation of the gelatinous elastomer. The use of antioxidants in mixtures of plasticizers and polymers is described in columns 25 and 26 of U.S. Pat. No. 5,994,450, previously incorporated by reference. The gelatinous elastomer may include up to about 5% by weight antioxidants. For instance, the gelatinous elastomer may include from about 0.10% by weight to about 1.0% by weight antioxidants.
In some embodiments, the gelatinous elastomer may include a pigment or a combination of pigments so as to provide the pillow cushion 102 with an appearance that is appealing to consumers. As one non-limiting example, the pigment may create a soothing color, which may be purple or lavender.
The gelatinous elastomer of the pillow cushion 102 is elastic in that it returns to its original shape after deformation, and may be elastically stretched and compressed. The gelatinous elastomer may be rubbery in feel, but may deform to the shape of an object applying a deforming pressure better than conventional rubber materials, and may have a durometer hardness lower than conventional rubber materials. For example, the gelatinous elastomer may have a hardness on the Shore A scale of from about 0.1 to about 50, and in some embodiments, less than about 5. The gelatinous elastomer is soft enough to not cause pain or discomfort to the ear or other facial parts of a person sleeping or resting their head on the pillow 100.
The gelatinous elastomer may be generally nonsticky, such that the pillow cushion 102 may return to its original shape after deformation. In some embodiments, the pillow cushion 102 may comprise between about six pounds and twelve pounds of the gelatinous elastomer. As one non-limiting example, the cushion may have a length of about twenty-four inches, a width of about sixteen inches, and a height or thickness of about three and one-half inches.
As shown in
As shown in
The zipper 112 may extend proximate and along three sides of the pillow cover 104 as shown in
In other embodiments, any other type of fastener, such as hook-and-loop material, may be used instead of a zipper 112 to securely close an aperture in the lower second major side 110 of the pillow cover 104.
In use, the pillow 100 with the pillow cover 104 thereon optionally may be inserted into a conventional linen pillowcase.
The pillow cushion 102 is illustrated in
The deformable wall members 124 are located and configured to define voids 126 therebetween such that the deformable wall members 124 may be displaced into adjacent voids 126 upon deformation of the deformable wall members 124. Furthermore, the deformable wall members 124 are configured to buckle when a pressure applied to a cushioning surface of the pillow cushion 102 (i.e., the first major surface 120), in a direction perpendicular to the first major surface 120, exceeds a threshold pressure level.
As shown in the plan views of
In the configuration described herein, the gelatinous elastomer of the cushion 102 is formed into the deformable walls 124, which define hollow columns with shared walls that behave like a spring under pressure unless the localized pressure exceeds a threshold pressure, at which time one or more of the hollow columns buckles and the load is spread out to a larger area encompassing surrounding columns. This mechanism provides enhanced comfort, while not being so soft as to not be supportive to the neck and head so as to preserve desired spinal alignment, and not being so soft as to allow the nose of person sleeping or resting on their side to be smothered by sinking too far into the pillow 100.
Referring again to
The deformable wall members 124 in the generally planar first portion 134 are located and configured such that the voids 126 defined therebetween have a first average size, and the deformable wall members 124 in the generally planar second portion 136 are located and configured such that the voids 126 defined therebetween have a second average size. In some embodiments, the first average size may be smaller than the second average size. In other words, the voids 126 in the first portion 134 may have a smaller cross-sectional area in a plane parallel to the first major surface 120 than the voids 126 in the second portion 136, as shown in
The deformable walls 124 in the generally planar first portion 134 may have a wall thickness T134 (
In some embodiments, the first portion 134 may include from two to six times (e.g., four times) as many voids 126 as are present in the second portion 136. Furthermore, the deformable wall members 124 in the first portion 134 may be thinner than the deformable wall members 124 in the second portion 136. By way of example and not limitation, the deformable wall members 124 in the first portion 134 may have a thickness that is between about 25% and about 75% (e.g., about 50%) of the thickness of the deformable wall members 124 in the second portion 136.
The first portion 134 may have a first average thickness (in the direction perpendicular to the first major surface 120), and the second portion 136 may have a second average thickness different from the first average thickness. For example, the first portion 134 may be thinner than the second portion 136 in the direction perpendicular to the first major surface 120, as shown in
Furthermore, the deformable wall members 124 in the first portion 134 may be configured to buckle when a pressure applied to a cushioning surface of the pillow cushion 102 (i.e., the first major surface 120) in the direction perpendicular to the first major surface 120 exceeds a first threshold pressure level, and the deformable wall members 124 in the second portion 136 are configured to buckle when a pressure applied to the cushioning surface of the pillow cushion 102 in the direction perpendicular to the first major surface 120 exceeds a second threshold pressure level that is different than the first threshold pressure level. In such a configuration, the cushion 102 may exhibit a dual-stage buckling property.
In additional embodiments, more than two layers of buckling columns defined by deformable wall members 124 and voids 126 may be employed, and the threshold buckling pressure level may vary amongst each of the layers so as to cause the cushion 102 to exhibit a multi-stage (e.g., three or more stages) buckling property.
In yet further embodiments, the cushion 102 may comprise a single layer of buckling columns defined by deformable wall members 124 and voids 126 extending continuously between the first major surface 120 and the second major surface 122, such that the cushion 102 exhibits a single-stage buckling property.
As shown in
As shown in
The stabilizing layer 140 may cause the peripheral regions 142 of the cushion 102, which support the neck of a person using the pillow 100, to be relatively firmer or stiffer (and more supportive) than the central region of the cushion 102, which supports the head of the user. This has an orthopedic shaping effect without having to make the un-deformed pillow shaped so as to have a three-dimensional contour under the neck and the head. Furthermore, the stabilizing layer 140 increases the side-load stiffness around the periphery of the cushion 102, which helps the pillow 100 keep, or rebound to, its un-deformed shape after deformation.
In additional embodiments, the stabilizing layer 140 may extend continuously across the entire area of the cushion 102 through the peripheral regions 142 and the central region of the cushion 102.
Apertures 144 may extend through the stabilizing layer 140 of the gelatinous elastomer so as to allow air flow through the stabilizing layer 140 between voids 126 on opposing sides of the stabilizing layer 140, as shown in
In some embodiments, the pillow cushion 102 of the pillow 100 may be free of foam and/or fiber cushioning material.
In some embodiments, a non-cushioning fabric may be fused to the second major surface 122 of the cushion 102, so as to improve the lateral stability of the cushion 102 and ensure that the pillow 100 will keep, or rebound to, its un-deformed shape after deformation. The fabric may comprise a non-stretchable fabric that is heat-fused to the second major surface 122 of the cushion 120. A non-stretchable woven fabric may be employed, though any fabric may be used including non-woven fabric, stretchy fabric, or woven fabric that has little to no stretch.
As previously mentioned, there may be no additional cushioning material between the cushion 102 and the pillow cover 104. The pillow cover 104 may comprise, for example, a stretchable knit material with a small amount (e.g., ⅛″ thick) of loft, in a weight of about 400 grams/m2. Such a material is sufficient to dampen the feel on the ear or the face of the user of the deformable wall members 124 of the cushion 102, so that the pillow 100 feels smooth to the face, ear, and/or head of the user. The pillow cover 104 may comprise any fabric, fabric laminate, multi-layer knit fabric, or spacer fabric with sufficient body, weight, and/or loft to substantially eliminate the feeling of, or ability of the user to feel the deformable wall members 124 and voids 126 on the user's face, ear, or head. Furthermore, the pillow cover 104 may comprise a stretchable fabric so as to not interfere with the soft, pressure-redistributing buckling hollow columns of the pillow cushion 102. In some embodiments, only the pillow cover 104 is between the soft gel columnar material of the pillow cushion 102 and the head or face of the user, and no other intermediate material may be present. In some embodiments, however, a thin, stretchy inner cover for the cushion 102 may be present to avoid the gelatinous material of the cushion 102 becoming dirty when removed from the pillow cover 104 for laundering of the pillow cover 104. Such a material, however, may not have a thickness intended to dampen the feel of the buckling hollow columns of the cushion 102.
The optional insert 106 is shown in the cross-sectional view of
Since the pillow cushion 102 is molded to a specific height (or thickness), and users may prefer a different height, the optional insert 106 may be used to increase the overall height of the pillow 100. The inflatable air bladder can be adjusted to multiple heights by insertion of more or less air through a mouth-inflatable air valve 151 (
As shown in
The inflatable insert 106 may enhance the cushioning effect of the pillow 100, especially when the air bladder is only partially filled. In such case, the deformability of the insert 106 may add another degree of freedom of movement to the overall cushioning effect. The insert 106 has no effect on height or on cushioning if empty of air, and may be left in the pillow cover 104 or removed. If the air bladder is full to the point of tightness, the thickness of the pillow 100 is maximized, but the insert 106 contributes little to the cushioning effect of the pillow 100. When the air bladder of the insert 106 is between about one-quarter and three-quarters full of air, the insert 106 may significantly contribute to the cushioning effect of the pillow 100.
In additional embodiments, the insert 106A may comprise a plurality of layers of foam, for example, several pieces of 0.75″ thick foam, so that the user may put one or more layers of foam under the cushion 102 within the cover 104 so as to configure the pillow 100 with a desired thickness.
In yet further embodiments, bonded polyester fluff fiber, quilted fabric or three-dimensional knitted fabric (often referred to as “spacer fabric”) may be employed as or in an optional insert.
A pillow 100 as described herein may be highly breathable due to the hollow buckling columns of the cushion 102, which reduces or eliminates build-up of sweat. The pillow 100 is temperature-neutral, not hot or cool to the touch. Furthermore, the pillow 100 is usable by a person sleeping on his or her side with a full-face CPAP mask, without making a feature of the pillow 100 to avoid contact with the CPAP mask (such as a side cut-out or an indentation as is classically used in pillows meant for use with CPAP masks).
Unlike a traditional pillows that employ particulate cushioning media such as feathers, chopped-foam or shredded-foam, seed-hulls, etc., a pillow 100 as described herein will not lose shape over time during use. Loss of shape is a problem even with non-shredded/chopped pillows, such as memory foam pillows made all in one piece, because, as the body heats up the foam, the stiffness of the foam changes and the foam loses support and shape. A pillow 100 as described herein will retain its same shape and support all night long, and needs no adjustment (e.g., fluffing) during the night or before use on a subsequent night.
Pillows according to further embodiments of the present disclosure may also employ particulate cushioning media in combination with gelatinous elastomer cushioning materials.
The first pillow cushion 202 and the second pillow cushion 206 may have different material compositions. The first pillow cushion 202 may consist essentially of the gelatinous elastomer as previously described herein with regard to the pillow cushion 102. Like the pillow cushion 102, the first pillow cushion 202 includes deformable wall members 212 extending from the interface 204 to the first major surface 208. The deformable wall members 212 are located and configured to define voids 214 therebetween such that the deformable wall members 212 may be displaced into adjacent voids 214 upon deformation of the deformable wall members 212. Furthermore, the deformable wall members 212 are configured to buckle when a pressure applied to a cushioning surface of the first pillow cushion 202 (i.e., the first major surface 208), in a direction perpendicular to the first major surface 208, exceeds a threshold pressure level. The deformable wall members 212 and voids 214 may have a shape, spacing, or other configuration as previously described herein with regard to the first portion 134 of the pillow cushion 102.
The second pillow cushion 206 may comprise a non-gelatinous elastomer material. In some embodiments, the second pillow cushion 206 may comprise a foam body. The foam body may comprise an open cell foam. For example, the open cell foam may comprise polyurethane foam, viscoelastic or memory foam, or latex foam. The open cell foam may be SERENE® foam commercially available from Carpenter Co. of Richmond, Va. The open cell foam may also comprise one or more additives distributed in the open cell structure. For example, the additive may comprise a metallic particulate material including, but not limited to, copper, gold, or silver particles. The additive-containing open cell foam may be CYPRIUM® foam commercially available from FXI, Inc. of Media, Pa. The additive may alternatively comprise a polymeric particulate including, but not limited to, gel beds. Foams including such gel additives include, for example, MEMGEL® Plus commercially available from FXI, Inc. of Media, Pa. The additive may further comprise magnetic elements. The foam body may comprise a single, unitary body or may comprise multiple foam layers of one or more foam compositions. The foam body of the second pillow cushion 206 may be coupled directly to the first pillow cushion 202. For example, the foam body of the second pillow cushion 206 and the gelatinous elastomer material of the first pillow cushion 202 may be coupled by an adhesive or may be heat-fused together.
According to further embodiments of the present disclosure, the second pillow cushion 206 may comprise a cushioning material disposed in a fabric enclosure. The fabric enclosure may comprise a woven or non-woven fabric. In some embodiments, the fabric may be comprised of stretchable fibers. The stretchable fibers may be selected from, for example, spandex (i.e., “a manufactured fiber in which the fiber-forming substance is a long chain synthetic polymer comprised of at least 85% of a segmented polyurethane” (see 16 C.F.R. § 303.7)), natural or synthetic rubber, olefins, polyesters, polyethers, etc., and combinations thereof. In other embodiments, the fabric may be comprised of non-stretchable fibers. The non-stretchable fibers may be selected from, for example, viscose (e.g., rayon) or cotton. In yet other embodiments, the fabric may be comprised of stretchable and non-stretchable fibers.
The fabric enclosure may comprise a material sufficient to dampen the feel on the ear or face of the user of the pillow 200 of the cushioning materials disposed therein so that the pillow 200 feels smooth to the face, ear, and/or head of the user. The fabric enclosure may comprise any fabric, fabric laminate, multi-layer knit fabric, or spacer fabric with sufficient body, weight, and/or loft to substantially eliminate the feeling of, or ability of the user to feel the cushioning materials disposed therein on the user's face, ear, or head. The fabric enclosure may comprise, for example, a stretchable knit material with a small amount (e.g., ⅛″ thick) of loft, in a weight of about 400 grams/m2. The fabric enclosure of the second pillow cushion 206 and the gelatinous elastomer of the first pillow cushion 202 may be coupled together at the interface 204 by an adhesive or may be heat-fused together.
The cushioning material of the second pillow cushion 206 may comprise shredded foam segments in the fabric enclosure. The shredded foam segments may be comprised of any of the foams of the foam body previously described herein. Such foam may be shredded into strips, blocks, spheres, or segments of any other regular or irregular shape. The second pillow cushion 206 may be formed of foam segments of a uniform or variable size distribution.
In other embodiments, the cushioning material of the second pillow cushion 206 may comprise a fibrous material. In such embodiments, the fibrous material may comprise cotton, polyester, polyurethane, wool, or other batting (e.g., wadding) material. The fibrous material may be provided in the fabric enclosure. In some embodiments, the second pillow cushion 206 may comprise the fibrous material and segments of the gelatinous elastomer previously described herein. The gelatinous elastomer segments may have a regular or irregular shape including, but not limited, to strips, blocks, and spheres, and may have a uniform or variable size distribution. The fibrous material and the gelatinous elastomer segments may be intermixed and provided in the fabric enclosure.
In yet further embodiments, the cushioning material of the second pillow cushion 206 may comprise a plurality of micron-sized spheres of a polymeric material often referred to in the art as microbeads. For example, the microbeads may comprise polystyrene or styrofoam. The microbeads may be provided in the fabric enclosure.
The pillow 200, the first pillow cushion 202, and the second pillow cushion 206 are sized and configured to support a head and neck of a person using the pillow 200. The first pillow cushion 202 may have a first maximum thickness T202 in a direction perpendicular to the first major surface 208, and the second pillow cushion 206 may have a second maximum thickness T206 in a direction perpendicular to the second major surface 210 different from the first average thickness. For example, the first pillow cushion 202 may be thinner than the second pillow cushion 206. For example, the first pillow cushion 202 may have a maximum thickness T202 measured from the first major surface 208 to the interface 204 in a range from about 0.5 inch to 2.0 inches, such as a maximum thickness of about 1 inch or about 1.5 inches. The second pillow cushion 206 may have a maximum thickness T206 measured from the second major surface 210 to the interface 204 in a range from about 1 inch to about 5 inches, such as a maximum thickness T206 of about 2 inches, 2.5 inches, 3 inches, or 3.5 inches. Accordingly, the pillow 200 may have a maximum thickness T200 measured between the first major surface 208 and the second major surface 210 of between about 1.5 inches and about 5.5 inches, such as a maximum thickness T200 of about 3.0 inches, 3.5 inches, 4 inches, 4.5 inches, and 5 inches.
As illustrated in
The first pillow cushion 202 and the second pillow cushion 204 may be enclosed in the pillow cover 104 as previously described herein. In other embodiments, the pillow cushions 202, 204 may be enclosed in a pillow cover like the pillow cover 104 but lacking a zipper. Accordingly, the pillow cushions 202, 204 may not be removable from the pillow cover without destruction thereof. In use, the pillow 200 with the pillow cover 104 thereon may optionally be inserted into a conventional linen pillowcase.
Additional non-limiting example embodiments of the disclosure are described below.
A pillow, comprising: a pillow cushion consisting essentially of a gelatinous elastomer, the pillow cushion sized and configured to support a head and neck of a person using the pillow cushion, the pillow cushion comprising: a first major surface; a second major surface; and deformable wall members extending between the first major surface and the second major surface, the deformable wall members located and configured to define voids therebetween such that the deformable wall members may be displaced into adjacent voids upon deformation of the deformable wall members, the deformable wall members configured to buckle when a pressure applied to a cushioning surface of the pillow cushion, in a direction perpendicular to the first major surface, exceeds a threshold pressure level; and a pillow cover covering the pillow cushion.
The pillow of Embodiment 1, wherein the pillow cushion comprises between six pounds and twelve pounds of the gelatinous elastomer.
The pillow of Embodiment 1, wherein the pillow does not include any additional cushioning material between the pillow cushion and the pillow cover.
The pillow of Embodiment 3, wherein the pillow consists of the pillow cushion and the pillow cover.
The pillow of Embodiment 1, wherein the pillow cushion further comprises: a generally planar first portion; and a generally planar second portion coupled with the first portion, wherein each of the first portion and the second portion comprises: a first major side; an opposite second major side; and a portion of the deformable wall members extending between the first major side and the opposite second major side; wherein the deformable wall members in the generally planar first portion are located and configured such that the voids defined therebetween have a first average size, and wherein the deformable wall members in the generally planar second portion are located and configured such that the voids defined therebetween have a second average size, the first average size being smaller than the second average size.
The pillow of Embodiment 5, wherein the deformable wall members of the first portion and the deformable wall members of the second portion are part of a single, unitary body.
The pillow of Embodiment 5, wherein the deformable wall members in the first portion are configured to buckle when a pressure applied to a cushioning surface of the pillow cushion in the direction perpendicular to the first major surface exceeds a first threshold pressure level, and wherein the deformable wall members in the second portion are configured to buckle when a pressure applied to a cushioning surface of the pillow cushion in the direction perpendicular to the first major surface exceeds a second threshold pressure level different than the first threshold pressure level.
The pillow of Embodiment 5, wherein the deformable wall members in the first portion are located and configured to define a first set of triangular voids therebetween, and wherein the deformable wall members in the second portion are located and configured to define a second set of triangular voids therebetween.
The pillow of Embodiment 8, wherein at least some of the first set of triangular voids are misaligned with all triangular voids of the second set of triangular voids in the direction perpendicular to the first major surface of the cushion.
The pillow of Embodiment 5, wherein the first portion has a first thickness, and the second portion has a second thickness different from the first thickness.
The pillow of Embodiment 1, wherein the deformable wall members are located and configured to define triangular voids therebetween.
The pillow of Embodiment 1, wherein the pillow cushion further comprises a band of the gelatinous elastomer extending entirely around a periphery of the cushion at lateral side surfaces of the cushion.
The pillow of Embodiment 1, further comprising a stabilizing layer of the gelatinous elastomer extending horizontally within the cushion between the first major surface and the second major surface in a direction generally parallel to at least one of the first major surface and the second major surface.
The pillow of Embodiment 13, wherein the stabilizing layer of the gelatinous elastomer is disposed in peripheral regions of the cushion and is not disposed in a central region of the cushion.
The pillow of Embodiment 14, further comprising apertures extending through the stabilizing layer of the gelatinous elastomer so as to allow air flow through the stabilizing layer between voids on opposing sides of the stabilizing layer.
The pillow of Embodiment 1, further comprising a fabric fused to the second major surface of the cushion.
The pillow of Embodiment 16, wherein the fabric comprises a non-stretchable fabric heat-fused to the second major surface of the cushion.
The pillow of Embodiment 1, further comprising an insert disposed between the second surface of the cushion and an inner surface of the pillow cover so as to increase a thickness of the pillow.
The pillow of Embodiment 18, wherein the insert comprises an inflatable bladder configured to be inflated and/or deflated with air so as to adjust a thickness of the pillow.
The pillow of Embodiment 18, wherein the insert has a length on a side of the insert adjacent the cushion greater than a length on a side of the insert adjacent the pillow cover, and a width on a side of the insert adjacent the cushion greater than a width on a side of the insert adjacent the pillow cover.
The pillow of Embodiment 18, wherein the insert further comprises apertures extending therethrough between a first side of the insert adjacent the cushion and an opposing second side of the insert adjacent the pillow cover.
The pillow of Embodiment 1, wherein the pillow case includes a zipper disposed on one major side of the pillow case, the zipper entirely located a distance of at least one inch from peripheral edges of the one major side of the pillow case.
The pillow of Embodiment 22, wherein the zipper of the pillow case extends proximate and along at least a portion of a first longitudinal peripheral edge of the pillow case, proximate and along a first lateral peripheral edge of the pillow case, and proximate and along at least a portion of a second longitudinal peripheral edge of the pillow case.
A method of fabricating a pillow, comprising: forming a pillow cushion consisting essentially of a gelatinous elastomer, the pillow cushion sized and configured to support a head and neck of a person using the pillow cushion, the pillow cushion comprising: a first major surface; a second major surface; and deformable wall members extending between the first major surface and the second major surface, the deformable wall members located and configured to define voids therebetween such that the deformable wall members may be displaced into adjacent voids upon deformation of the deformable wall members, the deformable wall members configured to buckle when a pressure applied to a cushioning surface of the pillow cushion, in a direction perpendicular to the first major surface, exceeds a threshold pressure level; and enclosing the pillow cushion in a pillow cover.
The method of Embodiment 24, wherein forming the pillow cushion comprises molding the pillow cushion.
The method of Embodiment 24, further comprising forming the deformable wall members of the first portion and the deformable wall members of the second portion to be part of a single, unitary body.
The method of Embodiment 24, wherein enclosing the pillow cushion in a pillow cover comprises enclosing the pillow cushion in the pillow cover without including any additional cushioning material between the pillow cushion and the pillow cover.
The method of Embodiment 24, wherein forming the pillow cushion further comprises forming the pillow cushion to comprise: a generally planar first portion; and a generally planar second portion coupled with the first portion, wherein each of the first portion and the second portion comprises: a first major side; an opposite second major side; and a portion of the deformable wall members extending between the first major side and the opposite second major side; wherein the deformable wall members in the generally planar first portion are located and configured such that the voids defined therebetween have a first average size, and wherein the deformable wall members in the generally planar second portion are located and configured such that the voids defined therebetween have a second average size, the first average size being smaller than the second average size.
The method of Embodiment 28, wherein forming the pillow cushion further comprises forming a single, unitary body comprising the deformable wall members of the first portion and the deformable wall members of the second portion.
The method of Embodiment 28, wherein forming the pillow cushion further comprises configuring the deformable wall members in the first portion to buckle when a pressure applied to a cushioning surface of the pillow cushion in the direction perpendicular to the first major surface exceeds a first threshold pressure level, and configuring the deformable wall members in the second portion to buckle when a pressure applied to the cushioning surface of the pillow cushion in the direction perpendicular to the first major surface exceeds a second threshold pressure level different than the first threshold pressure level.
The method of Embodiment 28, further comprising locating and configuring the deformable wall members in the first portion so as to define a first set of triangular voids therebetween, and locating and configuring the deformable wall members in the second portion so as to define a second set of triangular voids therebetween.
The method of Embodiment 31, further comprising misaligning the first set of triangular voids with the second set of triangular voids in the direction perpendicular to the first major surface of the cushion.
The method of Embodiment 28, wherein forming the pillow cushion further comprises forming the first portion to have a first thickness, and forming the second portion to have a second thickness different from the first thickness.
The method of Embodiment 24, wherein forming the pillow cushion further comprises locating and configuring the deformable wall members so as to define triangular voids therebetween.
The method of Embodiment 24, wherein forming the pillow cushion further comprises forming a band of the gelatinous elastomer extending entirely around a periphery of the cushion at lateral side surfaces of the cushion.
The method of Embodiment 24, wherein forming the pillow cushion further comprises forming a stabilizing layer of the gelatinous elastomer extending horizontally within the cushion between the first major surface and the second major surface in a direction generally parallel to at least one of the first major surface and the second major surface.
The method of Embodiment 36, wherein forming the pillow cushion further comprises disposing the stabilizing layer of the gelatinous elastomer in peripheral regions of the cushion and not in a central region of the cushion.
The method of Embodiment 37, wherein forming the pillow cushion further comprises forming apertures extending through the stabilizing layer of the gelatinous elastomer so as to allow air flow through the stabilizing layer between voids on opposing sides of the stabilizing layer.
The method of Embodiment 24, further comprising fusing a fabric to the second major surface of the cushion.
The method of Embodiment 39, further comprising selecting the fabric to comprise a non-stretchable fabric, and heat-fusing the non-stretchable fabric to the second major surface of the cushion.
The method of Embodiment 24, further comprising disposing an insert between the second surface of the cushion and an inner surface of the pillow cover so as to increase a thickness of the pillow.
The method of Embodiment 41, further comprising selecting the insert to comprise an inflatable bladder configured to be inflated and/or deflated with air so as to adjust a thickness of the pillow.
The method of Embodiment 41, wherein the insert has a length on a side of the insert adjacent the cushion greater than a length on a side of the insert adjacent the pillow cover, and a width on a side of the insert adjacent the cushion greater than a width on a side of the insert adjacent the pillow cover.
The method of Embodiment 41, wherein the insert further comprises apertures extending therethrough between a first side of the insert adjacent the cushion and an opposing second side of the insert adjacent the pillow cover.
The method of Embodiment 24, wherein the pillow case includes a zipper disposed on one major side of the pillow case, the zipper entirely located a distance of at least one inch from peripheral edges of the one major side of the pillow case.
The method of Embodiment 45, wherein the zipper of the pillow case extends proximate and along at least a portion of a first longitudinal peripheral edge of the pillow case, proximate and along a first lateral peripheral edge of the pillow case, and proximate and along at least a portion of a second longitudinal peripheral edge of the pillow case.
A pillow, comprising: a first pillow cushion defining a first major surface of the pillow, the first pillow cushion consisting essentially of a gelatinous elastomer, the first pillow cushion defining a first major surface of the pillow, the first pillow cushion sized and configured to support a head and neck of a person using the pillow; a second pillow cushion coupled to the first pillow cushion at an interface, the second pillow cushion defining a second major surface of the pillow opposite the first major surface, the second pillow cushion having a material composition different from the first pillow cushion; and a pillow cover enclosing the first pillow cushion and the second pillow cushion; wherein the first pillow cushion comprises: deformable wall members extending between the first major surface and the interface, the deformable wall members are located and configured to define voids therebetween such that the deformable wall members may be displaced into adjacent voids upon deformation of the deformable wall members, the deformable wall members configured to buckle when a pressure applied to the first major surface of the first pillow cushion, in a direction perpendicular to the first major surface, exceeds a threshold pressure level.
The pillow of Embodiment 47, wherein the first pillow cushion is coupled to the second pillow cushion using an adhesive.
The pillow of Embodiment 47, wherein the pillow consists of the first pillow cushion, the second pillow cushion, and the pillow cover.
The pillow of Embodiment 47, wherein the deformable wall members of the first pillow cushion form a single, unitary body.
The pillow of Embodiment 47, wherein the second pillow cushion comprises a single, unitary foam body.
The pillow of Embodiment 47, wherein the second pillow cushion comprises segments of foam disposed in a fabric enclosure.
The pillow of Embodiment 47, wherein the second pillow cushion comprises a fibrous material disposed in a fabric enclosure.
The pillow of Embodiment 53, wherein the fibrous material comprises cotton or polyester.
The pillow of Embodiment 53, wherein the second pillow cushion further comprises segments of a gelatinous elastomer.
The pillow of Embodiment 47, wherein the second pillow cushion comprises microbeads disposed in a fabric enclosure.
The pillow of Embodiment 47, wherein the first pillow cushion has a first thickness, and the second pillow cushion has a second thickness different from the first thickness.
The pillow of Embodiment 57, wherein the first thickness is less than the second thickness.
The pillow of Embodiment 47, wherein the pillow case is not removable from the first pillow cushion and the second pillow cushion using non-destructive means.
A method of fabricating a pillow, comprising: forming a first pillow cushion consisting essentially of a gelatinous elastomer, the first pillow cushion sized and configured to support a head and neck of a person using the first pillow cushion, the first pillow cushion comprising: deformable wall members located and configured to define voids therebetween such that the deformable wall members may be displaced into adjacent voids upon deformation of the deformable wall members, ends of the deformable wall members defining a first major surface of the pillow, the deformable wall members configured to buckle when a pressure applied to the first major surface of the pillow first cushion, in a direction perpendicular to the first major surface, exceeds a threshold pressure level; coupling the first pillow cushion to a second pillow cushion, the second pillow cushion defining a second major surface of the pillow opposite the first major surface of the pillow, the second pillow cushion having a material composition different from the first pillow cushion; and enclosing the first pillow cushion and the second pillow cushion in a pillow cover.
The method of Embodiment 60, wherein forming the first pillow cushion comprises molding the pillow cushion.
The method of Embodiment 60, further comprising forming the deformable wall members to be a single, unitary body.
The method of Embodiment 60, further comprising selecting the second pillow cushion to comprise a single, unitary foam body.
The method of Embodiment 60, further comprising selecting the second pillow cushion to comprise shredded foam segments disposed in a fabric enclosure.
The method of Embodiment 60, further comprising selecting the second pillow cushion to comprise a fibrous material disposed in a fabric enclosure.
The method of Embodiment 65, wherein the second pillow cushion further comprises segments of a gelatinous elastomer.
Embodiments of the disclosure are susceptible to various modifications and alternative forms. Specific embodiments have been shown in the drawings and described in detail herein to provide illustrative examples of embodiments of the disclosure. However, the disclosure is not limited to the particular forms disclosed herein. Rather, embodiments of the disclosure may include all modifications, equivalents, and alternatives falling within the scope of the disclosure as broadly defined herein. Furthermore, elements and features described herein in relation to some embodiments may be implemented in other embodiments of the disclosure, and may be combined with elements and features described herein in relation to other embodiments to provide yet further embodiments of the disclosure.
This application is a continuation-in-part of U.S. patent application Ser. No. 15/333,486 filed Oct. 25, 2016, which application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 62/397,818, filed Sep. 21, 2016, the disclosure of each of which is hereby incorporated herein in its entirety by this reference.
| Number | Date | Country | |
|---|---|---|---|
| 62397818 | Sep 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15333486 | Oct 2016 | US |
| Child | 15936175 | US |
