Patent Publication Number: US-6988286-B2

Title: Cushioning device and method of producing the same

Description:
FIELD OF THE INVENTION 
   The present invention is directed at a cushioning device with preferred embodiments directed at a pillow cushioning device, preferably a pillow cushioning device having an intermediate foam core and one or more outer filler material filled pockets. 
   BACKGROUND OF THE INVENTION 
   Pillows come in a variety of forms, with the more typical consisting of rectangular, fabric enclosures filled with feathers, down, chipped foam, or a polyester fill. These pillows may be shaped by the user to provide reasonably adequate support for the user while the user falls asleep. However, many people suffer from an uncomfortable night&#39;s sleep because of the inadequate support that their head and neck receive while using these traditional pillows throughout the night. This is because traditional pillows either have a body that is so soft that the neck support area compresses to result in no support, or the body is so firm that the head sits considerably higher than the shoulders of the user, resulting in an abnormal sleeping position. Chronic neck pain or stiffness and a tense upper back are often the result of these inadequate forms of support these traditional pillows provide. 
   Various foam pillows have also been developed typically comprising a foam body taking the place of the above-noted fillers and inserted into an overall fabric enclosure. These foam based pillows avoid problems such as filler clumping and can facilitate washing by allowing for easier removal of the pillow support from its fabric enclosure. 
   There is also known in the art a pillow featuring a foam core generally surrounded by loose fiber. There can be, however, an undesirable degree of migration or area clumping with a pillow having a foam core generally surrounded by fiberfill within a ticking. 
   SUMMARY OF THE INVENTION 
   The present invention is directed at providing a cushioning device such as a pillow or mattress topper which utilizes a core and outer layer arrangement generally directed at providing desirable load support features in conjunction with good “look and feel” contact characteristics. 
   An embodiment of the present invention includes a cushion apparatus having a first flexible pocket defining a filler reception cavity with a first pocket filler material received within the reception cavity of the first flexible pocket. Preferably, the first pocket filler material is formed of a compilation of individual filler material components. A preferred embodiment also features a second flexible pocket defining a second filler reception cavity within which is received second pocket filler material. A flexible core is positioned between the first and second flexible pockets such as an arrangement where the upper pocket fully covers the top of the flexible (e.g. foam) core and the lower pocket fully covers the lower surface of the core with each preferably having peripheral overhang. The second pocket filler material is also preferably formed of a compilation of individual filler material components such as down material, polyester fiberfill material, and/or polyester fiber-ball material. 
   When down is used as a filler material, an amount of 2 to 5 ozs. (e.g. 4.5 or 5 ozs.) is preferred, and the average thickness of the first pocket is preferably 0.5 to 2 inches. When the first pocket filler material is a polyester fiberfill material, there is preferably utilized an amount of 2 to 12 ozs. per pocket with 5 to 8 ozs. being preferable to facilitate providing the desired thickness in the pocket relative to the supporting core materials. A preferred cushion is in the form of a pillow with the first and second pockets having the same characteristics (e.g. the average thickness of each pocket being 0.75 to 1.5 inches with 0.85 to 1.25 inches being a preferred sub-range). 
   The core is preferably formed of a foam material (e.g. a polyurethane foam material including visco-elastic foam materials). Also, a preferred pillow embodiment features a core with a convex exposed surface supporting the first pocket, and also preferably a similar relationship (symmetric arrangement both core and ticking) for the second pocket and core bottom surface. A foam core of visco-elastic foam when utilized, preferably has a density of 30 to 60 kg/m 3  and a hardness range of 25N to 90N measured at 25% compression at 20 degrees Celsius, and takes up a majority of the overall height of the cushion even relative to the sum of the upper and lower pockets. 
   The first and second flexible pockets are preferably connected together such as by way of an intermediate cover section which is connected to a peripheral region of said first and second flexible pockets. The intermediate cover section preferably, further includes an intermediate gusset section extending peripherally about the core. The noted intermediate gusset section includes a first peripherally extending upper gusset section, a second peripherally extending gusset section and an inner border line between said upper and lower peripherally extending gusset sections. 
   There is also preferably included at least one bead defining a border edge of at least one of said upper and lower gusset sections. The bead(s) preferably include(s) a bead cord and a cloth covering for one or two possible upper and lower gusset beads. 
   The present invention also features a method of forming a cushion such as a pillow that includes providing a cover having a first pocket, a second pocket, and an intermediate pocket, inserting filler material in the first and second pockets, and inserting a core filler in the intermediate pocket. The step of inserting filler material preferably includes inserting filler material of down, fiberfill, fiber-balls, etc. or combination thereof in each of the outer pockets (e.g. by hand or an automated process). A visco-elastic foam or an alternate polyurethane foam core placed in the intermediate pocket represent suitable core fillers. 

   
     BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  shows a perspective view of a first embodiment of the pillow of the present invention. 
       FIG. 1A  shows an enlarged cross-sectional view of a portion of  FIG. 1  along cross-section line IA—IA (see also the circled region in  FIG. 4 ). 
       FIG. 1B  shows an enlarged cross-sectional view of another portion of  FIG. 1  along cross-section line IB—IB (see also the circled region in  FIG. 4 ). 
       FIG. 2  shows an elevational end view of the pillow of  FIG. 1  with intermediate cut away. 
       FIG. 3  shows an elevational side view of the pillow of  FIG. 1  with an intermediate cut away. 
       FIG. 4  shows a cross-sectional view of the pillow of  FIG. 1  taken along cross-section line IV—IV in  FIG. 3 . 
       FIG. 5  shows a cross-sectional view of the pillow of  FIG. 1  taken along cross-section line V—V in  FIG. 2 . 
       FIG. 6  shows a perspective view of a foam core of the present invention. 
       FIG. 7  shows a schematic side view of a foam core of the present invention. 
       FIG. 8  shows a schematic end elevational view of the foam core. 
       FIG. 9  shows a top plan view of the foam core. 
       FIG. 10  shows a schematic view of a pillow of the present invention in side view with filler and outer covering. 
       FIG. 11  shows an end elevational view of an alternate embodiment of the pillow of the present invention. 
       FIG. 12  shows a cross-sectional view taken along cross-section line XII—XII in  FIG. 11 . 
       FIG. 13  shows in schematic cutaway fashion a cushioning device such as a mattress topper. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1  shows, in perspective, a first embodiment of the present invention in the form of pillow  20 . As shown in  FIG. 1 , pillow  20  comprises cover  22  which is of a flexible material such as a textile material, non-woven material, plastic sheeting or laminate. That is, various cover materials are usable depending on the desired environment of use, including, for example, water impervious and non-water impervious materials (e.g. vinyl sheeting, neoprene fabric, natural fiber fabrics such as cotton, man-made fiber fabrics such as polyester and woven and unwoven materials as a few examples). In a preferred embodiment, the cover material is a breathable fabric such as cotton (e.g. 100% or mixtures with other materials such as polyester or rayon) having, for example, a thread count of 200 to 300). Cover  22  is loose enough to enable the cover to conform to depressions and contortions anticipated in use such as the compression forces induced by the head and limited by the interior pillow core contents described below. The cover is strong enough, however, to avoid ripping during usage and in most uses is machine washable. 
   As can be seen from a review of  FIGS. 1 ,  2  and  3 , cover  22  includes an upper top layer  24 . It should be noted that “top” and “bottom” have been used merely to facilitate the discussion of the illustrated embodiments, as the pillow can be used with the illustrated “top” layer in the down or support contact position. Top layer  24  can be of a variety of peripheral shapes such as those most common in pillows (e.g., rectangular and circular), with a rectangular embodiment being illustrated.  FIG. 1  thus illustrates pillow  20  having ends  26 ,  28  and more elongated sides  30 ,  32 . In a preferred embodiment of the present invention, because of the shape of the below described interior pillow contents, upper top layer  24  assumes a convex cross-section end-to-end and a conforming cross-sectional convex surface in the side-to-side direction as well. 
   As further shown in  FIG. 1 , pillow  20  has an intermediate gusset zone  34  which preferably extends about the entire periphery of pillow  20 , although alternate embodiments of the invention include variations relative to this feature, such as a no gusset panel, two edge or three edge only gusset embodiments, or where gussets are only provided along the elongated sides or a portion of the periphery or around all sides but for one side or section made openable for interior access. 
     FIGS. 1–3  also illustrate pillow  20  having lower bottom layer  36  which preferably is similar in material and general layout relative to that of upper top layer  24 . Intermediate gusset zone  34  is also preferably of the same material utilized for the top and bottom layers, but other material combinations are included in the present invention including, for example, elastic material intermediate panels. Intermediate gusset zone  34  is also preferably centrally positioned relative to the upper top layer  24  and lower bottom layer  36 , but can also be provided so as to be closer to the top or bottom layer also such as by way of an added cloth flange extension. 
   At the border between gusset  34  and upper top layer  24 , there is preferably provided an external, border edge or bead edge  38  which extends, in a preferred embodiment, continuously along sides  30 ,  32  and ends  26 ,  28  at the junction between the gusset zone  34  and the top layer  24 . In the region of end  28  there is also preferably provided an access opening which in a preferred embodiment is access controlled by access means such as zipper  40  extending along end  28  with zipper ends positioned just inward of each side  30 ,  32 . In  FIG. 1 , one of the ends includes zipper handle  42 . 
   The section of bead  38  extending along end  28  is preferably positioned immediately below the lower half teeth run of the zipper  40  supported by a cloth or plastic strip base which in turn is secured to cover  22  on one side and on an opposite side, to the bead and/or to an upper region of the gusset zone. The bead and lower zipper tooth run (the actual teeth) are thus preferably arranged in a side-to-side relationship (e.g., in abutting contact) when the zipper is in an unzippered state. 
     FIG. 1  also illustrates gusset zone  34  as comprising upper gusset section  44 , interior dividing line  46  and lower gusset section  48 . Upper gusset section  44 , in the rectangular embodiment illustrated, forms four corners, three of which are shown in  FIG. 1  and represented by reference numbers  50 ,  52  and  54 . In a preferred embodiment, upper gusset section  44  is continuous and uninterrupted with the visible gusset corners being smooth transition corners in the generally rectangular configuration of the pillow (similar to the smooth cornered beading  38 ) with hidden, interior ruffled corner zones (not shown) to accommodate the curvature. 
   With reference to  FIG. 1A , taken along cross-section line, IA—IA of  FIG. 1 , bead  38  is preferably comprised of a bead insert  56  such as a string cord and bead cover  59 . Bead insert  56  preferably runs continuously about pillow  20  to define a circular cross sectional bead that is sufficiently large as to permanently define the gusset upper boundary while providing additional peripheral tension cover strength. The beading preferably extends about the entire pillow including the same section of pillow having the zipper (which is an area of increased user handling). 
     FIGS. 1A ,  1 B and  FIG. 4  illustrate in cross-section additional features relative to the intermediate gusset zone  34 . As seen from  FIG. 1A  upper top layer  24  is joined at its periphery inward of (and essentially at) bead  38  to upper bottom layer  58  (e.g. a fold-in arrangement for top cover  24  with the peripheral inwardly folded-edge of upper bottom layer  58  received in the recess defined by the inwardly extending top cover edge). As this connection (e.g. threaded double seam  57 ) extends peripherally about the pillow, there is formed upper filler pocket  60  in the upper half of pillow  20 . Filler pocket  60  is preferably sealed peripherally about the entire pillow (including when zipper  40  is opened). Upper bottom layer  58  is also preferably formed of the same material as upper top layer  24  although variations are also included in the present invention including forming the outer cover layer  24  and upper bottom layer  58  of different materials (e.g., different grade fabrics or different type material such as netting and cloth combination). 
     FIG. 1B  illustrates an expanded view of the bottom portion of intermediate gusset zone represented by expansion circle  1 B in  FIG. 4  taken in the region represented by cross-section line IB—IB of  FIG. 1 . As shown in  FIG. 1B , upper gusset section  44  extends into connection with lower gusset section  48  and lower top layer  62  such as by way of a threaded connection  64  which extends about the periphery of pillow  20  (e.g. a threaded seam connecting abutting, interior fold edges for section  48  and layer  62  receiving therebetween an extension of upper gusset section  44 ). For example, lower gusset section  48  can be folded inward, lower top layer  62  can also be folded inward, and the inward folds of each defining a sandwich arrangement relative to an extension of upper gusset section therepast. The junction point of these preferably common material pillow sections defines intermediate gusset line  46  which is shown to represent the interiormost portion of the visible intermediate gusset zone  34 .  FIGS. 1 ,  1 B and  4  also illustrate a second gusset bead or external border edge  66  that defines the lower border edge between intermediate gusset zone  34  and the lower bottom layer  36  of pillow  20 . This second bead or border edge is provided to define and help maintain the shape of the lower gusset border edge. It can take on the same form as that of bead  38 , but in a preferred embodiment is formed without a bead cord insert relying instead on stacked or folded bottom layers joined together by a threading, for example. 
     FIG. 1B  illustrates one possible embodiment of gusset border edge  66  defined by a lower region of lower gusset section  48  and an upper region of lower bottom layer  36  so as to provide a symmetry of border effect relative to the top and bottom of gusset zone  34 . In the  FIG. 1B  illustration, layer  36  and section  48  are separate sheets of material that are connected as by the illustrated threaded connection  68 . The combination of layers or sections  36 ,  48  and  62  and the illustrated peripheral connections  64  and  68  define lower filler pocket  70  which, like above, has its peripheral edges sealed and the material is flexible enough to provide for some degree of vertical filler zone expansion and conformance to a preferred convex shaped bottom surface for the core. In a preferred embodiment, lower gusset zone  48  has its corners formed by threaded connections, two of four of which are denoted in  FIG. 1  by dashed reference lines  72 . The dual upper and lower individual pocket arrangement can be formed in a variety of other ways such as adhesive or heat bonding common peripheral edges of the upper pocket layers and the lower pocket layers. The pockets can also joined directly together at common peripheral edges, although the intermediate panel arrangement is preferred for maintaining less directly interlinked pocketed comfort zones. 
   As shown in  FIGS. 1A and 1B , between upper bottom layer  58  and lower top layer  62  is defined intermediate core pocket  74  which is limited peripherally by mainly the interior gusset line  46 . As shown best by  FIGS. 4 and 5 , intermediate core pocket  74  provides a reception area for receipt of core  76 .  FIGS. 4 and 5  also illustrate, respectively, the above noted, filler pockets  60  and  70  containing filler material  78  and  80 , respectively. The providing of the multiple pockets (e.g. upper, intermediate and lower) provides a wide variety of filler options (e.g. core or loose or non-integrated filler material) to a manufacturer (or user when the multipockets are made accessible—although in a preferred embodiment only the intermediate pocket  74  is made accessible by way of zipper  40 ). This versatility facilitates providing different products to suit different intended customer needs and desires, although a wide variance of universal comfort is achieved by the arrangements described herein. For example, with the preferably sealed upper and lower pockets, a wide variety of filler options are possible such as down and polyester fiber fillers. Suitable polyester or other man-made fiber fillers include, for example, such staple polyester fiber such as RICHLOFT® polyester fiber sold by Carpenter Co. or polyester fiber-balls such as disclosed in U.S. Pat. No. 5,344,707 which are described as avoiding a high degree of clumping (which is even further lessened by the relatively thin, individual pockets arrangement of the present invention). 
   In an illustrative preferred embodiment of the present invention, upper and lower filler pockets  60  and  70  contain a common filler material (as opposed to different filler materials which represents an alternate embodiment of the present invention). As best shown in  FIGS. 1A ,  1 B,  4  and  5 , one preferred embodiment of the invention features upper pocket  60  provided with a down feather filler  78  and the lower pocket  70  also provided with a down filler  80 . A variety of down types and/or mixtures represent suitable down filler options such as gray duck down or white goose down, etc. with the preferred embodiment featuring a sealed pocket both from the standpoint of having peripheral sealed edging and a pocket forming material that, while preferably being breathable or air flow capable, blocks the escape of the filler material. In this context, cover  22  can be considered a ticking and a 100% cotton ticking with a suitable thread count (e.g. 200 to 300) to avoid down feather escape and/or partial exposure is preferred. Other well suited ticking fabric includes woven yarns of synthetic polyester continuous filament such as described in U.S. Pat. No. 5,659,911. 
   In a preferred embodiment of the invention, each pocket ( 60 ,  70 ) is preferably provided with down in an amount of 1 to 12 oz. of filler material with a preferred intermediate, general sub-range of 3 to 7 oz. being preferred. In one preferred embodiment, each pocket is provided with 2–5 oz. of down (e.g. 2–4 oz. of Gray Duck Down) with 4.5±0.5 oz. being well suited for many uses of the present invention. The above ranges of down for a preferred pillow shape provides the preferred pocket thickness height range of 0.5 to 2 inches, with a 0.75 to 1.25 inch thickness being well suited for most uses of the present invention and a 1 inch thickness being preferred. (The thickness of the filler and pockets are preferably made generally consistent (e.g. less than a 0.25 inch deviation) across the plane or curvature of the pocket although there can be expected to be some degree of reduction in the peripheral area where the two pocket forming panels are shown coming together for attachment). The thickness range is thus maintained relatively low relative to the height of the core (e.g. a relationship where half of the core height (maximum if non-planar)) is greater than the pocket thickness and preferably half the (maximum) core height is greater than the sum thickness of both pockets. 
   Rather than down (e.g., as some people are allergic to down and down is generally not recommended for washing, requiring dry cleaning), other filler materials are suited for use of the present invention including synthetic “staple fiber” including polyester fiberfill (e.g. polyethylene terephthalate staple (i.e. cut)) fibers with a preferred dtex of 5–6 and preferably slickened (e.g. coated with silicones or polyethylene terephthalate/polyether segmented copolymers to reduce friction and clumping). In one embodiment of the invention, each pocket is provided with 2 to 12 oz. of staple polyester fiberfill (e.g. the aforementioned RICHLOFT®. polyester fiber) with 5–8 oz. being a preferred sub-range used in forming embodiments of the present invention and 6 oz. being well suited for many uses of the present invention. These preferred ranges of fiberfill also generally provides a pocket thickness within the above described preferred range of 0.5 to 2 inches, as is the case for the down pocket filler. 
   Intermediate core pocket  74  also provides for reception of a wide variety of different core embodiments. The preferred intermediate pocket embodiment features an accessible pocket such as a pocket accessible by way of zipper  40 . Core  76  is preferably a unitary or integrated (e.g. monolithic, laminated or interconnected) body which can have planar top, bottom and side surfaces, but is more preferably non-planar with convex top and bottom smooth surfaces. Thus, unlike a non-unitary or non-integral filler material which can be formed of a large number of separable or independent components such as down feathers and staple fibers (the preferred material for the upper and lower zones), the intermediate core preferably receives a unitary or integrated body. Alternate embodiments of the invention also include, however, variations both as to type and characteristics of the filler material for the upper and lower pockets and the core received in the intermediate pocket. These include, for example, the use of a non-unitary, non-integrated filler in the intermediate zone as a core material like the above noted fiberfill filler (e.g. cluster of fiber-balls or conjugated or staple fibers) or mixtures of foam and filler. Again, however, in a preferred embodiment, a unitary or integrated core body is preferably used in the intermediate pocket or layer in conjunction with a non-unitary, separable material such as the aforementioned down and fiberfill fiber in the upper and lower pockets. Accessibility such as by way of a zipper can be altered for the three illustrated pocket zones so as to make for example, all pockets accessible, all non accessible or each possible variation relative to the three different pockets which depends, for example, on what material is received in the pockets (a sealed pocket is preferred for a non-unitary inserted material). 
   Examples of integrated core bodies include, for example, a fluid filled body such as an air cushion, or more viscous gel core cushion or a foam body. Preferably, core  76  is formed as a molded body of a compressible foam material such as a polyurethane foam, synthetic or natural foam rubbers, or combinations (e.g. laminated layers) of these materials, etc. Preferred foams include visco-elastic foam, “conventional” polyurethane foams and high-resiliency polyurethane foams. 
   Visco-elastic foam was originally developed in the early 1970&#39;s at NASA&#39;s Ames Research Center in an effort to relieve astronauts of the g-forces experienced during lift off and then later placed on the market for medical use, particularly in combating decubitus ulcers, by the Swedish company Fagerdala World Foams AB under the mark TEMPUR-PEDIC® foam. The medical pad products formed by Fagerdala World Foams AB are formed from visco-elastic foam described as being made by A/S Dan-Foam, 5560 Arup, Denmark under the trademark TEMPUR® foam. 
   Visco-elastic foam is also made by Carpenter Co. of Richmond, Va. under the trademark VISCOLUX® foam and CONFORM® foam. 
   Visco-elastic foam is a high density, visco-elastic, open-cell material. The open-cells are generally spherical with windows and are temperature and weight sensitive (becoming softer upon being heated such as by body heat). When a visco-elastic material is utilized as the core of the present invention, the preferred density range is 16 to 120 kg/m 3 , more preferably 16–95 kg/m 3 , with 30–60 kg/m 3  and 40–45 kg/m 3  being preferred sub-ranges. A hardness ranging from 25 to 90N at 25% compression at 20° C. represents a preferred hardness range with 30 to 40N being a preferred sub-range and 35N a preferred value therein. For pillows, a 25% compression value is most informative due to the typical compression force asserted by a user&#39;s head. It is also noted that a preferred hardness range of 10N to 60N is applicable at 65% compression at 20° C. The alternate “conventional” and “high resiliency” polyurethane foams also preferably have the above noted visco-elastic foam density and hardness ranges and values. Suitable “conventional” densified polyurethane foam includes OMALAN® and HYPERSOFT® foam products of Carpenter Co. and a suitable high-resiliency foam includes QUALATEX® foam of Carpenter Co. 
     FIGS. 6–10  of the present invention illustrate some preferred features for foam core  76  such as the above described visco-elastic and alternate polyurethane foam materials.  FIGS. 7–9  provide a schematic illustration of some preferred sizing characteristics, which are well suited for use in combination with the above and below described upper and lower pocket filler material embodiments.  FIG. 7  illustrates a preferred configuration for core  76  as a monolithic or integrated foam body having a smoothly curved domed or convex configuration both relative to the width W direction and across the length L direction, with the highest areas relative to both the upper and lower half sections (a preferred arrangement of the present invention features a common shape relative to a bisecting horizontal plane which is represented by the peripheral mold edging line M in  FIG. 6 ) being in the center of the pillow. A molding formation technique is a preferred method of production for the visco-elastic foam material and is suitable for other types of polyurethane foam. Core  76  can also be formed by other common core forming techniques such as contour cutting or convoluted roller, conveyor or impression die plate contouring techniques. 
     FIG. 6  illustrates the conforming nature of visco-elastic foam which assumes the contour of whatever object is compressed into the material and retains it while the compressive force is in effect and even for a brief time period following release of the compression as illustrated by hand print HA shown in the foam body in  FIG. 6  after removal of a compressing hand (now shown). This ability to directly conform to the contouring of a compressive body provides a high level of low pressure support as all points or essentially all points of possible contact find foam support. The fact that the foam material softens with body heat also means that the higher compression areas will tend to heat up the most, and correspondingly soften the most applicable pressure points. Visco-elastic foam is also described as being breathable. Despite this breathability, the direct conforming support, typically with only a cloth barrier between the user and foam body in the prior art, provides little chance for any convective or conductive heat flow external to the foam body, relying instead on the breathability of the foam itself to remove and dissipate the heat. 
   The present invention features, in a preferred embodiment, a filler material that is interposed, together with the covering or ticking between the compressing object (e.g., a head in the instance of a pillow), and the receiving core  76 . With the use of a filler material of the type and quantity described above and below (e.g. the relatively low thickness), the contouring benefit of the foam core can still be maintained to a favorable extent while the filler material also provides a degree of added breathability in the region with high comfort and favorable pressure level maintenance. This filler material is preferably a non-unitary, loose fill material contained within individual, sealing pockets. The preferred embodiment also features a non-planar (at least on one side) core body that allows for height variations in the overall pillow, while maintaining a relatively common outer pocket thickness. 
   A preferred embodiment of the invention preferably includes separate pockets for the core and filler material so as to provide for example, a first ticking layer, a filler material layer, and a second ticking or barrier layer relationship between the body contact surface and core surface on at least one side and preferably on both sides as illustrated. An external pillow case fabric covering is also preferably provided in use. Also, while a smooth, non-convoluted exposed core surface is shown in the preferred embodiment, the present invention also includes other embodiments (not shown) including convoluted surface cores from the standpoint of, for example, a patterned configuration (e.g. a smooth, wavy convoluted upper surface such as a valley/protrusion, checkerboard or egg-carton configuration) or more general convolution(s) such as forming an interior or edge valley or slot and/or a raised contour section for extension into a person&#39;s neck cavity, for example. 
     FIGS. 7–9  above show schematically the preferred pillow core outer surface outline for core  76 .  FIG. 9  provides a top plan view showing a preferred rounded corner rectangular configuration having elongated length L and width W.  FIG. 9  further illustrates the preferred rounded corners C for core  76 .  FIG. 7  illustrates a side elevational view of core  7  showing its length L and maximum height H and the preferred generally ellipsoidal outline for each.  FIGS. 7 and 8  illustrate the length and width of core  76  having a “stretched” ellipsoidal shape with an elongated intermediate region which shape is well suited as a comfortable core shape in the present invention.  FIG. 8  shows the width-wise outline for core  76  of width W and height H, and the stretched ellipsoidal configuration, but to a lesser extent than the elongated sides shown in  FIG. 7 .  FIGS. 7 and 8  illustrate curvature C 1  for the long side and curvature C 2  for the shorter width curvature of core  76  with each preferably falling from 10 to 50 degrees relative to the degree of curvature of the outer surface. The top surface and below surface width contour of the pillow preferably are equal in curvature as is preferably the top and bottom lengthwise curvature of the pillow. The above curvature range provides for the formation of both thin (e.g. 5.5 inch maximum core height) and thick (e.g. 6.5 inch maximum core height) pillows. A well suited sub-range for C 1  is 10 to 50° with 18.5° being well suited for a thin pillow and 32° well suited for a thick pillow. A range of 15 to 60° is well suited for C 2  with its value preferably being within 15° of C 1  (e.g. 42° for C 2  in a thick pillow and 24° for a thin pillow). 
   In a preferred embodiment, which is well suited for use with pocket filler features of the present invention (and is generally a universal adult size) and well suited for standard pillow case insertion without great difficulty, L=23.0 inches; W=16.0 inches and H=5.5 inches. A ±2 to ±7 inch deviation for L, a ±2 to ±5 inch deviation relative to W, and a ±1.25 inch deviation for H represent preferred size deviations for a typical adult pillow embodiment of the present invention. The cover&#39;s intermediate maximum pocket expansion is designed to closely conform to the core body received while still allowing for easy insertion and removal (e.g. a 0.5 to 2 inch clearance). A variety of consumer option sizes are also a feature of the present invention such as a 6 inch or “high loft” embodiment or a miniaturized (e.g. 10 inch wide travel version with equivalent ratio dimensioning) or an expansive length size of 30 inches are representative examples. 
     FIG. 10  illustrates, schematically, the preferred filler/core interrelationship (e.g., well dispersed loose down or polyester staple fiberfill material within pockets used with a unitary foam core). Preferably the filler thickness (e.g. an average thickness with a common thickness throughout within the pockets representing a preferred embodiment, as the preferred filler material types like those described above typically avoid clumping and are generally evenly dispersed throughout the pocket) of 12 to 25% for one pocket relative to height H is preferred, with 12 to 20% and 16 to 20% representing suitable sub-ranges and a ratio of 1:5.5 being well suited for many uses of the present invention (i.e. a 1 inch pocket thickness to a 5.5 inches maximum core height). 
   As can be seen from the figures, the preferred embodiments feature filler pockets that are on average of the same height, and conform to the core surface like the domed core described above, except for perhaps some minor compression along the upper and lower pocket joining edges. This peripheral compression in thickness is minimized to some extent however, when utilizing the preferred intermediate panel arrangement of the present invention such as the gusseted intermediate panel described above. A generally common pocket thickness across the surface of the pillow is preferred for consistent comfort as the size and contour manipulation of an integrated core body provides greater consistency in the final product in use as a thinner layer of the non-integrated filler material has less chance to migrate and/or clump to deviate from the preferred manufactured contact characteristics. Although less preferred, variations on this feature are contemplated under the present invention such as relying on the pocket volume characteristics to define a non-planar pillow surface (e.g. a greater or “overstuffing” of a pocket) to define a higher central area relative to, for example, a planar surface core). Alternatively, a contoured depression in the pillow case is filled with filler to form a thicker, non-integrated filler zone. 
     FIG. 10  also illustrates a continuous, encompassing layer which is an alternate embodiment of the above described embodiment featuring an intermediate gusset dividing zone.  FIG. 10  schematically represents an outer cover  82  which is core encompassing such as in the above described embodiment with an interior barrier  84  and end (preferably added) separators  86 ′ and  88 ′, which together define a multi-pocket embodiment as above (e.g. pockets  60 ′,  70 ′, and  74 ′), and can be formed with a dividing peripheral flange insert relative to the upper and lower layers defining each pocket which includes, for example, but less preferably, flanges directly fixed to the core. Within the outer pockets  60 ′ and  70 ′ is provided a filler material such as that described above and within the interior zone is core  76 ′ formed of material such as that described above. In an alternate embodiment, which is less preferred, particularly when using a visco-elastic core in view of its tackiness and from the standpoint of the potential for some preferred types of filler material to migrate or clump, the filler material is provided directly in contact with the core (i.e. without the inner pocket liner) but preferably with side and/or end separators secured to the core. Also, rather than direct top and bottom cover securement about their respective peripheries, an alternate embodiment of the invention features an intermediate side wall panel therebetween (vertically extending and planar rather than a more preferred gusset arrangement with or without access means). Under this latter embodiment, a pocketed arrangement like that described above is preferred, but the present invention also features a pocketless embodiment, preferably with the core extending into contact or close to contact (&lt;⅛ to ¼ inch spacing) relative to the surrounding intermediate panel to form at least to some extent, a free migration blocking relationship therebetween. The above described filler thickness ranges are applicable for these alternate embodiments relative to  FIG. 10  as well, and the invention includes the use of the same upper and lower thickness values as well as different upper and lower thickness values (e.g. the low end of the range of filler thickness and the upper end of the range to provide a degree of comfort choice options to the user). For the added sealing effect, however, the above described independent pocket configuration are preferred.  FIG. 10  also illustrates pillow dimension references  1  and E. 
     FIGS. 11 and 12  illustrate an alternate pillow  20 ′ embodiment of the present invention wherein a similar triple pocket ticking cover  22  as that described above for  FIG. 1  is utilized having upper and lower pockets  60  and  70 , intermediate core pocket  74  and intermediate gusset zone  34 . 
   Core  76 ′ is of a different construction than the above described core in having an inner core covering  84  which surrounds an interior core body  86  such as the above described visco-elastic high density polyurethane foam core. In a preferred embodiment, inner core covering  84  is a pocketless covering formed of a 75% cotton/25% polyester mix with a velour type texture, inner core covering (preferably the velour surface provided as the exterior cover surface). Inner core covering  84  preferably also has three non-openable side edges and a fourth side edge having access means such as zipper  88  (in similar fashion to the preferred pocketed covering  22  or running along an elongated side instead). The filler represented in  FIG. 12  is a polyester fiber based filler having the above described characteristics. 
     FIGS. 11 and 12  are also illustrative of the refurbishing potential of the present invention relative to a pre-existing pillow. That is, the multi-pocket cover can be used to upgrade pre-existing, earlier purchased pillows. Also, although the pocketed pillow cover of the present invention can be used for direct contact with the user, a pillow case is preferably placed over the pocketed cover  22 ′ (as is the case for the above described pillow embodiments) as protection from spoiling, for example.  FIG. 11  further illustrates the preferred corresponding dual zipper end arrangement relative to the pocketed cover, with each zipper being shown partially opened exposing the interior core body with core covering received in the intermediate pocket of ticking cover  22 . 
   While the above described disclosure is directed at preferred pillow embodiments of the present invention, various other pillows and non-pillow cushion and pad embodiments are also intended to be encompassed by the present invention as schematically illustrated in  FIG. 13 , for example. In  FIG. 13 , where is disclosed a core body or layer or planar pad  92  such as a solid body (e.g. foam body of polyurethane or foam core or a laminated or multi-section core arrangement with or without visco-elastic foam) on which is supported a filler material pocketed layer  94 . Boundary layer  98  is preferably defined by an interior layer of material such as the interior layer of a pocket covering which is preferably sealed about its periphery with a means to access at one end or side to define pocketed layer  94 . Pocketed layer  94  preferably has the filler material and thickness range values described above for the other embodiments such as a 1 to 2 inch thickness filler material layer of non-integrated filler material such as down of fiberfill preferably having similar thickness ratios as described above between the immediately supporting foam core and the filler material pocketed barrier. The pocketed layer is preferably designed to extend all the way around the supporting core body or layer  92 . A second similar or different filler material layer  100  is shown in dashed lines in  FIG. 13  to illustrate the option of providing a second filler material layer which, like the top, is preferably sealed in a second pocket with interior pocket layer  98 ′. With layer  100  present, it can be joined to the upper layer such as in the gusset arrangement described above to form an inner body pocket relative to body  92  or by direct pocket peripheral edge joining or by way of a non-gusseted intermediate independent peripheral panel. Thus, a planar pad  92 , for example, is covered with upper and lower pocketed filler filled layers with connected/shared peripheral edging keeping the body  92  encompassed. This pad/cushion can be used in a variety of settings such as a mattress pad (e.g., a futon pad, pet bed or sofa bed or topper mattress pad). Core body  92  can be varied to best suit the intended usage, such as a minimized height for the core and/or pockets for use as a mattress pad (e.g., a core of 2 to 3 inches thickness) to supplement a preexisting mattress or is made of higher thickness values like those described above for use as, for example, a futon or sofa bed mattress. Thickness ranges for the core pad will depend on use, with 1 to 12 inches being illustrative of a representative range with 2 to 6 inches illustrative of a preferred sub-range, and with a 1 to 2 inch down or fiber based filler pocket thickness being preferred. 
   While the invention has been described in detail with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made, and equivalents employed, without departing from the scope of the appended claims.