Pillow and method of manufacturing a pillow

Some embodiments of the disclosed pillows have a sleeve of viscoelastic material within which is received and enclosed a plurality of loose pieces of filler material. The sleeve can have one or more openings shaped and dimensioned to provide ventilation for the interior of the pillow and/or to enable a user to insert and remove an inner sleeve within which the filler material is retained. In some embodiments, the inner sleeve has two or more compartments for holding the same or different filler materials having the same or different densities, thereby providing a pillow adapted for different uses and support characteristics.

BACKGROUND OF THE INVENTION

The neck of a person lying in a supine or sidelying position is often out of alignment with the person's spine. This is commonly the case when the person's neck is supported by a pillow or multiple pillows such that the neck lies at an angle defined by the deflected height of the pillow(s), and this angle is typically not co-planar with the spine. The deflected height of the pillow is closely related to its stiffness, which is conventionally provided with filling material disposed within a fabric covering. Conventional filling material can include feathers, cotton, or a synthetic filler.

SUMMARY OF THE INVENTION

To provide a pillow structure more likely to properly align the user's neck and spine, some embodiments of the invention provides a pillow having multiple foam components.

Some embodiments of the present invention include a pillow having a viscoelastic sleeve defining a cavity and filler material positioned within the cavity.

In some embodiments, a pillow is provided, and comprises a sleeve comprising visoelastic material and defining an internal cavity; and a plurality of loose pieces of filler material substantially enclosed within the cavity.

Also, some embodiments of the present invention include a pillow having outer layers and a filler material comprised of granulated viscoelastic foam disposed between the outer layers.

Some embodiments of the present invention includes a pillow having outer layers of reinforcing fabric, intermediate layers of viscoelastic foam, and a filler material comprised of granulated viscoelastic foam disposed between the intermediate layers.

In some embodiments, a pillow is provided, and comprises a first layer of viscoelastic material; and a second layer of viscoelastic material, the first and second layers of viscoelastic material coupled together to form a cavity therebetween; wherein a plurality of loose pieces of filler material is positioned between the first and second viscoelastic layers and is substantially enclosed within the cavity.

The present invention also includes methods of manufacturing a pillow. In some embodiments, a method of manufacturing a pillow includes providing a viscoelastic sleeve that defines a cavity, inserting filler material within the cavity, and closing the sleeve to maintain the filler material within the cavity.

Some embodiments of the present invention provide a method of manufacturing a pillow, comprising coupling a first peripheral edge of a first panel of viscoelastic material to a second peripheral edge of a second panel of viscoelastic material; and enclosing a plurality of loose pieces of filler material between and within the first and second panels of viscoelastic material.

The viscoelastic foam responds to changes in temperature such that body heat molds the pillow to conform to the curves of a body for comfort and support. This allows the shape of the pillow to more closely follow the contours of the body, and in some embodiments can promote an improved alignment of the neck and spine when a person is in a supine or sidelying position.

A cover preferably encases the pillow and contours to the shape of the pillow. The cover is removable, washable, and has a resealable slot through which the pillow may be inserted or removed. The slot extends across an edge portion of the pillow and is preferably opened and closed by a zipper.

DETAILED DESCRIPTION

FIGS. 1-3illustrate a pillow10of the present invention having a sleeve construction formed of multiple layers. The pillow10illustrated inFIGS. 1-3has the generally rectangular shape of a standard pillow. However, it will be appreciated that the pillow10can have any other shape desired, including without limitation those that are round, oval, rod, crescent, U-shaped, Y-shaped, L-shaped, star, irregular, and the like. The pillow10comprises a filler material14disposed between layers of viscoelastic foam18. The viscoelastic foam layers18can possess specific thermally responsive properties which cause the pillow10to conform to the shape of the portion of a person's body that contacts the pillow10. The viscoelastic foam layers18can have a lower stiffness or hardness at an elevated temperature as compared to the stiffness at a cooler temperature. The body heat of the person acts to soften the portion of the pillow10in contact with the body, while the portion of the pillow10not contacting the body remains more firm. As a result, the pillow10illustrated inFIGS. 1-3can allow for greater comfort over a conventional pillow by accommodating each user's body form.

In some embodiments of the present invention, the filler material14is granulated, or shredded, viscoelastic foam having a density of about 85 kg/m3. However, a suitable density for the viscoelastic foam filler material14for an average weight pillow10, for example, can be between about 30 and about 140 kg/m3. Further, a suitable density for the viscoelastic foam filler material14for a light-weight pillow10, for example, can be less than about 40 kg/m3. Likewise, a suitable density for the viscoelastic foam filler material14for a heavy-weight pillow10, for example, can be greater than about 130 kg/m3. Alternatively, the granulated visoelastic foam utilized as the filler material14can have any density in accordance with the desired characteristics of the pillow10. In addition, a suitable viscoelastic foam filler material14possesses an indentation load deflection, or “ILD,” of 65% between 100-500 N loading, and a maximum 10% rebound according to the test procedure governed by the ASTM-D-1564 standard.

The granulated viscoelastic foam of the filler material14in the embodiment ofFIGS. 1-3is non-reticulated viscoelastic foam. However, in other embodiments, the viscoelastic foam of the filler material14can be or include reticulated viscoelastic foam. The cells of reticulated foam are essentially skeletal structures in which many (if not substantially all) of the cell walls separating one cell from another do not exist. In other words, the cells are defined by a plurality of supports or “windows”, and by no cell walls, substantially no cell walls, or by a substantially reduced number of cell walls. A foam can be considered “reticulated” if at least 50% of the walls defining the cells of the foam do not exist (i.e., have been removed or were never allowed to form during the manufacturing process of the foam). The granulated viscoelastic foam of the filler material14can be 100% reticulated viscoelastic foam, 100% non-reticulated viscoelastic foam, or can include any relative amounts of reticulated and non-reticulated viscoelastic foams desired.

The granulated filler material14can be made up of recycled, virgin, or scrap viscoelastic material. As will be appreciated by one of ordinary skill in the art, the granulated filler material14can be produced in any manner desired, including without limitation by shredding, cutting, grinding, chopping, tearing, or ripping virgin, recycled, or scrap viscoelastic material, by molding or casting individual pieces, or in any other suitable manner. The granulated filler material14may consist of pieces of a nominal length, or the granulated filler material14may consist of pieces of varying length. For example, granulated filler material14may have a nominal length of about 1.3 cm. Also, granulated filler material14may consist of varying lengths between about 0.6 cm and about 2 cm. The granulated filler material14can be as short at 0.3 cm and as long as 4 cm., or the filler material14can be any length in accordance with the desired characteristics of the pillow10. In some embodiments, the granulated filler material14is comprised of 16-20% having a length longer than 2 cm, 38-42% having a length between 1 and 2 cm, and 38-42% of the pieces shorter than 1 cm. Significant cost savings and waste reduction can be realized by using scrap or recycled filler material14rather than virgin filler material14. Viscoelastic foam used as the filler material14can be made from a polyurethane foam material, however, the filler material14can be made from any other viscoelastic polymer material that exhibits similar thermally-responsive properties.

The composition of the filler material14can be varied to alter the characteristics of the pillow10and the cost of the pillow10. In some embodiments of the present invention, the filler material14is a combination of granulated viscoelastic foam and a fiber material. The fiber material can be made from any kind of textile, such as an organic textile (cotton) or a synthetic textile. In some embodiments of the present invention, the fiber material has a density of about 1 g/cm3. However, a suitable density for the fiber material for an average weight pillow10, for example, is 0.1-2 g/cm3. Further, a suitable density for the fiber material for a light-weight pillow10, for example, can be less than about 0.3 g/cm3. Likewise, a suitable density for the fiber material for a heavy-weight pillow10, for example, can be greater than about 1.8 g/cm3. Alternatively, the fiber material utilized in combination with the granulated viscoelastic foam as the filler material14can have any density in accordance with the desired characteristics of the pillow10.

In some embodiments, the filler material14is comprised of about 50% fiber material, while the remaining composition includes granulated viscoelastic foam. However, a suitable range of fiber material in the filler material14for some pillows10, for example, can be between about 20% and about 80%. Further, a suitable range of fiber material in the filler material14for other pillows10, for example, can be less than about 30% of the filler material14. Likewise, a suitable range of fiber material in the filler material14for still other pillows10, for example, can be greater than about 70% of the filler material14.

In some embodiments, the filler material14is a combination of granulated viscoelastic foam and polystyrene balls. The filler material14can also or instead include an organic or synthetic fiber material depending on the desired characteristics of the pillow10. The polystyrene balls may consist of balls of a nominal diameter, or the polystyrene balls may consist of balls of varying diameters. For example, the polystyrene balls may have a nominal diameter of about 5 mm. Also, the polystyrene balls may consist of varying diameters between about 1 mm and about 10 mm. The polystyrene balls can also be as small as 0.5 mm and as large as 20 mm, or the polystyrene balls can have any size in accordance with the desired characteristics of the pillow10.

The filler material14in some embodiments comprises about 50% polystyrene balls, while the remaining composition includes granulated viscoelastic foam. However, a suitable range of polystyrene balls in the filler material14for some pillows10, for example, can be between about 20% and about 80%. Further, a suitable range of polystyrene balls in the filler material14for other pillows10, for example, can be less than about 30% of the filler material14. Likewise, a suitable range of polystyrene balls in the filler material14for still other pillows10, for example, can be greater than about 70% of the filler material14.

In some embodiments, the filler material14can include granulated highly-elastic (“HE”) foam in addition to granulated viscoelastic foam. Such HE foam can take any of the granulated forms described above with reference to the granulated viscoelastic foam. Furthermore, the filler material14can include still other materials, such as feathers, down, granulated cotton, cotton fibers, wool, beads, beans, latex, other types of foam (in any of the granulated forms described above), and the like. The filler material14can be comprised of any single filler described herein or any combination of such fillers. In some embodiments, for example, the filler material14includes HE foam having a density of about 35 kg/m3. However, a suitable density for the HE foam for an average weight pillow10, for example, can be between about 20 kg/m3and about 50 kg/m3. Further, a suitable density for the HE foam for a lightweight pillow10, for example, can be less than about 25 kg/m3. Likewise, a suitable density for the HE foam for a heavyweight pillow10, for example, can be greater than about 45 kg/m3. Alternatively, the HE foam utilized in the filler material14can have any density in accordance with the desired characteristics of the pillow10.

If used, the granulated HE foam (or other types of granulated non-viscoelastic foam, as described above) may consist of pieces of a nominal length, or the granulated HE foam may consist of pieces of varying lengths. For example, the granulated HE foam may have a nominal length of about 1.3 cm. Also, the granulated HE foam may consist of varying lengths between about 0.6 cm and about 2 cm. The granulated HE foam can be as short as 0.3 cm and as long as 4 cm., or the granulated HE foam can be any length in accordance with the desired characteristics of the pillow10. In some embodiments, the granulated HE foam is comprised of 16-20% having a length longer than 2 cm, 38-42% having a length between 1 and 2 cm, and 38-42% of the pieces being shorter than 1 cm. Such foam lengths can also be utilized for other granulated non-viscoelastic foams.

In some embodiments, the filler material14comprises about 50% granulated HE foam (or other granulated non-viscoelastic foam, as described above), while the remaining composition includes the granulated viscoelastic foam. However, a suitable range of HE foam in the filler material14for some pillows10, for example, is 20%-80%. Further, a suitable range of granulated HE foam in the filler material14for other pillows10, for example, can be less than about 30% of the filler material14. Likewise, a suitable range of granulated HE foam in the filler material14for still other pillows10, for example, can be greater than about 70% of the filler material14. Such foam amounts can also be utilized for other granulated non-viscoelastic foams.

As previously mentioned, the filler material14in the illustrated embodiment ofFIGS. 1-3is disposed between layers18of viscoelastic foam. It should be noted that the layers18of viscoelastic foam described herein can be defined by two separate pieces of viscoelastic foam, or a single piece of viscoelastic foam folded upon itself. Alternatively, the layers18of viscoelastic foam can be defined by three or more pieces of viscoelastic foam connected in any suitable manner (e.g., stitching, gluing, melting, and the like) to define a sleeve within which the filler material14is enclosed and retained.

In some embodiments, the layers of viscoelastic foam18have a density of about 85 kg/m3. However, a suitable density for the layers of viscoelastic foam18for an average weight pillow10, for example, can be between about 30 and about 140 kg/m3. Further, a suitable density for the layers of viscoelastic foam18for a lightweight pillow10, for example, can be less than about 40 kg/m3. Likewise, a suitable density for the layers of viscoelastic foam18for a heavyweight pillow10, for example, can be greater than about 130 kg/m3. Alternatively, the layers of viscoelastic foam18can have any density in accordance with the desired characteristics of the pillow10.

The viscoelastic foam of the layers18illustrated inFIGS. 1-3is non-reticulated viscoelastic foam. However, in other embodiments, the viscoelastic foam18of either or both layers18can comprise reticulated viscoelastic foam (described in greater detail above with reference to the granulated viscoelastic foam filler material14).

The layers of viscoelastic foam18can be about 10 mm thick and have thermally-responsive properties similar to the granulated viscoelastic foam of the filler material14. Likewise, a suitable thickness for the layers of viscoelastic foam18for an average weight pillow10, for example, can be between about 5 mm and 15 mm. However, a suitable thickness for the layers of viscoelastic foam18for a heavyweight pillow10, for example, can be greater than about 13 mm. The layers of viscoelastic foam18can be made from a polyurethane foam material. However, the layers of viscoelastic foam18can be made from any other viscoelastic polymer material that exhibits similar thermally-responsive properties.

In some embodiments, the layers18can comprise any other type of sheet material desired, including without limitation cloth or fabric in woven or non-woven form, webbing, netting, velour, felt, and the like comprised of cotton, wool, synthetic materials (e.g., polyester or polyester blends), reticulated and/or non-reticulated non-viscoelastic foam, silk, satin, and the like.

The overall stiffness or hardness of the pillow10is dependent at least in part upon the stiffness of the individual viscoelastic foam layers18and the filler material14. As such, the overall stiffness or hardness of the pillow10may be affected by varying the stiffness of the individual viscoelastic foam layers18and/or the filler material14.

As shown inFIGS. 1-3, reinforcing layers22are positioned on the outside of the layers of viscoelastic foam18. The reinforcing layers22can comprise fabric, and can act as an anchor for stitches26that secure together the layers of reinforcing layers22and the layers of viscoelastic foam18. Without the reinforcing layers22, the viscoelastic foam layers18, which can be less durable than the reinforcing layers22, would have to directly anchor the stitches26such that the filler material14is secured between the viscoelastic foam layers18. In a pillow having this construction (not shown) and depending upon the type of foam employed for the layers18, the viscoelastic foam layers18could be more likely to tear near the stitches26as a result of normal use of the pillow. Therefore, reinforcing layers22can provide a measure of durability to the pillow10. The reinforcing layers22can be made from a durable material, such as a cotton/polyester blend, or any of the non-viscoelastic sheet materials described above in connection with the layers18.

Although only two reinforcing layers22are illustrated in the embodiment ofFIGS. 1-3(positioned on external surfaces of the viscoelastic foam layers18), it should be noted that additional reinforcing layers22can be positioned on internal surfaces of either or both viscoelastic foam layers18. Depending at least in part upon the construction of the pillow (e.g., in those embodiments in which the edges of the viscoelastic foam layers18are turned inward and are stitched together along the inwardly-turned edges), reinforcing layer(s)22adjacent internal surfaces of either or both viscoelastic foam layers18can be utilized in addition to or instead of reinforcing layers22on the external surfaces of either or both viscoelastic foam layers18. Such internal reinforcing layers22can be utilized to cover internal surfaces of the viscoelastic foam layers18, and need not necessarily perform a reinforcing function for the stitches26at all. In some embodiments, either or both viscoelastic foam layers18are substantially encased by reinforcing layers22on both faces of the layer(s)18.

A cover30surrounds and encases the pillow10illustrated inFIGS. 1-3, and can conform to the shape of the pillow10. The cover30can be made from a durable and washable fabric material, such as a cotton/polyester blend. Alternatively, the cover30can be made from any other type of sheet material desired, including without limitation cloth or fabric in woven or non-woven form, webbing, netting, velour, felt, and the like comprised of cotton, wool, synthetic materials (e.g., polyester or polyester blends), silk, satin, and the like.

As shown inFIG. 1, a slot34extends across the illustrated cover30along the cover's edge. The pillow10may be inserted into the cover30through the slot34. The pillow10may also be removed from the cover30through the slot34to facilitate cleaning of the cover30. The slot34can be resealable to close the cover30around the pillow10and to open the cover30for removing the pillow10. A closure device can be used to open and close the slot34. In some embodiments, the closure device is a zipper38, although the closure device could also or instead include snaps, buttons, clasps, pieces of hook and loop fastener material, hook and eyelet sets, overlapping flaps, laces, tied ribbons, strings, cords, and the like

manufacture, the layers of viscoelastic foam18in the illustrated embodiment ofFIGS. 1-3can be sewn together with the reinforcing layers22to form a sleeve or casing having an open end, wherein the layers of viscoelastic foam18comprise the inner layers of the casing and the reinforcing layers22comprise the outer layers of the casing. The filler material14can then be inserted through the open end of the casing until a desired amount of filler material14is reached within the casing. The open end can then be sewn closed, thereby encasing the filler material14within the casing and defining a pillow10. In other embodiments, the filler material14can be positioned adjacent or upon either or both layers of viscoelastic foam18, which can then be moved to enclose the filler material14and can thereafter be sealed (e.g., sewn, melted, and the like) together to form the sleeve or casing. The pillow10can then be inserted within the cover30and the cover30closed by the zipper38.

FIGS. 4 and 5illustrate a pillow according to another embodiment of the present invention. The pillow illustrated inFIGS. 4 and 5employs much of the same structure and has many of the same features and properties as the embodiments of the pillow described above in connection withFIGS. 1-3. Accordingly, the following description focuses primarily upon the pillow structure and features that are different than the pillow embodiments described above in connection withFIGS. 1-3. Reference should be made to the description above in connection withFIGS. 1-3for additional information regarding the structure and features, and possible alternatives to the structure and features of the pillow illustrated inFIGS. 4 and 5and described below. Structure and features of the embodiment shown inFIGS. 4 and 5that correspond to structure and features of the embodiment ofFIGS. 1-3are designated hereinafter in the 100 series of reference numbers.

Like the pillow illustrated inFIGS. 1-3, the pillow110illustrated inFIGS. 4 and 5has layers118of viscoelastic foam forming a sleeve and defining an internal cavity at least partially filled with filler material114. The filler material114and layers118are described in greater detail above in connection with the embodiment illustrated inFIGS. 1-3, as are alternatives to the type, features, and characteristics of the filler material114and layers118.

With continued reference to the pillow110illustrated inFIGS. 4 and 5, the pillow can have reinforcing layers122positioned on the exterior surfaces of the layers118of viscoelastic foam. The reinforcing layers122can have any of the same properties, be comprised of any of the same materials and perform any of the same functions as described above with reference to the pillow10illustrated inFIGS. 1-3. Also, the reinforcing layers122can instead be positioned on the interior surfaces of the layers118of viscoelastic foam. In some embodiments, the reinforcing layers122can be positioned on the interior and exterior surfaces of the layers118of viscoelastic foam. Furthermore, the reinforcing layers122can be positioned on selected areas of the layers118of viscoelastic foam. For example, the reinforcing layers122can be positioned only at the seams where the layers118of viscoelastic foam are attached.

The pillow110can have a cover130which surrounds and encases the pillow110, and which can conform to the shape of the pillow110. The cover130can have any of the same properties, be comprised of any of the same materials, and perform any of the same functions as described above with reference to the pillow10illustrated inFIGS. 1-3. Also, the cover130illustrated inFIGS. 4 and 5is provided with a zipper138described above in connection withFIGS. 1-3, although any of the other types of closure device also described above can instead be used. Alternatively, the cover130can be a sleeve with at least one end open for insertion of the pillow110, but having no closure device.

The filler material114can comprise loose pieces of material having any of the same properties, comprising any of the same materials (and combinations of materials), and performing any of the same functions described above with reference to the illustrated embodiment ofFIGS. 1-3.

The layers118of viscoelastic foam illustrated inFIGS. 4 and 5form a sleeve, and can have any of the same properties, be comprised of any of the same materials, and perform any of the same functions as described above with reference to the pillow110illustrated inFIGS. 1-3.

The layers118of viscoelastic foam illustrated inFIGS. 4 and 5are connected together along their respective peripheries to define openings140at the sides of the pillow110(only one of which is visible inFIG. 4, the other being located on the opposite side of the pillow110). The openings140in the embodiment ofFIGS. 4 and 5are defined by leaving portions of the peripheral edges of the layers118unconnected to one another. Alternatively, the openings140can be created by cutting openings140in or between the layers118, or by forming the openings in any other suitable manner.

As described above, openings140are defined at opposite ends of the pillow110between the layers118of viscoelastic foam illustrated inFIGS. 4 and 5. These openings permit airflow between a cavity142defined between the layers118and the exterior of the layers118, thereby providing enhanced ventilation for the pillow110and/or permitting air to enter or leave the cavity142more rapidly during shape change of the pillow110(e.g., when a user's head or body compresses the pillow, when the pillow is “fluffed”, and the like).

Although two relatively large openings140in the illustrated embodiments ofFIGS. 4 and 5are located at opposite ends of the pillow110, any number of openings140can be in any other locations in or between the layers118, and on any single side of the pillow110or combination of sides of the pillow110. For example, a single opening140can be defined between an unconnected portion of the layers118at the front or rear of the pillow110, at a lateral side of the pillow110(such as the location of the visible opening140shown inFIG. 4), or at a corner of the pillow110. As another example, one or more openings140can be located in the body of either or both layers118. As yet another example, several openings140can be defined between unconnected portions of the layers118on the same side of the pillow110. Still other numbers and locations of openings140are possible, and fall within the spirit and scope of the present invention.

The openings140in the illustrated embodiment ofFIGS. 1-3are substantially elongated, and take the form of slits extending along opposite sides of the pillow110as described above. In other embodiments, however, the openings140have any other shape desired, including without limitation round, rectangular, oval, and irregularly-shaped openings140.

In some embodiments, the openings140are utilized only for purposes of ventilation as described above, and can therefore be sufficiently small while still performing this function. For example, a number of relatively small openings140aare defined in both layers118of viscoelastic material illustrated inFIGS. 4 and 5(seeFIG. 5). However, in other embodiments, the openings140are utilized for enabling a user to insert filler material114into the cavity142and/or to remove filler material114from the cavity142. Such openings140can also be sufficiently large to insert and remove an inner sleeve144at least partially filled with filler material114as will be described in greater detail below. For example, the openings140in the illustrated embodiment extend along a substantial portion of the sides of the pillow110, and in some embodiments can extend along a majority of the length of such sides. In still other embodiments, one or more openings can extend along substantially an entire side of the pillow110. As another example, one or more openings (e.g., slits) can be defined in a top side and/or bottom side of the pillow110, such as in the body of either or both layers118of viscoelastic foam. Such openings140can be sufficiently large for a user to insert and remove an inner sleeve144at least partially filled with filler material114as will be described in greater detail below.

In some embodiments, any or all of the larger openings140used for insertion and removal of an inner sleeve144with filler material114(as described above) can be provided respective closure devices (not shown) to open and close such openings. The closure device(s) can take any of the forms described above with reference to the closure device138of the cover130.

As mentioned above, filler material114can be located within an inner sleeve144between and enclosed within the layers118of viscoelastic foam. Although filler material114can be located both within the inner sleeve144and between the inner sleeve144and either or both layers118of viscoelastic foam, the filler material114inFIGS. 4 and 5is located only within the inner sleeve144. The inner sleeve144and filler material114therein can take the form of a traditional pillow received between the layers118of viscoelastic foam. For example, the inner sleeve144and filler material114therein can be a down or feather pillow, can be a conventional pillow having any type of fill (e.g., cotton, balls, beads, beans, or foam), and the like. In some embodiments, such a pillow can be selected by a user and inserted through an opening140between the layers118of viscoelastic foam or in a layer118of the viscoelastic foam, thereby constructing a pillow110having desired characteristics.

The inner sleeve144can comprise any traditional pillow covering material, including without limitation cloth or fabric in woven or non-woven form, webbing, netting, velour, felt, and the like comprised of cotton, wool, synthetic materials (e.g., polyester or polyester blends), silk, satin, and the like. In some embodiments, the inner sleeve144can be made of another layer of reticulated or non-reticulated viscoelastic material or another type of foam. The inner sleeve144can be constructed in any suitable manner, such as by being sewn together along seams. Also, the inner sleeve144can have a closure device on one or more sides to facilitate user access to the filler material114therein. The closure device (not shown) can take any of the forms described above with reference to the closure device138of the cover130.

During manufacture of the pillow110illustrated inFIGS. 4 and 5, the layers118of viscoelastic foam118are sewn together with the reinforcing layers122to form a sleeve or casing having one or more openings140sufficiently large to receive the inner sleeve144and filler material114therein. Separately, the layers of the inner sleeve144are sewn or otherwise connected to form a sleeve in which the filler material114is retained. In some embodiments, the filler material114is enclosed within the inner sleeve by sewing and/or by closing a zipper or other closure device of the inner sleeve144. The inner sleeve144with its filler material114is then inserted through an opening140and into the cavity142between the layers118of viscoelastic foam118. If a closure device is provided for the opening, the closure device can then be closed. In the illustrated embodiment however, the opening140remains open so that the inner sleeve144is open to the environment. The pillow110can then be inserted into the cover130, which in the illustrated embodiment ofFIGS. 4 and 5can be closed by the zipper138. In other embodiments, the cover130can remain open.

FIGS. 6 and 7illustrate a pillow according to yet another embodiment of the present invention. The pillow illustrated inFIGS. 6 and 7employs much of the same structure and has many of the same features and properties as the embodiments of the pillow described above in connection withFIGS. 4 and 5. Accordingly, the following description focuses primarily upon the pillow structure and features that are different than the pillow embodiments described above in connection withFIGS. 4 and 5. Reference should be made to the description above in connection withFIGS. 4 and 5for additional information regarding the structure and features, and possible alternatives to the structure and features of the pillow illustrated inFIGS. 6 and 7and described below. Structure and features of the embodiment shown inFIGS. 6 and 7that correspond to structure and features of the embodiment ofFIGS. 4 and 5are designated hereinafter in the200series of reference numbers.

Like the pillow illustrated inFIGS. 4 and 5, the pillow210illustrated inFIGS. 6 and 7has layers218of viscoelastic foam forming a sleeve and defining an internal cavity at least partially filled with filler material214(seeFIG. 7). The filler material214and layers218are described in greater detail above in connection with the embodiments illustrated inFIGS. 1-3and4-5, as are alternatives to the type, features, and characteristics of the filler material214and layers218.

The pillow210illustrated inFIGS. 6 and 7, can have reinforcing layers222(seeFIG. 7) positioned on the exterior surfaces of the layers218of viscoelastic foam. The reinforcing layers122can be located in any of the positions, have any of the same properties, be comprised of any of the same materials and perform any of the same functions as described above with reference to the pillows10,110illustrated inFIGS. 1-5.

The pillow210can have a cover230which surrounds and encases the pillow210, and which can conform to the shape of the pillow210. The cover230can also have any of the same properties, be comprised of any of the same materials, and perform any of the same functions as described above with reference to the pillows10,110illustrated inFIGS. 1-5. Also, the cover230illustrated inFIGS. 6 and 7is provided with a zipper238described above in connection withFIGS. 1-5, although any of the other types of closure device also described above can instead be used. Alternatively, the cover230can be a sleeve with at least one end open for insertion of the pillow210, but having no closure device.

The filler material214can comprise loose pieces of material having any of the same properties, comprising any of the same materials (and combinations of materials), and performing any of the same functions described above with reference to the illustrated embodiments ofFIGS. 1-5.

The layers218of viscoelastic foam illustrated inFIGS. 6 and 7form a sleeve, and can have any of the same properties, be comprised of any of the same materials, and perform any of the same functions as described above with reference to the pillows10,110illustrated inFIGS. 1-5.

Like the pillow110illustrated inFIGS. 4 and 5, the pillow210illustrated inFIGS. 6 and 7has openings240(seeFIG. 6) through which an inner sleeve244with filler material214therein can be inserted into and removed from a cavity242between the layers218of viscoelastic material. Although only one opening240is visible inFIG. 6, a similar opening240is located between the layers218of viscoelastic material on an opposite end of the pillow210. Any number of openings240for the inner sleeve244and filler material214can be in any of the locations described above in connection with the illustrated embodiment ofFIGS. 4 and 5, and can take any of the forms also described above. The opening240illustrated inFIG. 6provides an example of a different opening size that can be employed for the pillow (when compared toFIG. 4), although it should be noted that any other opening size and shape suitable for insertion and removal of the inner sleeve244and filler material214can instead be used.

The openings240in the illustrated embodiment ofFIGS. 4 and 5can serve to permit user insertion and removal of the inner sleeve244with its filler material214, as well as to provide ventilation of the pillow210as also described in greater detail above in connection with the illustrated embodiment ofFIGS. 4 and 5. However, additional openings240aserving primarily for ventilation purposes can also be defined in the layers218of viscoelastic material as best shown inFIG. 7, and can be in any of the locations and take any of the forms described above in connection with the illustrated embodiment ofFIGS. 4 and 5.

The inner sleeve244of the pillow illustrated inFIGS. 6 and 7can be partially or entirely filled with any of the filler materials described above in connection with the embodiment ofFIGS. 4 and 5, and can be provided with a closure device as also described above. The inner sleeve244illustrated inFIGS. 6 and 7differs from that ofFIGS. 4 and 5in that the inner sleeve has separate internal compartments250,252within which the filler material214is located. The separate compartments250,252of the illustrated pillow210can be defined at least in part by a seam254running along the inner sleeve244, such as a stitch line or a line along which different portions of the inner sleeve244are connected in any other manner (e.g., by adhesive or cohesive bonding material, by hook and loop fastener material, by melting, by one or more fasteners, and the like). Alternatively, the separate compartments250,252can be defined by different pieces of sheet material shaped to enclose respective amounts of filler material214and then connected together in any of the manners just described to arrive at the structure illustrated,

The compartments250,252of the illustrated pillow210have different sizes, and carry different amounts of filler material214. However, this need not necessarily be the case, as compartments having the same size250,252and containing the same amounts of filler material214are possible. In some embodiments, the compartments250,252have different densities of filler material214. For example, the density of filler material214in the first compartment250of the pillow210illustrated inFIGS. 6 and 7is less than that of the second compartment252. In this regard, the second compartment252is more completely filled than the first compartment250, resulting in a corresponding portion of the pillow210that is firmer, stiffer, and/or more plump. Such a difference between compartments250,252can provide a pillow adapted to support different parts of a user in different manners. By way of example only, the second compartment252in the illustrated embodiment ofFIGS. 6 and 7can provide greater support for a user's neck than the amount of support provided to the user's head by the first compartment250by virtue of the difference in filler densities described above. If less support is desired in the neck area than for the user's head, the filler density can be reversed in other embodiments.

The different compartments250,252of the pillow210illustrated inFIGS. 6 and 7can also provide a manner in which to retain different types and combinations of filler materials in different areas of the pillow210. For example, the first compartment250of the pillow210illustrated inFIGS. 6 and 7can retain down filling214, whereas the second compartment252of the pillow210can retain granulated viscoelastic foam. As another example, the first compartment250of the pillow210illustrated inFIGS. 6 and 7can retain a combination of viscoelastic and non-viscoelastic granulated foam, while the second compartment252of the pillow210can retain polystyrene balls and/or beads. The filler material(s)214in each of the compartments250,252can therefore be selected based upon the desired support, weight, hardness, body-conforming, and other characteristics of the pillow210in that location of the pillow210. Any filler or combination of fillers (described above) in any desired density can be received within each compartment for this purpose

The ability to provide different pillow characteristics in different areas of the pillow210based upon the density and type of filler214included in different pillow compartments250,252facilitates the design of a wide variety of pillows210adapted for different users, different types of use (e.g., side-sleeping versus prone or supine, cradled versus non-cradled, and the like), and different types of support. In this regard, the inner sleeve244can be provided with any number of different compartments located in any desired locations of the pillow210—many of which will be determined at least in part by the shape of the pillow.

By way of example only, the pillow210can have three compartments: a central compartment flanked by two compartments similar in shape to the second compartment252illustrated inFIGS. 6 and 7. As another example, the pillow210can have separate compartments located along the same side of the pillow, such as for different support of a user's neck and shoulders. In other embodiments, the pillow210can have different compartments on all sides of the pillow210for defining a perimeter portion having different characteristics than a central portion. As another example, the pillow210can have different compartments on different sides of the pillow210for users sharing the same pillow210. As yet another example, the pillow210can have different compartments beneath opposite faces of the pillow, such that a user can flip the pillow210over for different support characteristics. In still other embodiments, a rectangular or other elongated pillow can have different compartments located along the length thereof, such as for a body, neck, or cheek pillow providing different types of support at different positions along the pillow.

Depending upon the type of pillow and the purpose for which the pillow is adapted, it will be appreciated that the compartments250,252can have a number of different shapes and sizes (in addition to being located in a variety of different positions as described above). The compartments can have any rectangular, triangular, or other polygonal shape, can be rod-shaped, round, or oval, can have an irregular shape, can be pie, wedge, U, V, or L-shaped, or can have any other shape desired. The compartment shape(s) selected for the pillow210can depend at least in part upon the shape of the pillow210and the intended use of the pillow. For example, a rod-shaped or other elongated compartment can be used as a border for the pillow210, whereas an L or V-shaped compartment can be used as a corner of the pillow210. Still other shapes and positions of the compartments250,252are possible, and fall within the spirit and scope of the present invention.