Patent Publication Number: US-7222379-B2

Title: Pillow kit with removable interior cores

Description:
TECHNICAL FIELD 
     This invention relates generally to the field of pillow construction, and more specifically concerns a pillow having interior chambers. 
     BACKGROUND OF THE INVENTION 
     Generally, pillows have a “permanent” construction, i.e. most pillows are not configured or arranged to accommodate a change in fill or interior arrangement after manufacture. Such pillows thus have a fixed support characteristic, from soft to firm, although in some cases, they have other support features or characteristics which are intended to address particular concerns or desires of various users. 
     However, there are some pillows which have a construction which permits change in support. One such pillow, shown in U.S. Pat. No. 6,415,466 to Laiso, includes pockets on the outside of the pillow to receive different inserts which change to an extent the support characteristics of the pillow. There are also other pillows, such as shown in U.S. Pat. No. 5,953,777 to Buck, which show pillow inserts which change the pillow characteristics. Those pillows, however, do not provide a reliable, convenient “adjustable” support capability. It would be desirable to have a pillow which is capable of being adjusted with different inserts or filling to provide different support characteristics. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention is a pillow kit, comprising: a cover assembly which includes substantially identical top and bottom portions, the top and bottom portions including spaced longitudinal sides and end sides, wherein the top and bottom portions are secured around the peripheries thereof except for one side, means for selectively opening and closing said one side; at least one chamber section located interiorly of the cover assembly; filling located interiorly of the cover assembly; and at least one core member, constructed to be insertable into and removable from the chamber section, for selectively changing the support characteristics of the pillow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a perspective view of the assembled pillow kit of the present invention, from one end thereof. 
         FIG. 2  shows an exploded view of the pillow of  FIG. 1 . 
         FIG. 3  shows a perspective view of an insert member of the pillow kit of the present invention. 
     
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
       FIGS. 1 ,  2  and  3  show the pillow kit of the present invention, providing an adjustable support capability. Pillow kit  10  includes identical top and bottom layer assemblies  12  and  14 , the top layer assembly including an outer layer portion  18  and an inner layer portion  20 . The bottom layer assembly includes an outer layer portion  22  and an inner layer portion  24 . In this embodiment, inner layer portions  20  and  24  are polyester material or similar slick fabric, while outer layer portions  18  and  22  are cotton. This could, however, be changed to other materials, although a slick fabric for the inner layer portions is generally advantageous. 
     Extending between inner layer portions  20  and  24  are two baffle walls  30  and  32 , defining three internal chambers, which, in the embodiment shown, extend for the full length of the pillow, although the baffle walls can, alternatively, extend for less than the full length of the pillow, if so desired. 
     In the embodiment shown, baffle walls  30 ,  32  are identical, are approximately 5 inches high, and are made from polyester or other slick material, although they could be cotton or other fabric as well. For a pillow 20 inches wide and 26 inches long, as shown, baffle walls  30 ,  32  are positioned 6.75 inches from the longitudinal edges  34 ,  36  of the pillow, leaving a separation of 6.5 inches between the two baffle walls. This spacing, however, can be altered to define different size chambers. 
     In the embodiment shown, the two baffle walls  30 ,  32  define chambers  40 ,  42  and  44 . The chambers are adapted to receive core inserts  46  shown in  FIG. 3 . Filling material, such as natural fill (feathers and down)  48  or polyester foam fill material, is inserted in the chambers  42 ,  44  and  46  along with the inserts  46 , between the inserts and the inner layers  20  and  24  and the baffle walls  30  and  32 . Fill can be also positioned between the outer and inner layer portions of the top and/or bottom layer assemblies. In some cases, fill will be positioned only between the outer and inner layer portions and not in one or more of the chambers. 
     To complete the pillow, the top and bottom layer assemblies  12  and  14  are secured around their longitudinal edges  34 ,  36  and one end  52 , with the remaining end  54  being closable and openable by a closing member  56 , which when open reveals the interior chambers  40 ,  42  and  44 . Appropriate core inserts  46  may be inserted and removed, depending upon the desires of the user. 
     The number of chambers can be varied, as well as their respective sizes, by varying the number and location of the baffle members. Each chamber is adapted to receive a core insert  46 , shown in  FIG. 3 . In the embodiment shown, the core insert  46  is an elongated soft cylinder, approximately 3-5 inches in diameter, 26 inches long and includes a cover  62  which may be filled with various filling materials, including polyester or natural fillings, such as feathers, down or foam. Furthermore, the pillow kit can include a plurality of such inserts, with various fillings, to enable a change in the support characteristics of the pillow. The inserts may also have various fill weights, i.e. various densities and may vary in size. The core inserts  46  are typically configured to fill a significant portion of their receiving chamber volumes, while being easy to insert and remove. 
     As indicated above, the top and bottom layer assemblies  12  and  14  are secured together, such as by stitching along the two longitudinal edges  34  and  36  and one end  52 . The other end  54  has a closing member  56 , such as a zipper, or Velcro® members, or similar member. In use, closing member  56  is first opened, revealing an open end of the receiving chambers. One or more core inserts are then positioned in one or more (typically all) of the chambers to provide a desired support characteristic. The closing member  56  is then closed, resulting in a pillow having a particular support characteristic. A significant advantage of the disclosed structure is that the support characteristic of the pillow can be changed by removing an existing core insert and replacing it with another with a different characteristic, e.g. a different size or kind of fill or fill weight. Further, one or more of the receiving chambers can remain without an insert, with just filling  48  in the chamber. 
     Accordingly, a pillow kit has been disclosed which provides an adjustable support capability. This is accomplished by a pillow with a plurality of interior chambers, which are accessible for insertion and removal of core inserts, each of which typically includes a core cover and interior filling. 
     Although a preferred embodiment of the invention has been disclosed for purposes of illustration, it should be understood that various changes, modifications and substitutions may be incorporated in the embodiment without departing from the spirit of the invention which is defined by the claims which follow.