Patent Publication Number: US-11641959-B2

Title: Pillow with baffles and related methods

Description:
RELATED APPLICATION 
     This application is a continuation of application Ser. No. 16/697,628 filed on Nov. 27, 2019, which claims priority to prior filed Application No. 62/775,536 filed Dec. 5, 2018, the entire subject matter of these applications is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to the field of bedding accessories, and, more particularly, to a pillow and related methods. 
     BACKGROUND 
     The bedding industry is a large and well developed industry in the U.S. Indeed, the U.S. industry alone boasts annual revenue over $15 billion. Nevertheless, the industry has undergone rapid disruption in last decade with the advent of online stores for mattresses and other bedding products. 
     One of the most common bedding products is the pillow. The pillow is not a modern creation and dates back to Mesopotamia and ancient Egypt. Nevertheless, the pillow has changed dramatically in the modern age. For example, pillows were once filled with natural pillow inserts, such as down and other plant based materials. Now, the modern pillow may be filled with hypoallergenic polymer foams. 
     A common condition that affects a user&#39;s sleep pattern is sleep apnea. One of the common treatments for sleep apnea is use of a continuous positive airway pressure (CPAP) machine. The CPAP machine is a positive airway pressure ventilator, which applies mild air pressure on a continuous basis to keep the airways continuously open in people. Typically, the CPAP machine comprises a powered base, a mask to be worn by the user, and one or more tubes coupled between the powered base and the mask. 
     SUMMARY 
     Generally, a pillow may include a pillowcase having a first end, a second end opposing the first end, and first and second opposing sides extending between the first end and the second end. The pillowcase may include first and second end chambers respectively adjacent the first and second ends, and a medial chamber between the first and second end chambers, and a plurality of baffles extending between the first and second opposing sides and defining the first and second end chambers and the medial chamber. The pillow may comprise at least one pillow insert within the first and second end chambers, and the medial chamber. 
     The plurality of baffles may each comprise a baffle piece, and baffle stitching along longitudinal sides of the baffle piece for coupling to adjacent portions of the pillowcase. The pillowcase may further comprise a plurality of dart stitches extending from a periphery of the pillowcase inwardly. 
     In some embodiments, the at least one pillow insert may comprise a plurality thereof respectively within the first and second end chambers, and the medial chamber. Each of the first and second ends, and the second opposing side may include a curved recess. Also, the first opposing side may comprise a closable opening. For example, the at least one pillow insert may comprise a foam material or a fiber material. Also, the pillowcase may be dog-bone shaped. 
     Another aspect is directed to a method for making a pillow. The method may include forming a pillowcase having a first end, a second end opposing the first end, and first and second opposing sides extending between the first end and the second end. The pillowcase may include first and second end chambers respectively adjacent the first and second ends, and a medial chamber between the first and second end chambers, and a plurality of baffles extending between the first and second opposing sides and defining the first and second end chambers and the medial chamber. The method may comprise positioning at least one pillow insert within the first and second end chambers, and the medial chamber. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic diagram of an example embodiment of a pillow, according to the present invention. 
         FIG.  2    is a schematic diagram of a baffle from the pillow of  FIG.  1   . 
         FIG.  3    is a flowchart illustrating a method for making the pillow of  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which several embodiments of the invention are shown. This present disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art. Like numbers refer to like elements throughout. 
     Referring initially to  FIGS.  1 - 2   , a pillow  10  according to the present disclosure is now described. The pillow  10  illustratively includes a pillowcase  11  having a first end  12 , and a second end  13  opposing the first end. The pillow  10  illustratively includes first and second opposing sides  14 - 15  extending between the first end  12  and the second end  13 . The pillowcase  11  may comprise a natural fabric material, such as cotton, or wool, or an artificial fabric material, such as a woven polymer material. 
     The pillowcase  11  illustratively comprises first and second end chambers  16 - 17  respectively adjacent the first and second ends  12 - 13 , and a medial chamber  20  between the first and second end chambers. The pillowcase  11  also includes a plurality of baffles  21 - 22  extending between the first and second opposing sides  14 - 15  and defining barriers between the first and second end chambers  16 - 17  and the medial chamber  20 . 
     As perhaps best seen in  FIG.  2   , the plurality of baffles  21 - 22  each comprises a baffle piece  30 , and baffle stitching  31   a - 31   b  along longitudinal sides of the baffle piece for coupling to adjacent portions of the pillowcase  11 . The baffle stitching  31   a - 31   b  may comprise mesh fabric sewn into adjacent opposing major surfaces of the pillowcase  11 . Helpfully, this may aid in ventilation between the first and second end chambers  16 - 17 , and the medial chamber  20 . 
     In the illustrated embodiment, the baffle piece  30  extends completely between the first and second opposing sides  14 - 15  of the pillowcase  11 . In other embodiments, the baffle piece  30  extends partially between the first and second opposing sides  14 - 15  of the pillowcase  11 , defining gaps adjacent the first and second opposing sides  14 - 15  of the pillowcase  11 . In other words, the gaps would flank the baffle piece  30 , but in other embodiments, the baffle piece  30  defines a plurality of spaced apart slots or gaps therein. 
     In some embodiments, the pillow  10  also includes a pillow insert  23   b  only within the medial chamber  20 . In the illustrated embodiment, the pillow  10  also additionally includes respective pillow inserts  23   a ,  23   c  for each of the first and second end chambers  16 - 17  (i.e. all three chambers  16 - 17 ,  20  receive a pillow insert). Each of the pillow inserts  23   a - 23   c  may comprise a polymer foam insert, or a fiber material insert (e.g. synthetic or natural). In some embodiments, each of the pillow inserts  23   a - 23   c  may comprise a blown fill material, for example, a synthetic fiber fill material. 
     Each of the first and second ends  12 - 13 , and the second opposing side  15  includes a curved recess  26   a - 26   c . Also, the first opposing side  14  illustratively comprises a closable opening  25  extending across all three chambers  16 - 17 ,  20 . For example, the closable opening  25  may comprise a zipper, a plurality of buttons and respective opposing slits, or a hook and loop fastener. The closable opening  25  is configured to permit access to the first and second end chambers  16 - 17 , and the medial chamber  20 . In some embodiments, the pillowcase  11  may comprise individual closable openings for each of the first and second end chambers  16 - 17 , and the medial chamber  20 . In other embodiments (single pillow insert embodiments), the pillowcase  11  may comprise a single zipper permitting access to only the medial chamber  20 . 
     In the illustrated example, the pillowcase  11  is dog-bone shaped. In particular, the first opposing side  14  is straight. The first end  12  comprises first and second lateral protrusions  27   a ,  27   d  with the curved recess  26   a  therebetween. The second end  13  also comprises first and second lateral protrusions  27   b ,  27   c  with the curved recess  26   b  therebetween. In the illustrated embodiment, each of the bottom lateral protrusions  27   c - 27   d  is substantially circular in shape. Each of the top lateral protrusions  27   a - 27   b  comprises a first portion extending directly from the first opposing side  14  at a canted angle of approximately 10° (i.e. ±7°), a second portion extending directly from the first portion and having a curved edge, and a third portion extending directly from the second portion and being substantially straight (i.e. ±7° of straight plumb). The third portion merges into a medial curved edge for defining the curved recesses  26   a - 26   b . Advantageously, this shape is conducive to the use of a CPAP machine. 
     Also, the pillowcase  11  illustratively comprises a plurality of dart stitches  24   a - 24   m  extending from a periphery of the pillowcase inwardly. In particular, each of the plurality of dart stitches  24   a - 24   m  extends inwardly at a substantially perpendicular angle (i.e. 90°±10°) from the peripheral edge, and a linear length of substantially 10% (i.e. ±5%) of the length between the first and second opposing sides  14 - 15 . The plurality of dart stitches  24   a - 24   m  are helpful in maintaining the position of the pillow inserts  23   a - 23   c.    
     Referring now additionally to  FIG.  3   , another aspect directed to a method for making the pillow  10  is now described with reference to a flowchart  60 . The method includes forming a pillowcase  11  having a first end  12 , a second end  13  opposing the first end, and first and second opposing sides  14 - 15  extending between the first end and the second end. (Blocks  61 ,  63 ). The pillowcase  11  also includes first and second end chambers  16 - 17  respectively adjacent the first and second ends  12 - 13 , a medial chamber  20  between the first and second end chambers, and a plurality of baffles  21 - 22  extending between the first and second opposing sides  14 - 15  and defining the first and second end chambers and the medial chamber. The method also comprises positioning at least one pillow insert  23   a - 23   c  within the medial chamber  20 . (Blocks  65 ,  67 ). 
     Many modifications and other embodiments of the present disclosure will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the present disclosure is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.