US20090199341A1

US20090199341A1 - Chambered pillow

Info

Publication number: US20090199341A1
Application number: US12/338,745
Authority: US
Inventors: Andrew E. Schantz
Original assignee: E&E Co Ltd
Current assignee: E&E Co Ltd
Priority date: 2008-02-12
Filing date: 2008-12-18
Publication date: 2009-08-13

Abstract

A chambered pillow with zones of varied densities for supporting a plurality of sleeping positions. The chambered pillow has varied density zones comprising a neck support zone wherein the neck support zone is medium to firm density, a central zone wherein the central zone is medium to firm density and two side zones wherein the side zones are a soft density. The chambered pillow may be filled with a fiberfill blend material, where the fiberfill blend consists essentially of, by weight, (a) from about 50 to about 70% eviscerated latex, and (b) from about 30 to about 50% polyester fiberfill.

Description

CLAIM OF PRIORITY

This application claims priority under 35 U.S.C. §120 as a continuation-in-part of U.S. application Ser. No. 12/029,517, filed on Feb. 8, 2008, the contents of which are incorporated herein by reference.

FIELD OF INVENTION

The invention relates generally to the textile or bedding industry, specifically, pillows and filling for the same.

BACKGROUND OF THE INVENTION

A pillow is used to provide support to the head and neck of a person while sleeping. The amount of support desired depends upon the users sleeping position. A sleeper typically buys a pillow designed for their most often used sleeping position. However, the majority of sleepers alter between several sleeping positions during a nights rest. Accordingly, the pillow chosen by the sleeper won't always be designed for the maximum support and comfort for the individual user's sleeping pattern.
The drawback to standard, single chambered pillows is the inability to vary the density of different sections of the pillow. Pillows are generally provided to the end user in only one density. The user does not have the option of selecting variations of density in one pillow. This is problematic because people sleep in different ways and thus require different densities in different sections of the pillow in order to be comfortable. People who sleep on their side require the side sections of the pillow to be the softest, while people who sleep on their back require the middle of the pillow to be firm.
Pillows filled with down and feathers have become very popular. Items that contain feathers are typically baffled to prevent the feathers or down from clumping into one particular spot. Baffling is sewn in cloth walls that create quilted-type squares to hold a set amount of fill. The amount of baffling varies, but typically higher quality items include baffling. Baffling is predominantly found on comforters and other larger bedding items.
It is also known to fill pillows with fibers. Fiber filled pillows are preferred by users who may be allergic to feathers or down. Fiber filled pillows are typically filled with synthetic fibers, such as puffball polyester fiberfill, also known simply as puffballs or polyester fiberfill. The puffballs are puff-blown polyester fiberfill that are resilient, fluffable and shapeable. Puffball polyester fiberfill is ideal for use in pillows because it retains softness and fluffiness and creates loft and support.
Polyester fiberfill is used as filling or insulating material for pillows, cushions, bedding materials, such as mattress pads, quilts, comforters, duvets, and in apparel, such as coats, parkas, and boots.
Fiber filled, single chamber pillows have issues retaining resiliency. The polyester puffball or fiberfill tends to become compressed after use and requires a user to fluff the pillow. Even with fluffing, the polyester puffball or fiberfill tends to remain compressed after several uses.
U.S. Pat. Nos. 4,818,599 and 4,794,038 describe polyester fiberfill. One patent describes a blend of polyester fiberfill and a binder of hydrophilic poly(alkylene oxide) to increase properties of the fiberfill such as durability, softness, good bonding, reduced flammability and improved moisture transport. The other patent describes a polyester fiberfill having a spiral crimp that is randomly arranged and entangled in the form of fiberballs with binder fibers, so as to be air transportable on account of the low cohesion between the balls.
U.S. Pat. No. 5,458,971 describes pillows and other filled articles filled with biocomponent polyester fibers that have a spiral crimp. The spiral crimp is caused by a difference in a chain branched content on the polyester polymers of the components. The biocomponent polyester fibers may be used as a filling in combination with fiberballs, where the biocomponent polyester fiberfill fibers of helical configuration are randomly entangled into such fiberballs.
U.S. Pat. No. 6,988,286 describes a cushioning device and method of producing the cushioning device. The cushioning device may be a pillow which includes an upper pocket with a cavity for receiving filler material such as down, fiberfill, or fiberballs and second cavity for receiving additional filler material such as a foam core. The foam core is a visco-elastic or polyurethane foam.
U.S. Pat. No. 6,701,555 describes a dual-filled adjustable postural health pillow. The layered pillow consists of a three dimensionally rectangular outer casing which holds at least two discretely, proportionately filled casings/chambers. The bottom casing is filled with grain hulls to elevate the head and support the neck. The top casing is filled with a compressible material such as wool or down to provide cushion. An aperature in the grain-filled casing allows a user to adjust the volume of fill for customization.
U.S. Pat. No. 4,207,636 describes a cushion construction. A resilient, flexible foam material such as polyurethane foam or latex foam rubber with a convoluted front and rear surface is wrapped with a batt or web of soft resilient non-woven fibrous material.
U.S. Pat. No. 7,152,263 describes a multi-layer multi-chamber pillow with an unfilled center chamber in the top layer. The pillow has an upper layer which includes at least two chambers in addition to a center chamber and a lower layer which includes at least three chambers arranged laterally side-by-side. The first and second layers have approximately the same outline and are secured together around the peripheries thereof. There is filling in at least three chambers of the lower layer and in at least the two chambers of the upper layer, with no filling in the center chamber of the upper layer. The pillow of the '263 patent is required to have a distinct top and bottom horizontal layer. The top layer is required to have a center chamber with no fill and the lower layer is required to have at least three, side by side chambers. The '263 pillow does not include a neck support.
U.S. Pat. No. 4,660,239 describes a therapeutic layered pillow with a soft resilient bottom pillow section and a top pillow section. The top section includes top and bottom fabric covers peripherally interconnected with a pair of rows of stitching spaced from the ends of the pillow sections and a transverse stitching between the rows of stitching interconnecting the covers defining a first tubular neck support of rectangular shape and a pair of laterally spaced supplemental neck supports of rectangular shape. The bottom section is filled with a mass of loosely confined resilient fiber stuffing. This pillow does not include soft side chambers for a side sleeper or a neck roll that is a continuous horizontal chamber.
U.S. Pat. No. 5,038,432 describes a compartmented orthopedic cervical pillow to be used to support the neck and head of a person. The pillow includes two or more elongated pieces of woven material which are disposed lengthwise and upstanding relative to the pillow. The pieces of woven material are distributed inside the pillow to constitute one central, one wider and one narrower lateral tubular shaped compartments which extend lengthwise inside the pillow. The central compartment will receive a sleeper's ear, while one of the outside compartments will support the sleeper's neck.
None of the devices, pillows or fillers mentioned above describe a chambered pillow with zones of different densities for various sleeping positions. One of the benefits to a varied density chambered pillow is the ability of one pillow to be comfortable for a variety of sleeping positions. This is critical because the majority of people sleep in number of positions during the night. However, pillows known in the industry typically only provide one density which is tailored to one position of sleeping. Accordingly, when a user changes their sleeping position, the pillow is no longer comfortable. For example, a pillow designed for back sleepers is typically more firm than a pillow designed for side sleepers. Should a back sleeper roll over on his or her side, the firmer pillow is no longer suited for such a position and is no longer comfortable.
None of the known prior art methods solve the problem of providing chambered pillow with zones of varying densities that is resilient and which retains its original fluffiness and varying densities even after extended periods of compression.

SUMMARY OF THE INVENTION

The current invention satisfies the above needs by providing a chambered pillow with zones of varied densities for a variety of sleeping positions. The chambered pillow may be filled with a fiberfill blend material. As used herein, the terms fiberfill blend, fiberfill, blend and filler are used to generally define the content of the filling of a pillow. The invention provides a chambered pillow filled with an improved fiberfill blend, said fiberfill blend comprising by weight, (a) from about 50 to about 70% eviscerated latex, and (b) from about 30 to about 50% polyester fiberfill. The invention also provides for a chambered pillow filled with an improved feather and latex blend, said blend comprising, by weight, (a) from about 40 to about 60% feathers and down, and (b) from about 40 to about 60% eviscerated latex. Alternatively, the pillow may be filled with fiberfill alone or any other suitable material.
Provided is a chambered pillow with varied density zones comprising a neck support zone wherein the neck support zone is medium to firm density, a central zone wherein the central zone is medium to firm density and two side zones wherein the side zones are a soft density.
The important features of the chambered pillow include neck support zone, a central zone and side zones. The neck support zone extends horizontally across a bottom portion of the pillow and is a medium to firm density. The central zone is located in the center of the pillow and is substantially circular and is a medium to firm density. The left and right side zones are located on either side of the central zone and are a soft density. The zones are separated by baffling and the soft, medium and firm densities are created by varying the amount of fill used in each zone.
These and other objects, features, and advantages of the present invention may be better understood and appreciated from the following detailed description of the embodiments thereof, selected for purposes of illustration and shown in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a chambered pillow with four zones of varying densities.

FIG. 2 is a top view of a chambered pillow with three zones of varying densities.

FIG. 3 is a perspective view of a chambered pillow with four zones of varying densities.

DETAILED DESCRIPTION

FIGS. 1, 2 and 3 show two embodiments of the chambered pillow of the invention. FIGS. 1 and 2 depict a chambered pillow with four zones of varying densities. FIG. 2 is a chambered pillow with three zones of varying densities.
FIGS. 1 and 3 shows four zones of varying densities in the chambered pillow 5. The zones of the pillow 5 are created by baffling 10 and then each zone is filled to a desired density with fill to create a variety of densities. Baffling 10 is sewn in cloth walls that create quilted-type squares to hold a set amount of fill and separates the pillow into several non-continuous compartments or zones with limited communication between the zones. The baffling 10 prevents the filler from clumping in any one spot. The baffling 10 also ensures that the original density of the filler is maintained in each zone through out the use of the pillow 5.
The neck support zone 1 is designed to support the neck and forms a horizontal strip or roll the entire length of the pillow 5. The neck support zone 1 is filled to a medium to firm density to provide medium to firm support. Likewise, the central zone 4 is filled to a medium to firm density to provide medium to firm support. However, central zone 4 is located in the center of the pillow 5 to support the head of a user. The central zone 4 would ideally support the head of a user when the user is sleeping on their back and thus the back of the head would be in contact with central zone 4.
The side zones 2 and 3 are on the right and left sides of the pillow 5 respectively. Side zones 2 and 3 are designed to receive less fill and therefore be less dense. This provides a softer zone for side sleepers. When a user sleeps on their side and uses the pillow 5, their face will contact side zone 2 or 3, which will provide a softer zone that will be more comfortable for the user in a side sleeping position.
FIG. 2 is a chambered pillow 9 with three zones of varying densities. The chambered pillow 9 of this embodiment includes a neck support zone 6 and left and right side zones 7 and 8. This embodiment would be ideal for side sleepers. The neck support zone 6 is filled to a medium to firm density to provide medium to firm support. Side zones 7 and 8 are filled with less fill and are less dense than the neck support zone 6 and therefore softer than neck support zone 6. Side zones 7 and 8 will provide a softer zone that will be more comfortable for the user in a side sleeping position.
In one embodiment, the fill for the chambered pillows 5, 9 shown in FIGS. 1, 2 and 3 is an improved filler containing latex. The chambered pillow 5, 9 can be filled with an improved filler that contains eviscerated or chopped latex, which allows the pillow 5, 9 to have varying zones of densities. The use of latex in the filler also provides the user with consistent softness or firmness over time. The filler, which includes eviscerated latex, prevents the pillow 5, 9 of the invention from being permanently compressed. The pillows 5, 9 can include an outer cover or pillow case that can be a plain cotton twill, plain cotton weave, or it could be any fabric and optionally include a decorative design. The filler is blown into the baffled zones of the pillow 5, 9 to create the varied density zones.
In one embodiment of the invention, the filler is a blend of puffball polyester fiberfill and eviscerated latex blended at a ratio of about 60% latex and about 40% puffball polyester fiberfill. The latex is preferably an organic latex that has been eviscerated to particles approximately several millimeters in circumference to an inch in circumference. The size of the particles may be varied and can be larger or smaller depending upon the particular use and desired effect.
In another embodiment, the eviscerated latex can be combined with feathers to create filler for a pillow 5, 9. The preferred ratio is 50% feathers to 50% latex foam. The cover for the feather pillow 5, 9 is a plain weave cover that prevents the quills and feathers from poking through the cover. The use of latex in combination with the feathers provides a feather pillow 5, 9 that is more resilient and retains its fluffiness use after use.
Accordingly, it will be understood that the preferred embodiments of the present invention have been disclosed by way of example and that other modifications and alterations may occur to those skilled in the art.

Claims

1. A chambered pillow with varied density zones comprising:

a neck support zone wherein said neck support zone is medium to firm density;

a central zone wherein said central zone is medium to firm density; and

two side zones wherein said side zones are a soft density.

2. The chambered pillow of claim 1 wherein said varied density zones are separated with baffling.

3. The chambered pillow of claim 1, wherein said soft, medium and firm densities are created by varying the amount of fill used in each zone.

4. The chambered pillow of claim 1, wherein the neck support zone supports the neck of a sleeper, the central zone supports the back of a sleeper's head when the sleeper is sleeping on his back, and the side zones support the side of the sleeper's face when the sleeper is sleeping on his side.

5. The chambered pillow of claim 1 wherein said pillow is filled with an improved fiberfill blend, said fiberfill blend comprising, by weight, (a) from about 50 to about 70% eviscerated latex, and (b) from about 30 to about 50% polyester fiberfill.

6. The chambered pillow of claim 1, wherein said pillow is filled with an improved fiberfill blend comprising by weight, (a) 50% eviscerated latex, and (b) 50% polyester fiberfill.

7. The chambered pillow of claim 1, wherein said pillow is filled with an improved feather and latex blend, said blend comprising by weight, (a) from about 40 to about 60% feathers and down, and (b) from about 40 to about 60% eviscerated latex.

8. The chambered pillow of claim 1, wherein said pillow is filled with an improved blend comprising by weight, (a) 50% feather, and (b) 50% eviscerated latex.

9. A chambered pillow comprising:

a neck support zone, wherein said neck support zone extends horizontally across a bottom portion of said pillow;

a central zone, wherein said central zone is located in the center of the pillow and is substantially circular;

a left and right side zone, wherein said left and right side zones are located on either side of the central zone; and

wherein the zones are separated by baffling and the density of each zone is varied based upon the use of each zone for various sleeping positions.

10. The chambered pillow of claim 9, wherein said neck support zone is medium to firm density.

11. The chambered pillow of claim 9, wherein said central zone is medium to firm density.

12. The chambered pillow of claim 9, wherein said left and right side zones are a soft density.

13. The chambered pillow of claim 9, wherein said soft, medium and firm densities are created by varying the amount of fill used in each zone.

14. The chambered pillow of claim 9, wherein the neck support zone supports the neck of a sleeper, the central zone supports the back of a sleeper's head when the sleeper is sleeping on his back, and the side zones support the side of the sleeper's face when the sleeper is sleeping on his side.

15. The chambered pillow of claim 9 wherein said pillow is filled with an improved fiberfill blend, said fiberfill blend comprising, by weight, (a) from about 50 to about 70% eviscerated latex, and (b) from about 30 to about 50% polyester fiberfill.

16. The chambered pillow of claim 9, wherein said pillow is filled with an improved fiberfill blend comprising by weight, (a) 50% eviscerated latex, and (b) 50% polyester fiberfill.

17. The chambered pillow of claim 9, wherein said pillow is filled with an improved feather and latex blend, said blend comprising by weight, (a) from about 40 to about 60% feathers and down, and (b) from about 40 to about 60% eviscerated latex.

18. The chambered pillow of claim 9, wherein said pillow is filled with an improved blend comprising by weight, (a) 50% feather, and (b) 50% eviscerated latex.

19. A chambered pillow with zones of varying densities comprising:

a neck support zone, wherein said neck support zone extends horizontally across a bottom portion of said pillow and is a medium to firm density;

a central zone, wherein said central zone is located in the center of the pillow and is substantially circular and is a medium to firm density;

a left and right side zone, wherein said left and right side zones are located on either side of the central zone and are a soft density; and

wherein the zones are separated by baffling and said soft, medium and firm densities are created by varying the amount of fill used in each zone.

20. The chambered pillow of claim 19, wherein the neck support zone supports the neck of a sleeper, the central zone supports the back of a sleeper's head when the sleeper is sleeping on his back, and the side zones support the side of the sleeper's face when the sleeper is sleeping on his side.

21. The chambered pillow of claim 19 wherein said pillow is filled with an improved fiberfill blend, said fiberfill blend comprising, by weight, (a) from about 50 to about 70% eviscerated latex, and (b) from about 30 to about 50% polyester fiberfill.

22. The chambered pillow of claim 19, wherein said pillow is filled with an improved fiberfill blend comprising by weight, (a) 50% eviscerated latex, and (b) 50% polyester fiberfill.

23. The chambered pillow of claim 19, wherein said pillow is filled with an improved feather and latex blend, said blend comprising by weight, (a) from about 40 to about 60% feathers and down, and (b) from about 40 to about 60% eviscerated latex.

24. The chambered pillow of claim 19, wherein said pillow is filled with an improved blend comprising by weight, (a) 50% feather, and (b) 50% eviscerated latex.

25. A chambered pillow with varied density zones comprising:

a neck support zone, wherein said neck support zone extends horizontally across a bottom portion of said pillow and is a medium to firm density; and

a left and right side zone, wherein said left and right side zones are formed from equal halves of the remainder of the pillow and are a soft density.

26. The chambered pillow of claim 25 wherein said varied density zones are separated with baffling.

27. The chambered pillow of claim 25, wherein said soft, medium and firm densities are created by varying the amount of fill used in each zone.

28. The chambered pillow of claim 25, wherein the neck support zone supports the neck of a sleeper and the side zones support the side of the sleeper's face when the sleeper is sleeping on his side.

29. The chambered pillow of claim 25 wherein said pillow is filled with an improved fiberfill blend, said fiberfill blend comprising, by weight, (a) from about 50 to about 70% eviscerated latex, and (b) from about 30 to about 50% polyester fiberfill.

30. The chambered pillow of claim 25, wherein said pillow is filled with an improved feather and latex blend, said blend comprising by weight, (a) from about 40 to about 60% feathers and down, and (b) from about 40 to about 60% eviscerated latex.