SLEEP PRODUCTS HAVING ADJUSTABLE FIRMNESS LEVELS AND ADJUSTABLE HEIGHTS

BACKGROUND OF THE INVENTION
Field of the Invention

The present patent application is generally related to sleep products, and is more particularly related to sleeping pillows.

Description of the Related Art

There have been many efforts directed to providing pillows that may be modified by a user. For example, U.S. Pat. No. 6,347,421 to D'Emilio discloses portable encased pillows having open and closed states for carrying about in public and for selective use in the open state. In one embodiment, a water proof neoprene impregnated sheet material fabric support is formed into an hour-glass shape with two mirror image sections and is surrounded by a zipper which closes the support to form an inner pocket that is water impervious. Two right circular cylindrical cushions form pillow portions made of an inner core of foam rubber encased by an outer woven cotton layer that is mounted to the sections within the periphery thereof. The cushions compress when the pocket is closed forming a watertight pillow that is portable and easily opened for use. A carrying strap is attached to the support for carrying the zipped pillow.

U.S. Pat. No. 6,691,352 to Wang discloses an adjustable pillow including a first pillow body which has a first opening and a second pillow body disposed at a selected location in the first opening. The first and second pillow bodies have a plurality of stuffing materials held therein. User may adjust the pillow to a height and curvature desired by shuffling the stuffing materials between the first and second pillow body and then wrap and fold the second pillow body to form a stable state for use. The second pillow body may be used to support user's neck to conform ergonomics and to enable the user to get most comfortable sleep.

U.S. Pat. No. 8,572,779 to Pratt et al. discloses an expandable pillow having an upper fabric section with a peripheral edge, a lower fabric section having a peripheral edge, a gusset section joining the upper and lower fabric sections around the peripheral edges thereof, and a zipper assembly. The zipper assembly has a gusset zipper portion, a peripheral edge zipper portion, and a slider member. The gusset zipper portion extends from a selected start point along one side of the pillow and extends a selected distance to the peripheral edges of the upper and lower fabric sections. The peripheral edge zipper portion extends from a distal end of the gusset zipper portion around the peripheries of the upper and lower fabric sections, joining the peripheral edges thereof together, and terminating at a point just before a start point of the peripheral edge zipper portion. The pillow is in a gusseted configuration when the zipper assembly is open and in a conventional configuration, with the peripheral edges of the upper and lower fabric sections joined together, when the zipper assembly is closed.

In spite of the above advances, there remains a need for a pillow that is height adjustable. There also remains a need for a pillow having an adjustable firmness level.

SUMMARY OF THE INVENTION

In one embodiment, an expandable pillow includes an upper pillow section having a first perimeter with a first perimeter edge, a lower pillow section having a second perimeter with a second perimeter edge, a center layer having an outer perimeter disposed between the upper and lower pillow sections, and a zipper extending around the outer perimeter of the center layer. In one embodiment, the zipper has a first row of teeth secured to the first perimeter edge of the upper pillow section, a second row of teeth secured to the second perimeter edge of the lower pillow section, and a slider that moves along the first and second rows of teeth for opening and closing the zipper. In one embodiment, the pillow has an expanded configuration when the zipper is opened and a compressed configuration when the zipper is closed.

In one embodiment, the pillow has a greater height when the zipper is opened and a smaller height when the zipper is closed.

In one embodiment, the pillow is softer when the zipper is opened and the pillow is firmer when the zipper is closed.

In one embodiment, the first and second perimeters of the upper and lower pillow sections have a greater dimension than the outer perimeter of the center layer so that the first and second perimeters of the upper and lower pillow sections surround the outer perimeter of the center layer when the zipper is closed.

In one embodiment, the upper pillow section has an interior face that is secured to a top surface of the center layer, and the lower pillow section has an interior face that is secured to a bottom surface of the center layer.

In one embodiment, the center layer may define a gusset region of the pillow. In one embodiment, the center layer may include a foam layer or a memory foam layer. In one embodiment, the center layer may include filler materials including but not limited to natural fibers, polyester fibers, shredded foam, chopped foam, shredded latex, chopped latex, foam, memory foam, down, feathers, rice, and buckwheat. In one embodiment, the center layer may include a pouch that contains one or more of the filler materials listed in the preceding sentence.

In one embodiment, the upper pillow section includes a first fabric layer that covers the upper pillow section, and a first filler material disposed within the first fabric layer.

In one embodiment, the lower pillow section includes a second fabric layer that covers the lower pillow section, and a second filler material disposed within the second fabric layer.

In one embodiment, at least one of the first and second fabric layers is treated with a cooling gel material or a phase change material.

In one embodiment, the first and second filler material may be natural fibers, polyester fibers, shredded foam, chopped foam, shredded latex, chopped latex, foam, memory foam, down, feathers, rice, and buckwheat.

In one embodiment, the filler material may be treated with a cooling gel material or a phase change material.

In one embodiment, the pillow is substantially rectangular and the center layer defines a gusset region of the pillow that is about 1.5 inches high. The perimeter edges of the first and second pillow sections preferably cover the outer perimeter or side edges of the center layer when the zipper is closed.

In one embodiment, the zipper terminates adjacent a corner of the pillow.

In one embodiment, the upper and lower pillow sections have similar respective lengths and widths, and the center layer has a length that is less than the lengths of the upper and lower pillow sections, and the center layer has a width that is less than the widths of the upper and lower pillow sections.

In one embodiment, an expandable pillow includes an upper pillow section having a first fabric layer and a first filler material disposed within the first fabric layer, whereby the upper pillow section has a first perimeter with a first perimeter edge. In one embodiment, an expandable pillow has a lower pillow section having a second fabric layer and a second filler material disposed within the second fabric layer, whereby the lower pillow section has a second perimeter with a second perimeter edge.

In one embodiment, the pillow has a center layer (e.g., a foam layer, a pouch filled with filler material) disposed between the upper and lower pillow sections, the center layer having an upper surface secured to the upper pillow section, and a lower surface secured to the lower pillow section.

In one embodiment, the pillow includes a zipper extending around an outer perimeter of the center layer, the zipper having a first row of teeth secured to the first perimeter edge of the upper pillow section, a second row of teeth secured to the second perimeter edge of the lower pillow section, and a slider that moves along the first and second rows of teeth for opening and closing the zipper. In one embodiment, the pillow is expanded and has a greater height when the zipper is opened and the pillow is compressed and has a smaller height when the zipper is closed.

In one embodiment, the upper pillow section has an interior face that is secured to the top surface of the center layer, and the lower pillow section has an interior face that is secured to the bottom surface of the center layer.

In one embodiment, at least one of the first and second fabric layers is treated with a cooling gel material or a phase change material.

In one embodiment, the first and second filler material may be natural fibers, polyester fibers, shredded foam, chopped foam, shredded latex, chopped latex, foam, and/or memory foam.

In one embodiment, at least one of the first and second filler material is treated with a cooling gel material or a phase change material.

In one embodiment, the pillow is substantially rectangular and the center layer defines a gusset region of the pillow that is about 1.0-2.0 inches high, and more preferably about 1.5 inches high.

In one embodiment, an expandable mattress includes an upper mattress section having a first perimeter with a first perimeter edge, a lower mattress section having a second perimeter with a second perimeter edge, a center layer having an outer perimeter disposed between the upper and lower mattress sections, and a zipper extending around the outer perimeter of the center layer. In one embodiment, the zipper has a first row of teeth secured to the first perimeter edge of the upper mattress section, a second row of teeth secured to the second perimeter edge of the lower mattress section, and a slider that moves along the first and second rows of teeth for opening and closing the zipper. In one embodiment, the mattress has an expanded configuration when the zipper is opened and a compressed configuration when the zipper is closed. In one embodiment, a mattress includes a pillow top section that may be expanded when a zipper is opened and compressed when the zipper is closed for adjusting the height and/or firmness level of the pillow top section

In one embodiment, an expandable mattress topper includes an upper mattress topper section having a first perimeter with a first perimeter edge, a lower mattress topper section having a second perimeter with a second perimeter edge, a center layer having an outer perimeter disposed between the upper and lower mattress topper sections, and a zipper extending around the outer perimeter of the center layer. In one embodiment, the zipper has a first row of teeth secured to the first perimeter edge of the upper mattress topper section, a second row of teeth secured to the second perimeter edge of the lower mattress topper section, and a slider that moves along the first and second rows of teeth for opening and closing the zipper. In one embodiment, the mattress topper may be placed atop and/or secured over a top of a mattress. The mattress topper may come in different sizes to fit over different sized mattresses. In one embodiment, the mattress topper has an expanded configuration when the zipper is opened and a compressed configuration when the zipper is closed.

These and other preferred embodiments of the present invention will be described in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a pillow having an adjustable firmness level, in accordance with one embodiment of the present patent application.

FIG. 2 is a bottom view of the pillow shown in FIG. 1.

FIG. 3A shows a top plan view of a center layer for the pillow shown in FIGS. 1 and 2, in accordance with one embodiment of the present patent applications.

FIG. 3B shows a front elevation view of the center layer shown in FIG. 3A.

FIG. 4 is a front elevation view of the pillow of FIGS. 1 and 2 with the pillow in an unzipped, expanded configuration.

FIG. 5 shows a front elevation view of the pillow of FIGS. 1, 2, and 4 with the pillow in a zipped, compressed configuration.

FIG. 6 is a top plan view of a pillow having an adjustable firmness level, in accordance with one embodiment of the present patent application.

FIG. 7 is a bottom view of the pillow shown in FIG. 6.

FIG. 8 shows a cross-sectional view of the pillow shown in FIGS. 6 and 7.

FIG. 9 is a front elevation view of the pillow of FIGS. 6 and 7 with the pillow in an unzipped, expanded configuration.

FIG. 10 shows a front elevation view of the pillow of FIGS. 6, 7, and 9 with the pillow in an zipped, compressed configuration. .

FIG. 11 shows a front elevation view of a pillow having a gusset zipper for adjusting a firmness level and an auxiliary zipper for inserting a filler material into the pillow, in accordance with one embodiment of the present patent application.

FIG. 12 is a top plan view of a pillow having an adjustable firmness level, in accordance with one embodiment of the present patent application.

FIG. 13 is a bottom view of the pillow shown in FIG. 12.

FIG. 14 shows a cross-sectional view of the pillow of FIGS. 12 and 13.

FIG. 15 is a front elevation view of the pillow of FIGS. 12 and 13 with the pillow in an unzipped, expanded configuration.

FIG. 16 shows a front elevation view of the pillow of FIGS. 12, 13, and 15 with the pillow in a zipped, compressed configuration.

FIG. 17 shows a cross-sectional view of a pillow having an adjustable firmness level, in accordance with another embodiment of the present patent application.

FIG. 18 is a front elevation view of a pillow having an adjustable firmness level and being in an expanded configuration, in accordance with one embodiment of the present patent application.

FIG. 19 shows the pillow of FIG. 18 in a compressed configuration.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIG. 1, in one embodiment, a pillow 120 having an adjustable firmness level preferably has a length L₁and a width W₁. In one embodiment, the pillow 120 has a length L₁of about 20-30 inches and more preferably about 26 inches, and the width W₁of about 16-24 inches and more preferably about 20 inches. In one embodiment, the pillow 120 may be produced in various sizes including a standard pillow size (20 inches×26 inches), a queen pillow size (20 inches×30 inches), a king pillow size (20 inches×36 inches), or a European square pillow size (26 inches×26 inches). In other embodiments, the pillow may have different dimensions.

In one embodiment, the pillow 120 desirably includes a zipper 122 that extends around a gusset region or mid-section of the pillow. In one embodiment, the zipper extends around the sides of the pillow and ends adjacent one of the corners of the pillow. In one embodiment, the zipper 122 desirably includes one or more sliders 125 that may be grasped by a user for pulling the zipper between an open configuration and a closed configuration.

In one embodiment, the pillow 120 may include a label 124 that is secured to a side of the pillow. In one embodiment, the zipper 122 ends at a region 126 adjacent the location of the label 124. In one embodiment, the label 124 is positioned a distance D₁of about three (3) inches from a corner 128 of the pillow 120. In one embodiment, the zipper 122 preferably ends adjacent the label 124.

Referring to FIG. 1, in one embodiment, an upper pillow section of the pillow 120 is covered with a first fabric layer 130. In one embodiment, the upper pillow section of the pillow may be filled with a filler material such as a natural or polyester fill material. The first fabric layer 130 preferably covers the filler material of the upper pillow section.

Referring to FIG. 2, in one embodiment, a lower pillow section of the pillow 120 is preferably covered with a second fabric layer 132. In one embodiment, the lower pillow section of the pillow may be filled with a filler material such as a natural or polyester fill material. The second fabric layer 132 preferably covers the filler material of the lower pillow section.

In one embodiment, the second fabric cover 132 desirably includes a cooling gel or a fabric containing a phase change material incorporated therein to provide a cooling fabric layer for a user. In one embodiment, the zipper 122 is located in a gusset region of the pillow and may be accessible at the sides of the pillow, between the first fabric layer 130 (FIG. 1) and the second fabric layer 132.

Referring to FIGS. 3A and 3B, in one embodiment, the pillow 120 (FIG. 1) preferably includes an intermediate section that is located between the upper and lower pillow sections. In one embodiment, the intermediate section preferably defines a gusset region of the pillow 120 and may include a center layer 134 that is desirably disposed between the upper pillow section covered by the first fabric layer 130 (FIG. 1) and the lower pillow section covered by the second fabric layer 132 (FIG. 2). In one embodiment, the center layer 134 is desirably made of compressible foam such as memory foam. In one embodiment, the center layer 134 preferably has a length L₂of about 20-26 inches and more preferably about 24 inches and a width W₂of about 14-18 inches and more preferably about 16 inches. In one embodiment, the center layer 134 preferably has an outer perimeter that is slightly smaller than the outer perimeter of the pillow so that the zipper may be selectively closed around the outer perimeter of the center layer for maintaining the pillow in a compressed state. In one embodiment, the center layer 134 has a thickness T₁of about 0.5-2 inches and more preferably about 1.5 inches.

As used herein, the phrase “center layer” may mean a foam layer, a memory foam layer, one or more pouches containing a filler material, and/or combinations of foam layers and pouches. In one embodiment, the center layer may be treated with a cooling gel. In one embodiment, the center layer may include one or more pouches containing filler materials including but not limited to natural fibers, polyester fibers, shredded foam, chopped foam, shredded latex, chopped latex, foam, memory foam, foam layers, down, feathers, rice, and buckwheat.

Referring to FIG. 4, in one embodiment, the pillow 120 desirably includes an upper pillow section 140 that is covered by the first fabric layer 130. The upper pillow section 140 may be filled with a filler material such as polyester fiber, shredded foam, chopped foam, shredded latex, and chopped latex. The pillow 120 preferably includes a lower pillow section 142 that is covered by the second fabric layer 132 and that contains a filler material such as polyester fiber, shredded foam, chopped foam, shredded latex, and chopped latex. The center layer 134 (e.g., a foam layer) preferably defines the intermediate section of the pillow 120, and is preferably disposed between the upper pillow section 140 and the lower pillow section 142 of the pillow 120. In one embodiment, the center layer 134 preferably defines a gusset region 144 of the pillow 120 that is bound by upper zipper teeth 146 and lower zipper teeth 148 of the zipper.

In one embodiment, the upper zipper teeth 146 are connected with the upper pillow section 140. In one embodiment, the upper zipper teeth are connected with and project from the lower end of the upper pillow section 140. In one embodiment, the lower zipper teeth 148 are connected with the lower pillow section 142. In one embodiment, the lower zipper teeth 148 are connected with and project from the upper end of the lower pillow section 142. In one embodiment, as the zipper is closed, the upper and lower pillow sections are drawn toward one another for reducing the height of the pillow, which may compress the center layer 134 and also change the firmness level of the pillow 120.

In one embodiment, the pillow 120 preferably includes piping 150 that extends around the outer perimeter of the upper pillow section 140. In one embodiment, the piping is decorative. In one embodiment, the piping 150 is located adjacent the upper zipper teeth 146.

In one embodiment, an interior face of the upper pillow section 140 is preferably secured to a top surface of the center layer 134 and an interior face of the lower pillow section 142 is preferably secured to a bottom surface of the center layer 134. The upper and lower pillow sections 140, 142 may be adhered, sewn or welded to the center layer.

FIG. 4 shows the pillow 120 in an unzipped, expanded configuration. In the expanded configuration, the pillow has a height H₁. In one embodiment, the height H₁is a maximum height for the pillow 120 when the pillow is fully expanded (i.e., the zipper is fully open). In one embodiment, the upper pillow section 140 may be pressed toward the lower pillow section 142 reducing the height of the pillow 120, whereupon the center layer 134 between the upper and lower pillow sections is compressed as the height between the upper and lower pillow sections is reduced.

FIG. 5 shows the pillow 120 with the zipper 122 in a closed configuration, whereby the pillow has a height H₂. The zipper 122 may include claps 127 that are secured to sliders 125. In one embodiment, when the zipper 122 is closed, the upper pillow section 140 of the pillow 120 is held closer to the lower pillow section 142 of the pillow 120 and the center layer 134 (FIG. 4) is compressed therebetween.

In one embodiment, when the zipper is in the open position (FIG. 4), the pillow 120 has a height H₁. When the zipper 122 is in the closed position (FIG. 5), the pillow 120 has a height H₂that is less than the height H₁. In one embodiment, the firmness level of the pillow may be adjusted by moving the pillow between the expanded position shown in FIG. 4 (e.g., zipper open) and the compressed position shown in FIG. 5 (e.g., zipper closed). In one embodiment, the pillow is softer (i.e., less firm) when in the expanded configuration shown in FIG. 4, and is harder (i.e., more firm) when in the compressed configuration shown in FIG. 5. In addition, by opening and closing the zipper 122, a user may adjust the height of the pillow to maximize user comfort.

Referring to FIG. 6, in one embodiment, a pillow 220 having an adjustable firmness level preferably has a length L₃and a width W₃. In one embodiment, the pillow 220 has a length L₃of about 20-30 inches and more preferably about 26 inches, and the width W₃of about 16-24 inches and more preferably about 20 inches. In one embodiment, the pillow 220 may be produced in various sizes including a standard pillow size (20 inches×26 inches), a queen pillow size (20 inches×30 inches), a king pillow size (20 inches×36 inches), or a European square pillow size (26 inches×26 inches). In other embodiments, the pillow may have different dimensions.

In one embodiment, the pillow 220 desirably includes a zipper 222 that extends around a gusset region of the pillow. In one embodiment, the zipper extends around all sides of the pillow and ends adjacent one of the corners 228 of the pillow. In one embodiment, the zipper 222 desirably includes a slider 225 that may be engaged by a user for pulling the zipper between an open position and a closed position.

In one embodiment, the pillow 220 may include a label 224 that is secured to a side of the pillow. In one embodiment, the zipper 222 ends at a region 226 adjacent the location of the label 224. In one embodiment, the label 224 is positioned a distance D₃of about three (3) inches from the corner 228 of the pillow 220. In one embodiment, the zipper 222 preferably ends adjacent the label 224.

Referring to FIG. 6, in one embodiment, the pillow 220 has an upper pillow section that is covered with a first fabric layer 230, such as a cotton fabric. In one embodiment, the upper pillow section of the pillow may be filled with a filler material such as a natural or polyester fill material. In one embodiment, the upper pillow section may include a blowfill chamber that is filled with a filler material (e.g., blowfilled) that includes memory fibers having a fiber thickness of about 1.5 Denier. The first fabric layer 230 preferably covers the filler material disposed within the upper pillow section.

Referring to FIG. 7, in one embodiment, the pillow 220 preferably includes a lower pillow section that is desirably covered with a second fabric layer 232. In one embodiment, the lower pillow section may include a blowfill chamber that is filled with a filler material that includes memory fibers having a thickness of about 1.5 Denier, a natural fill material, and/or a polyester fill material. The second fabric layer 132 preferably covers the filler material disposed within the lower pillow section.

Referring to FIG. 8, in one embodiment, the pillow 220 desirably includes the upper pillow section 240 that is covered by the first fabric layer 230. The upper pillow section 240 may be filled with filler material such as polyester fiber, shredded foam, chopped foam, shredded latex, and chopped latex. In one embodiment, the upper pillow section 240 may include a blowfill chamber that is filled with memory fibers having a thickness of about 1.5 Denier. The pillow 220 preferably includes the lower pillow section 242 that is covered by the second fabric layer 232 and that contains a filler material such as polyester fiber, shredded foam, chopped foam, shredded latex, and chopped latex. In one embodiment, the lower pillow section 242 may include a blowfill chamber that is filled with memory fibers having a thickness of about 1.5 Denier.

Referring to FIG. 8, in one embodiment, the pillow 220 preferably includes a gusset region 244 that desirably extends between and interconnects the upper pillow section 240 and the lower pillow section 242. The gusset region 244 may include a gusset fabric layer 245 that extends around the perimeter of the pillow 220. In one embodiment, a pouch 255 containing shredded foam or other well-known filler materials may be disposed within the gusset region 244. The gusset fabric layer 245 preferably surrounds the sides of the pouch 255 and contains the pouch 255 in place between the upper and lower pillow sections 240, 242. In certain embodiments, the pouch may contain filler materials including but not limited to natural fibers, polyester fibers, shredded foam, chopped foam, shredded latex, chopped latex, foam, memory foam, down, feathers, rice, buckwheat, and combinations of the above-listed filler materials.

Referring to FIG. 9, in one embodiment, the pillow 220 preferably has a zipper including upper zipper teeth 246 that are connected with the upper pillow section 240. In one embodiment, the upper zipper teeth 246 are connected with and project from the lower end of the upper pillow section 240. In one embodiment, the zipper preferably includes lower zipper teeth 248 that are connected with the lower pillow section 242. In one embodiment, the lower zipper teeth 248 are connected with and project from the upper end of the lower pillow section 242. In one embodiment, as the zipper is closed, the upper and lower pillow sections 240, 242 are drawn toward one another for reducing the height of the pillow, which may compress the fill material disposed within the gusset region 244, and may also change the firmness level and/or the height of the pillow.

In one embodiment, the pillow 220 preferably includes piping 250 that extends around the outer perimeter of the upper pillow section 240. In one embodiment, the piping 250 may be decorative. In one embodiment, the piping 250 is located adjacent the upper zipper teeth 246.

In one embodiment, an upper edge of the gusset fabric layer 245 is preferably secured to the perimeter of the upper pillow section 240, and a lower edge of the gusset fabric layer 245 is preferably secured to the lower pillow section 142. The gusset fabric layer may be adhered, attached, sewn, or welded to the upper and lower pillow sections.

FIG. 9 shows the pillow 220 in an unzipped (e.g., zipper is open), expanded configuration. In the expanded configuration, the pillow has a height H₃. In one embodiment, the height H₃is a maximum height for the pillow 220 when the pillow is fully expanded (i.e., the zipper is fully open). In one embodiment, the height H₃is about 4-10 inches. In one embodiment, the upper pillow section 240 may be pressed toward the lower pillow section 242 for reducing the height of the pillow 220, whereupon the shredded foam within the shredded foam pouch 255 (FIG. 8) located between the upper and lower pillow sections 240, 242 is compressed as the height between the upper and lower pillow sections is reduced.

In one embodiment, as the pillow is being compressed, the zipper 222 may be closed to hold the pillow in the compressed configuration. FIG. 10 shows the pillow 220 with the zipper 222 in a closed configuration, whereby the pillow has a height H₄. In one embodiment, when the zipper 222 is closed, the upper pillow section 240 of the pillow 220 is held closer to the lower pillow section 242 of the pillow 220 and the shredded foam pouch 255 (FIG. 8) is compressed between the upper pillow section and the lower pillow section.

In one embodiment, when the zipper is in the open position (FIG. 9), the pillow 220 has a height H₃. When the zipper is in the closed position (FIG. 10), the pillow 220 has a height H₄that is less than the height H₃. In one embodiment, the firmness level of the pillow may be adjusted by moving the pillow between the expanded position shown in FIG. 9 (e.g., zipper open) and the compressed position shown in FIG. 10 (e.g., zipper closed). In one embodiment, the pillow is softer (i.e., less firm) when in the expanded configuration shown in FIG. 9, and is harder (i.e., more firm) when in the compressed configuration shown in FIG. 10. In addition, by opening and closing the zipper 222, a user may adjust the height of the pillow to maximize user comfort.

Referring to FIG. 11, in one embodiment, a pillow 320 has a structure that is similar to that disclosed in other embodiments of the present patent application. The pillow 320 preferably has an auxiliary zipper 335 that is located above piping 350, on a side of the piping that is opposite upper zipper teeth 346. The auxiliary zipper 335 may be opened to insert fill material, such as a foam layer, into the upper pillow section 340 of the pillow. In one embodiment, the auxiliary zipper 335 is opened to insert a foam layer into the upper pillow section 340 to provide extra padding. In one embodiment, the auxiliary zipper 335 may be opened to remove a foam layer prior to washing the pillow. At the end of a wash cycle, the foam layer may be re-inserted back into the upper pillow section and the auxiliary zipper 335 may be closed to secure the foam layer in the upper pillow section 340. In other embodiments, other well-known filler material may be inserted through the auxiliary zipper opening.

Referring to FIG. 12, in one embodiment, a pillow 420 has an upper pillow section that is covered with a first fabric layer 430, such as Tencel, Modal, Cooling Rayon, Poly Blend woven, or cotton fabric. In one embodiment, the upper pillow section of the pillow may be filled with a filler material such as a natural or polyester fill material. In one embodiment, the upper pillow section may include a blowfill chamber that is filled with a filler material (e.g., blowfilled) that includes memory fibers having a fiber thickness of about 1.5 Denier. The first fabric layer 430 preferably covers the filler material disposed within the upper pillow section.

Referring to FIG. 13, in one embodiment, the pillow 420 preferably includes a lower pillow section that is desirably covered with a second fabric layer 432. In one embodiment, the lower pillow section may include a blowfill chamber that is filled with a filler material that includes memory fibers having a thickness of about 1.5 Denier, a natural fill material, and/or a polyester fill material. The second fabric layer 432 preferably covers the filler material disposed within the lower pillow section.

Referring to FIG. 14, in one embodiment, the pillow 420 desirably includes the upper pillow section 440 that is covered by the first fabric layer 430. The upper pillow section 440 may be filled with filler material such as polyester fiber, shredded foam, chopped foam, shredded latex, and chopped latex. In one embodiment, the upper pillow section 440 may include a blowfill chamber that is filled with memory fibers having a thickness of about 1.5 Denier. The pillow 420 preferably includes the lower pillow section 442 that is covered by the second fabric layer 432 and that contains a filler material such as polyester fiber, shredded foam, chopped foam, shredded latex, and chopped latex. In one embodiment, the lower pillow section 442 may include a blowfill chamber that is filled with memory fibers having a thickness of about 1.5 Denier.

Referring to FIG. 14, in one embodiment, the pillow 420 preferably includes a gusset region 444 that desirably extends between and interconnects the upper pillow section 440 and the lower pillow section 442. The gusset region 444 may include a gusset fabric layer 445 that extends around the perimeter of the pillow 420 (e.g., four sides of a pillow). In one embodiment, a pouch 455 containing shredded foam or another well-known filler material may be disposed within the gusset region 444. In one embodiment, the gusset fabric layer 445 preferably surrounds the sides of the pouch 455 and contains the pouch in place between the upper and lower pillow sections 440, 442.

Referring to FIG. 15, in one embodiment, the pillow 420 preferably includes a zipper having upper zipper teeth 446 that are connected with the upper pillow section 440. In one embodiment, the upper zipper teeth 246 are connected with and project from the lower end of the upper pillow section 440. In one embodiment, the zipper preferably includes lower zipper teeth 448 that are connected with the lower pillow section 442. In one embodiment, the lower zipper teeth 448 are connected with and project from the upper end of the lower pillow section 442. In one embodiment, as the zipper is closed, the upper and lower pillow sections 440, 442 are drawn toward one another for reducing the height of the pillow, which may compress the fill material disposed within the gusset region 444, and may also change the firmness level and/or the height of the pillow.

In one embodiment, the pillow 420 preferably includes piping 450 that extends around the outer perimeter of the upper pillow section 440. In one embodiment, the piping 450 may be decorative. In one embodiment, the piping 450 is located adjacent the upper zipper teeth 446 of the zipper.

In one embodiment, an upper edge of the gusset fabric layer 445 is preferably secured to the perimeter of the upper pillow section 440, and a lower edge of the gusset fabric layer 445 is preferably secured to the lower pillow section 442. The gusset fabric layer 245 may be adhered, attached, sewn, or welded to the upper and lower pillow sections. In one embodiment, the gusset 444 has an uncompressed height of about 1.5 inches.

FIG. 15 shows the pillow 420 in an unzipped (e.g., zipper is open), expanded configuration. In the expanded configuration, the pillow has a height H₅. In one embodiment, the height H₅is a maximum height for the pillow 420 when the pillow is fully expanded (i.e., the zipper is fully open). In one embodiment, the height H₅is about 4-10 inches. In one embodiment, the upper pillow section 440 may be pressed toward the lower pillow section 442 for reducing the height of the pillow 420, whereupon the filler material disposed within the pouch 455 (FIG. 14) located between the upper and lower pillow sections 440, 442 is compressed as the height between the upper and lower pillow sections is reduced.

In one embodiment, as the pillow is being compressed, the zipper 422 may be closed to hold the pillow in the compressed configuration. FIG. 16 shows the pillow 420 with the zipper 422 in a closed configuration, whereby the pillow has a height H₆that is less than the height H₅(FIG. 15). In one embodiment, when the zipper 422 is closed, the upper pillow section 440 of the pillow 420 is held closer to the lower pillow section 442 of the pillow 420 and the shredded foam pouch 455 (FIG. 14) is compressed between the upper pillow section and the lower pillow section.

In one embodiment, when the zipper is in the open position (FIG. 15), the pillow 420 has a height H₅. When the zipper is in the closed position (FIG. 16), the pillow 420 has a height H₆that is less than the height H₅. In one embodiment, the firmness level of the pillow may be adjusted by moving the pillow between the expanded position shown in FIG. 15 (e.g., zipper open) and the compressed position shown in FIG. 16 (e.g., zipper closed). In one embodiment, the pillow is softer (i.e., less firm) when in the expanded configuration shown in FIG. 15, and is harder (i.e., more firm) when in the compressed configuration shown in FIG. 16. In addition, by opening and closing the zipper 422, a user may adjust the height of the pillow 420 to maximize user comfort.

Referring to FIG. 17, in one embodiment, a pillow 520 has a structure that is similar to that disclosed in other embodiments of the present patent application. The pillow 520 preferably has an upper pillow section 540 including a blowfill chamber having a fill material such as memory fiber having a thickness of about 1.5 Denier. The pillow 520 preferably has a lower pillow section 542 including a blowfill chamber having a fill material such as memory fiber having a thickness of about 1.5 Denier. The pillow desirably includes a gusset region 544 that is covered by a gusset fabric layer 545. In one embodiment, a foam layer 555 and a blowfill pouch 565 containing a filler material 575 are disposed within the gusset region 544. The combination of the foam layer 555 and the blow fill pouch 565 may form a center layer of a pillow. In one embodiment, the foam layer 555 is disposed on top of the blowfill pouch 565. The pillow 520 preferably includes a zipper in the gusset region 544 for drawing the upper and lower pillow sections 540, 542 toward one another for compressing the foam layer 555 and the filler material 575 in the blowfill pouch 565 and reducing the height of the pillow 520.

Referring to FIG. 18, in one embodiment, a pillow 620 has a structure that is similar to that disclosed in other embodiments of the present patent application. The pillow 620 preferably has a flap 685 that is sewn along a side of the pillow. In one embodiment, the flap 685 has a lower edge 686 that is attached to the upper pillow section 640 and a free edge 688 that is remote therefrom. A first strip 690 of hook and loop fastener material is sewn to an inner face of the flap 685. In one embodiment, the pillow 620 desirably includes a second strip 692 of hook and loop fastener material that is attached to an outer face of a lower pillow section 642 of the pillow.

Referring to FIGS. 18 and 19, in one embodiment, the pillow 620 has a gusset region 644 that contains a compressible material (e.g., a foam layer, a pouch filled with filler material, and/or a combination of a foam layer and a pouch with filler material) as described in other embodiments disclosed herein. In one embodiment, the upper and lower pillow sections 640, 642 may be pressed toward one another for reducing the height of the pillow. After compression, the first strip 690 of hook and loop fastener material may be secured to the second strip 692 of hook and loop fastener material for holding the pillow in the compressed, reduced height configuration shown in FIG. 19. The pillow 620 is desirably softer and has a greater height in FIG. 18 and is firmer, with a reduced height in FIG. 19.

In one embodiment, the pillow 120 preferably includes filler material made of natural and/or synthetic fibers that are treated with cooling gels. In one embodiment, the fibers may be coated individually so that the material remains porous and allows air to pass therethrough. In one embodiment, the present patent application teaches pillows that maintain permeability to allow air to flow through the pillow. In one embodiment, the present patent application seeks to avoid completely coating a surface of filler material, a foam layer, or a fabric layer with a cooling gel, which may render one or more surfaces of the pillow non-permeable (i.e., will not allow air to pass through the surface).

In one embodiment, the filler material may be garneted fiber that is infused with a cooling gel. In one embodiment, an exposed surface of the garneted fiber is sprayed with a solution containing of cooling gel that binds to the individual fibers. The cooling gel may include a solvent, cooling gel and/or a phase change material that is atomized and sprayed onto the garneted fiber. The cooling gel may be cured, such as by using heat or by allowing the cooling gel to cure in ambient conditions. In one embodiment, the present patent application uses a cooling gel solution disclosed in U.S. 2014/0141233 assigned to Peterson Chemical Technology, Inc., the disclosure of which is hereby incorporated by reference herein. In one embodiment, the treated garneted fiber may be exposed, interior, or both. The percentage of the garneted fiber that is treated may be between 1-100%.

In one embodiment, the cooling gel may be rolled onto the garneted fiber for infusing the individual fibers with the cooling gel. In one embodiment, the cooling gel preferably bonds to the individual fibers and does not form a continuous masking layer that would render the substrate impermeable to air passing through the substrate. In one embodiment, the present patent application seeks to maintain permeability and air flow through the fibers that have been treated with the cooling gel.

In one embodiment, 100% of the garneted fiber may be infused with the cooling gel. In other embodiments, only a portion of the garneted fiber is treated with the cooling gel. The percentage of treatment may be anywhere between 0-100%. The technology disclosed herein may include filler material that has been infused with cooling gel, and that may be incorporated into a broad range of products including bedding, mattresses, mattress toppers, pillows, sheets, bed covers, textile fabrics, clothing, sleeping bags, and slippers.

In one embodiment, the filler material may be a fiber material that is carded. In one embodiment, the fiber material is carded and then infused with a cooling gel as described above so that the individual fibers are infused with cooling gel. In one embodiment, the treated fiber material preferably remains permeable and so that air may flow through the cooling gel infused fiber material.

In one embodiment, a roller may be used for rolling cooling gel onto the filler material. The roller may be made of a broad range of materials including rubber, foam, wool, etc. The cooling gel may be cured using heat and air to accelerate curing or may be cured using ambient air.

In one embodiment, the upper and lower pillow sections may be coated with a cooling gel. In one embodiment, 1-100% of the exposed surface area of the upper and lower pillow sections is coated with a cooling gel. The cooling gel may be provided on the first and second fabric layers using spraying or rolling techniques. The filler material inserted into the cavities of the upper and lower pillow sections may be infused with a cooling gel as described above. The percentage of the filler material that is infused with cooling gel may be between 0-100%. In one embodiment, the filler material is a fiber material that may be garneted fiber, air blown fiber, or carded fiber. In one embodiment, the filler material may be chopped or shredded foam, chopped or shredded latex, fibrous material, and/or other well known filling materials.

In one embodiment, a cooling gel is preferably applied to the upper and lower pillow sections by spraying cooling gel onto exposed surfaces. Spraying an atomized cooling gel enables the gel to completely cover the exposed surfaces of upper and lower pillow sections. In one embodiment, only certain regions of the upper and lower pillow sections may be covered by a cooling gel and other areas of the upper and lower pillow sections may remain untreated.

In one embodiment, the upper and lower pillow sections may be made of foam that incorporates surface modification technology (SMT) provided by FoamEx, also known as FXI of Media, Pa.

In one embodiment, the cooling gel may be rolled or brushed onto the exposed surfaces of the upper and lower pillow sections.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, which is only limited by the scope of the claims that follow. For example, the present invention contemplates that any of the features shown in any of the embodiments described herein, or incorporated by reference herein, may be incorporated with any of the features shown in any of the other embodiments described herein, or incorporated by reference herein, and still fall within the scope of the present invention.

SLEEP PRODUCTS HAVING ADJUSTABLE FIRMNESS LEVELS AND ADJUSTABLE HEIGHTS

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (1)