Abstract:
In one aspect, a pet bed includes an assembly of a plurality of separate cushion components and a shell containing the assembly. In another aspect, a method of assembling a pet bed includes inserting a plurality of separate cushion components into an opening of a shell, thereby forming within the shell an assembly comprising a single layer of cushion components.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 62/064,651, filed on Oct. 16, 2014, entitled “Component Pet Bed Assembly and Method,” which is fully incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    Pet beds are used to provide a resting place for pets, offering them a comfortable spot on which to lounge as an alternative to places such as the family&#39;s couch or bed. Pet owners sometimes prefer for their pets to have their own dedicated resting areas. One advantage of a resting area particularly suited to a pet is that fur, dander, and other pet sheddings are somewhat contained for ease of clean-up. 
         [0003]    Pet beds conventionally comprise a cushion within a shell. The shell can have a selectively closeable opening, such as an opening closable with a zipper, for example. The opening facilitates insertion of the cushion and/or removal of the shell for cleaning or replacement. In some cases, the cushion is not an integral element but rather is a filling that may consist of fibers, such as polyester fiber-fill, for example. 
         [0004]    During use, the fibers in a frequently used area of the pet bed, such as the middle, for example, may compact or be pushed to the periphery, thereby leaving a thin area having little cushioning material. This creates an inconsistent and uncomfortable surface over time. Such fill migration significantly shortens the useful service life of a pet bed. 
       SUMMARY 
       [0005]    In one aspect, a pet bed includes an assembly of a plurality of separate cushion components and a shell containing the assembly. 
         [0006]    In another aspect, a method of assembling a pet bed includes inserting a plurality of separate cushion components into an opening of a shell, thereby forming within the shell an assembly comprising a single layer of cushion components. 
         [0007]    This summary is provided to introduce concepts in simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the disclosed or claimed subject matter and is not intended to describe each disclosed embodiment or every implementation of the disclosed or claimed subject matter. Specifically, features disclosed herein with respect to one embodiment may be equally applicable to another. Further, this summary is not intended to be used as an aid in determining the scope of the claimed subject matter. Many other novel advantages, features, and relationships will become apparent as this description proceeds. The figures and the description that follow more particularly exemplify illustrative embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The disclosed subject matter will be further explained with reference to the attached figures, wherein like structure or system elements are referred to by like reference numerals throughout the several views. 
           [0009]      FIG. 1  is a front perspective view of an exemplary embodiment of a pet bed. 
           [0010]      FIG. 2  is a side perspective view of the pet bed of  FIG. 1 . 
           [0011]      FIG. 3  is a perspective view of cushion components for filling the shell of the pet bed of  FIGS. 1 and 2 . 
           [0012]      FIG. 4A  is a perspective view of a second exemplary embodiment of a cushion casing construction. 
           [0013]      FIG. 4B  is a perspective view of the cushion casing of  FIG. 4A , wherein ends of the casing are closed. 
       
    
    
       [0014]    While the above-identified figures set forth one or more embodiments of the disclosed subject matter, other embodiments are also contemplated, as noted in the disclosure. In all cases, this disclosure presents the disclosed subject matter by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this disclosure. 
         [0015]    The figures may not be drawn to scale. In particular, some features may be enlarged relative to other features for clarity. Moreover, where teems such as above, below, over, under, top, bottom, side, right, left, etc., are used, it is to be understood that they are used only for ease of understanding the description. It is contemplated that structures may be oriented otherwise. 
       DETAILED DESCRIPTION 
       [0016]    Exemplary embodiments of the present disclosure describe pet beds designed for ease of manufacture and so that fill material is prevented from shifting within the pet bed.  FIG. 1  is a front perspective view of an exemplary embodiment of a pet bed  10 . In an exemplary embodiment, pet bed  10  includes top surface  12 , bottom surface  14 , and perimeter side wall  16 . In an exemplary embodiment, perimeter wall  16  is composed of a first pair of side walls  18  and a second pair of side walls  20 . In the illustrated embodiment, pet bed  10  has a rectangular configuration; thus, the first pair of side walls  18  are parallel to each other, and the second pair of side walls  20  are parallel to each other. While four side walls  18 ,  20  are shown, it is contemplated that perimeter side wall  16  may be made of fewer or more side walls. Further, perimeter side wall  16  may possess any closed shape. 
         [0017]    In an exemplary embodiment, top surface  12  includes a perimeter bolster area  22  and a central area  24 . Valleys  26  may be provided between perimeter bolster area  22  and a central area  24  to delineate the areas and offer a pleasingly plump appearance. Moreover, valleys  26  may serve to help retain pet hair, dander and other shed material on top surface  12 . In an exemplary embodiment, pet bed  10  has a substantially uniform height dimension H at perimeter wall  16  and at a central area  24 . Accordingly, a pet resting on pet bed  10  does not have a tendency to roll off the pet bed  10 . 
         [0018]    In an exemplary embodiment, top surface  12 , bottom surface  14 , and perimeter side wall  16  are parts of a shell  28  that is filled with an assembly  30  of cushion components, as shown in  FIG. 3 . As shown in  FIG. 2 , in an exemplary embodiment, shell  28  includes an opening  32  that has a closure device  34  for selective opening and closing, such as for filling or emptying shell  28  of its cushion components. Suitable closure devices  34  include zippers, hook and loop fasteners, clamps, clips, and buttons, for example. In an embodiment where one of the pair of side walls  16 ,  18  is longer than the other pair of side walls  16 ,  18 , pet bed  10  in an exemplary embodiment has closure device  34  positioned on one of the side walls that is shorter. This results in a cleaner appearance on a longer side wall and allows for the use of a shorter closure device  34 . 
         [0019]      FIG. 3  is a perspective view of an assembly  30  of a single layer of cushion components for filling the shell  26  of the pet bed  10 . In the illustrated embodiment, assembly  30  includes center cushion  36 , first pair of perimeter cushions  38 , and second pair of perimeter cushions  40 . In an exemplary embodiment, each of perimeter cushions  38 ,  40  is elongated, with two opposing end surfaces  42 . In an exemplary embodiment, one of the end surfaces  42  of each perimeter cushion  38 ,  40  is provided with closure device  34 ′. Similarly, center cushion  36  has side wall surfaces  44 . In an exemplary embodiment, one of side wall surfaces  44  is provided with closure device  34 ″. Closure devices  34 ′ and  34 ″ may be similar to closure device  34 , but sized for end surfaces  42  and side surface  44 , respectively. 
         [0020]    In an exemplary embodiment, closure device  34 ,  34 ′,  34 ″ can be selectively opened and closed repeatedly, though more permanent closing means such as stitches can also be used. Suitable closure devices include zippers, hook and loop fasteners, clamps, clips, and buttons, for example. 
         [0021]    The illustrated embodiment of assembly  30  shows a longer pair of perimeter cushions  38  and a shorter pair of perimeter cushions  40 . In an exemplary embodiment, each of perimeter cushions  38 ,  40  is elongated and is substantially in the shape of a rectangular prism. Together, the perimeter cushions  38 ,  40  form the filling for the perimeter bolster area  22  of shell  28 . In the illustrated embodiment of shell  28  shown in  FIGS. 1 and 2 , miter seams  46  at the corners of perimeter bolster area  22  provide an attractive appearance. However, the substantially symmetrical construction of perimeter cushions  38 ,  40  offers a means by which to fill the perimeter bolster area  22  with simply shaped components that are easy to manufacture, handle and assemble together. Moreover, while the illustrated embodiment of assembly  30  shows a single center cushion  36 , a longer pair of perimeter cushions  38  and a shorter pair of perimeter cushions  40 , it is contemplated that fewer or more cushions may be used. Moreover, center and perimeter cushions having shapes different than shown may be used (e.g., the perimeter cushions  38 ,  40  may fit together with angled end surfaces  42  under miter seams  46 ). 
         [0022]      FIG. 4A  is a perspective view of a second exemplary embodiment of a cushion construction using tubular casing  50 . In an exemplary embodiment, casing  50  is formed from a non-woven polyurethane material. In an exemplary embodiment, casing  50  has first end  52  and second end  54 . As shown in  FIG. 4B , to form a tubular cushion  56  that can be used as center cushion  36 , one or more of the first perimeter cushions  38  and/or one or more of the second perimeter cushions  40 , each end  52 ,  54  is closed, as at seam  52 ′,  54 ′, for example. In an exemplary embodiment, one of the seams  52 ′,  54 ′ is provided with closure device  34 ′ or  34 ″. The structure of tubular cushion  56  is simpler than that of the more block-shaped cushions illustrated in  FIG. 3  but serves the same purpose in assembly  30 . 
         [0023]    In an exemplary embodiment, each component of assembly  30  of cushion components, namely center cushion  36  and perimeter cushions  38 ,  40  (having, for example, the illustrated structure or the tubular structure of cushion  56 ) consists of a casing  37 ,  39 , or  41 , respectively, filled with a cushioning material  48 . In an exemplary embodiment, the casing  37 ,  39 , or  41 , is formed from flexible sheet materials such as textiles and films. Cushioning material  48  may include polyester, polymers, cotton and other suitable synthetic and natural materials. Fibrous fill material is especially suitable for adding loft and softness to pet bed  10  while being light in weight. In an exemplary embodiment, fibrous fill material is a recycled polyester in crimped filament form. Fibrous fill material is typically supplied in a compressed bale of fibers having different lengths and crimp properties. As fibrous fill material is handled in a pillow filling blower machine, the machine opens up the fibers to allow air to occupy spaces between individual fibers. This air incorporation results in fibrous fill material having high level of loft, leading to a desirable softness and filled appearance when used in the casings of center cushion  36  and perimeter cushions  38 ,  40 . A particularly suitable polyester fiber is siliconized to facilitate its movement through a blower machine. 
         [0024]    Another suitable cushioning material  48  is a shredded foam fill material. Such a shredded foam fill material may be formed from polyurethane, and other suitable synthetic and natural materials. Shredded foam fill material is especially suitable for adding resilience to pet bed  10 , while adding density, which helps to retain pet bed  10  in a desired location. In an exemplary embodiment, shredded foam fill material is obtained by recycling foam scrap materials that are left over from the manufacture of larger mattress and cushion pieces. The shredded foam fill material need not be uniform; for example, it may include pieces of foam having different densities. In an exemplary embodiment, the pieces of shredded foam fill material are similar in size to popped corn. 
         [0025]    A combination fill material may also be used for cushioning material  48 , including a mix of fibrous fill material and shredded foam fill material. In an exemplary embodiment, a combination fill material includes approximately equal portions of fibrous fill material and shredded foam fill material by volume, although other proportional mixes are also suitable. In an exemplary embodiment, the fibrous fill material and shredded foam fill material are evenly distributed among each other, in whatever ratio they are provided. More information on suitable fill materials is disclosed in commonly assigned U.S. patent application Ser. No. 14/303,186, entitled “Pet bed with combination filler and filler isolation barriers,” which is fully incorporated by reference herein. 
         [0026]    In an exemplary embodiment, center cushion  36  is formed by filling center casing  37  with cushioning material  48 . Each perimeter cushion  38  is formed by filling perimeter casing  39  with cushioning material  48 . Each perimeter cushion  40  is formed by filling perimeter casing  41  with cushioning material  48 . A method of constructing pet bed  10  includes filling each of center casing  37  and perimeter casings  39 ,  41  with the desired amount of cushioning material  48  and then closing closure devices  34 ′,  34 ″. In an exemplary embodiment, at least one of the perimeter cushions  38 ,  40  is inserted into opening  32  of shell  28  before center cushion  36  is inserted therein. The center cushion  36  and perimeter cushions  38 ,  40  are inserted into shell  28  through opening  32 , thereby forming assembly  30  to be retained within shell  28 . Closure device  34  is then closed to complete the assembly of pet bed  10 . For extra cushioning, each of center cushion  36  and perimeter cushions  38 ,  40  may be over-filled. Because a casing  37 ,  39 , or  41 , of each of center cushion  36  and perimeter cushions  38 ,  40  is formed of a flexible sheet material, such over-filling will result in a pet bed  10  with a more rounded central area  24 , more rounded perimeter bolster area  22 , and more pronounced valleys  26 . 
         [0027]    Because center cushion  36  and perimeter cushions  38 ,  40  are separately formed and filled, cushioning material  48  from one of the components  36 ,  38 ,  40  of assembly  30  is prevented from shifting into another component. Therefore, pet bed  10  retains its shape for a longer period of use. Moreover, the provision of separate components in assembly  30  allows for the replacement of just one or some of the components of assembly  30 , in the case where not all of the components require replacement (for example, if the pet soils, damages, or flattens just a portion of the assembly  30 ). 
         [0028]    In an exemplary embodiment of pet bed  10 , top surface  12 , bottom surface  14 , and perimeter side wall  16  are formed of flexible sheet materials such as textiles and films, for example. Especially suitable materials are durable yet soft. Other features may include a surface texture that assists in retaining shed fur or possesses a waterproof property, for example. Moreover, the different surfaces  12 ,  14 , and  16  need not be made of the same material. For example, in one embodiment, top surface  12  is made from a plush or flannel fabric, while bottom layer  14  is made from a more durable twill, faux suede or vinyl material. Perimeter side wall  16  may be formed of a decorative material having an aesthetically pleasing design and/or texture, for example. In other cases, top layer  14  and bottom layer  16  are both made of soft materials, so that pet bed  10  is easily reversible for extended use. 
         [0029]    In one exemplary embodiment, pet bed  10  is rectangular, with dimensions of about 36 inches in length, about 29 inches in width, and about 4 inches in height “H”. Such a pet bed may contain about 46 ounces of polyester blown fiber fill. In an exemplary embodiment, each of the cushion components of assembly  30  has a tubular construction, as shown in  FIGS. 4A and 4B . The cushion components cover a larger surface area when flat and un-filled with cushioning material  48 . When filled, the cushion components cover less surface area to accommodate a height dimension. An unfilled casing  37  of center cushion  36  has flat dimensions of about 29.5 inches by about 22.5 inches. An unfilled casing  39  of one of the perimeter cushions  38  has flat dimensions of about 39 inches by about 12 inches. An unfilled casing  41  of one of the perimeter cushions  40  has flat dimensions of about 28 inches by about 12 inches. 
         [0030]    In another exemplary embodiment, pet bed  10  is rectangular, with dimensions of about 42 inches in length, about 32 inches in width, and about 4 inches in height “H”. Such a pet bed may contain about 60 ounces of polyester blown fiber fill. In an exemplary embodiment, each of the cushion components of assembly  30  has a tubular construction, as shown in  FIGS. 4A and 4B . The cushion components cover a larger surface area when flat and un-filled with cushioning material  48 . When filled, the cushion components cover less surface area to accommodate a height dimension. An unfilled casing  37  of center cushion  36  has flat dimensions of about 34.5 inches by about 23.5 inches. An unfilled casing  39  of one of the perimeter cushions  38  has flat dimensions of about 46 inches by about 12 inches. An unfilled casing  41  of one of the perimeter cushions  40  has flat dimensions of about 32 inches by about 12 inches. 
         [0031]    Pet bed  10  can also be inserted into a separate pet bed cover (not shown). In an exemplary embodiment, such a cover has a selectively closeable opening, such as an opening closable with a zipper, buttons, clips, clamps, or hook-and-loop fasteners. Thus, the cover is easily removable for cleaning and replacement when desired. 
         [0032]    Although the subject of this disclosure has been described with reference to several embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure. For example, while a rectangular pet bed  10  is illustrated, it is to be understood that pet bed  10  may be formed in other shapes and sizes, including but not limited to a square, circle, oval and fanciful shapes, such as a dog bone shape, for example. In addition, any feature disclosed with respect to one embodiment may be incorporated in another embodiment, and vice-versa.