Molded hybrid pillow

Abstract

A hybrid pillow includes a cushioning material defining a recess. A coil spring panel is positioned within the recess of the cushioning material, where the coil spring panel is formed from a plurality of coil springs, an upper fabric layer, and a lower fabric layer. The upper fabric layer and the lower fabric layer are bonded between the plurality of coil springs and along a peripheral edge of the first coil spring panel. A gel layer is also positioned within the recess of the cushioning material and over the coil spring panel. A method of manufacturing a pillow includes dispensing a liquid gel in a mold, positioning a coil spring panel in the mold and on top of the liquid gel, dispensing a foam precursor in the mold, and foaming the foam precursor to form a cushioning material secured to the coil spring panel.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application Serial No. 63 / 214,503, filed June 24, 2021, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This invention relates to a hybrid pillow. In particular, this invention relates to a molded hybrid pillow comprising a spiral spring panel and a gel layer embedded within a foam comfort layer. Background Technology

[0004] The effectiveness and desirability of support padding depend in part on the user's comfort with it over an extended period. In this respect, many users find support padding, particularly mattresses made of flexible foam, desirable. However, during the lifespan of body support padding (such as mattresses and pillows), the flexible foam may lose its height and firmness. This loss of durability then leads to a decline in the comfort of the body support padding.

[0005] Naturally, it is desirable to maintain the elasticity and comfort of body support pads for as long as possible, and there is a continuous expectation to improve the durability, comfort, and elasticity of these products. Therefore, it would be highly desirable and beneficial for body support pads to allow for such improvements in durability, comfort, and elasticity, and to allow these characteristics to be maintained over extended periods of time. Summary of the Invention

[0006] The present invention includes hybrid body support pads, such as hybrid pillows. In some embodiments, the hybrid pillow includes various layers including one or more helical spring panels and a gel layer encapsulating the helical spring panels between a gel and foam, wherein the one or more helical spring panels are integrally formed into a foam pad structure.

[0007] In some embodiments of the invention, an exemplary body support pad in the form of a pillow includes a padding material defining a recess. A helical spring panel and a gel layer, which together form an array of gel-molded springs, are positioned within the recess.

[0008] In some embodiments, the recess defined in the upper surface of the padding material is typically rectangular, but it is conceivable that the recess can be formed of various peripheral shapes and have various depths depending on the shape and size of the helical spring panel and the gel layer (i.e., the gel-molded spring array).

[0009] In some embodiments, the coil spring panel is formed of a plurality of coil springs arranged in an array or matrix of rows and / or columns. An upper first fabric layer is disposed above the upper end of each coil spring, and a lower second fabric layer is disposed below the lower end of each coil spring. The first and second fabric layers are bonded (e.g., welded) between the coil springs to form a coil spring pocket. The ends of the coil springs may be in direct contact with the fabric layers, or alternatively, a piece of material such as padding or loose fabric may be disposed between the coil springs and the fabric layers. This intermediate material can prevent the coil springs from passing through or otherwise tearing the fabric layers.

[0010] In some embodiments, the fabric layers are designed to minimize or completely prevent the gel layer from penetrating, creeping, or otherwise contacting the helical spring. For this purpose, in some embodiments, the first and second fabric layers are hydrophobic, waterproof, or the like.

[0011] In some embodiments, the gel layer is a substantially uniform layer of elastomeric gel material that can provide a cooling effect by acting as a thermal dump or radiator, into which heat from the user’s body or parts positioned on the pillow can be dissipated.

[0012] In some embodiments, the gel layer may have a substantially smooth outer surface, but the surface shape and texture of the gel may be determined by the corresponding surface of the mold in which the gel is poured. Furthermore, the density of the gel may vary along the surface of the pillow. The outer edges or periphery of the gel may be regular or irregular in shape, and the thickness and / or density of the gel layer may vary. For example, the gel may be thicker in the center than in the area towards the periphery.

[0013] In some embodiments, the pillow includes two or more helical spring panels and / or two or more gel-molded spring arrays. For example, multiple gel-molded spring arrays may be positioned across the upper surface of the padding material, or the pillow may include a first gel-molded spring array on the upper surface and a second gel-molded spring array on the lower surface.

[0014] According to some exemplary embodiments of the present invention, a mold is provided and a liquid gel is dispensed into the mold. After the liquid gel is dispensed into the mold, a helical spring panel is positioned on top of the gel in the mold. After the helical spring panel and the gel are positioned into the mold, a liquid foam precursor is dispensed into the mold and the liquid precursor is foamed to form a cushioning material.

[0015] According to some other embodiments, instead of forming the gel layer in the same mold as the padding material, the gel layer can be applied to the padding material after it has been formed separately. The helical spring panel can still be provided in the mold before the foam precursor is provided, allowing the helical spring panel to be integrated into the padding material. Alternatively, both the helical spring panel and the gel layer can be applied to the padding material after their formation.

[0016] Other features and advantages of the invention will become apparent to those skilled in the art after studying the description, drawings, and non-limiting examples in this document. Attached Figure Description

[0017] Figure 1 This is a perspective view of an exemplary hybrid pillow manufactured according to the present invention;

[0018] Figure 2 yes Figure 1 An exploded perspective view of a hybrid pillow;

[0019] Figure 3 yes Figure 2 An exploded perspective view of the helical spring panel shown;

[0020] Figure 3A yes Figure 2 The cross-sectional details of the helical spring panel are shown.

[0021] Figure 3B yes Figure 2 A schematic layer view of the helical spring pattern on the helical spring panel shown.

[0022] Figure 4 This is an exploded perspective view of another exemplary hybrid pillow manufactured according to the present invention;

[0023] Figure 5 This is a flowchart depicting an example method for forming a molded hybrid pillow;

[0024] Figure 6 This is a schematic layer view of another exemplary helical spring pattern used in a helical spring panel;

[0025] Figure 7 This is a top view of an exemplary fabric layer used in a coil spring panel, the fabric layer defining a plurality of holes in a first pattern; and

[0026] Figure 8 This is a top view of another exemplary fabric layer used in a helical spring panel, which defines a plurality of holes within a central welded portion. Detailed Implementation

[0027] This invention includes hybrid body support padding, such as hybrid pillows. In some embodiments, the hybrid pillow includes various layers including one or more helical spring panels integrally formed into a foam padding structure and a gel layer encapsulating the helical spring panels between a gel and foam. The use of one or more helical spring panels allows for adjustment by modifying various characteristics according to the user's expectations. For non-limiting examples, some users may want a thin pillow, while others may want a thick pillow. Furthermore, some users may prefer a firmer feel, while others may prefer a softer feel.

[0028] First refer to Figure 1 A perspective view of an exemplary body support pad 10 is provided, and for the purposes of this teaching and ease of reference, the body support pad 10 is also referred to as a pillow or hybrid pillow. However, the body support pad manufactured according to the present invention can be embodied in various structures that support one or more parts of the end user's body. As a non-limiting example, the term body support padding can include a wide variety of types of support, including bedding and / or padding for chairs and furniture, pillows, padding for medical equipment and gear (e.g., wheelchair seat cushions, wheelchair pads, medical pads, hospital wheelchair mattresses, operating table pads, positioning pads), padding for furniture (e.g., decorative pads, furniture padding, furniture mats), padding for sports equipment and gear (e.g., sports padding, sports and athletic mats, fitness mats), padding for recreational equipment and gear (e.g., camping and sleeping mats), padding for clothing (e.g., bra straps, shoulder pads, shoe linings, boot linings), padding for household items (e.g., anti-fatigue mats, mattress pads, mattress covers, mattress "top pads", pillow tops, pillow tops, pillows, etc.); padding accessories (e.g., briefcase shoulder straps, computer carrying cases, wallets, gloves, etc.), pet beds, etc. Therefore, any and all of these types of structures can fall within the scope of the terms pillow or body support padding, which are used interchangeably.

[0029] Still referencing Figure 1 The exemplary hybrid pillow 10 has a generally rectangular outer peripheral shape, having an arched upper surface 14 and an arched lower surface 16, which are joined by an arched curve at or around the outer peripheral edge 18 of the pillow 10. In the exemplary pillow, the height or distance between the upper surface 14 and the lower surface 16 of the pillow 10 is between approximately 2 inches and 10 inches. In some other embodiments, the height is between approximately three inches and five inches. However, it should be understood that this range is not exhaustive, and other sizes may also be utilized.

[0030] The exemplary pillow may be arcuate in one or two longitudinal (long) and lateral (short) dimensions. Similarly, the exemplary pillow may have a generally flat upper and / or lower surface joined by straight or arcuate curves at or around the outer peripheral edge of the pillow, or alternatively, the upper and / or lower surface may be fully arcuate. As used herein, "outer peripheral edge" may refer to one or more edges defining the shape of the pillow. The exemplary pillow may also have various shapes other than the rectangular shape shown, and therefore, the shape should not be considered limiting.

[0031] Now for reference Figure 2 The exemplary pillow 10 includes padding material 30. As previously described, the exemplary pillow 10 has a generally rectangular outer peripheral shape and has an actuated upper surface 14 and a lower surface 16. Therefore, as... Figure 2 As shown, the exemplary padding material 30 has a rectangular peripheral shape with a curved lower surface 34 and a curved upper surface 35. The upper surface 35 of the padding material 30 also defines a recess 36 that receives a helical spring panel 40 and a gel layer 50, which together form a gel-molded spring array 52, as will be further described below. Of course, depending on the use of the body support padding, the padding material of the present invention can be any number of various shapes. For example, in other embodiments, the upper and lower surfaces of the padding material can be planar and / or can include surfaces with ribs, bumps, and other protrusions of any shape and size, having grooves, recesses, and other holes extending partially, almost completely, or entirely through the padding material.

[0032] Regarding the padding material 30, in the exemplary pillow 10, the padding material 30 is made of viscoelastic foam (sometimes referred to as "memory foam" or "low-resilience foam"). However, in other embodiments, without departing from the spirit and scope of the invention, the padding material may be formed of a variety of materials, including but not limited to latex foam or mesh non-viscoelastic foam.

[0033] In various embodiments, the padding material can be formed from a variety of foams, and the following overview is non-exhaustive. For example, open-cell or non-reticulated viscoelastic foams can be used. In some embodiments, temperature-responsive foams can be used. Temperature responsiveness within the range of a user's body temperature (or the range of temperatures to which the pillow 10 is exposed by contact with or proximity to a user's body resting on it) can provide significant advantages. As used herein and in the appended claims, a material is considered "responsive" to temperature changes if it exhibits a change in stiffness of at least 10% as measured by International Organization for Standardization (ISO) Standard 3386 within a temperature range between 10 and 30 degrees Celsius. In other embodiments, it may be desirable for the foam to be substantially insensitive to temperature. As used herein, a material is considered "substantially insensitive" to temperature changes if it exhibits a change in stiffness of less than 10% as measured by ISO Standard 3386 within a temperature range between 10 and 30 degrees Celsius. In some embodiments, flexible polyurethane foams can be used, and in some embodiments, reticulated foams can be used.

[0034] The padding material of pillow 10 may consist of any of the various flexible foams described above, capable of distributing pressure from the user's body or a portion thereof across pillow 10 or more generally across body support padding 10. In some illustrative embodiments, the density of the flexible foam used is typically sufficient to support the user's neck and shoulders. Such flexible foams may include, but are not limited to, latex foam, mesh or non-mesh viscoelastic foam (sometimes referred to as memory foam or low-resilience foam), mesh or non-mesh non-viscoelastic foam (sometimes referred to as "conventional" foam), polyurethane high-resilience foam, expanded polymer foam (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), or any combination thereof.

[0035] The exemplary padding material 30 is a viscoelastic foam with low elasticity and sufficient density and stiffness, which allows pressure to be absorbed uniformly and distributed evenly across the padding material 30 of the pillow 10. Typically, such flexible foams have a stiffness of at least about 10 N to no more than about 80 N, as measured by applying pressure from a board to a sample of the material at about room temperature (i.e., 21°C to 23°C) to compress at least 40% of the original thickness of the material, wherein the 40% compression is maintained for a set time period, as established by the International Organization for Standardization (ISO) 2439 standard for the measurement of stiffness. In some examples, the body support padding or pillow 10 may utilize a foam composed of viscoelastic foam having a stiffness of about 70 kg / m³. 3 Approximately 110 kg / m 3The density and hardness are from about 25N to about 50N. In some embodiments, the viscoelastic foam may have a hardness of about 10N, about 20N, about 30N, about 40N, about 50N, about 60N, about 70N, or about 80N to provide a desired level of comfort and body fit.

[0036] The viscoelastic foam of the exemplary padding material 30 used for the pillow 10 may also have a density that helps provide a desired level of comfort and body fit, as well as increases the degree of material durability. In some embodiments, the density of the viscoelastic foam used may have a density of not less than about 30 kg / m³. 3 Up to approximately 150 kg / m 3 The density. In some embodiments, the density of the viscoelastic foam used in the pillow 10 may be approximately 30 kg / m³. 3 Approximately 40kg / m 3 Approximately 50kg / m 3 Approximately 60kg / m 3 Approximately 70kg / m 3 Approximately 80kg / m 3 Approximately 90 kg / m 3 Approximately 100 kg / m 3 Approximately 110 kg / m 3 Approximately 120 kg / m 3 Approximately 130 kg / m 3 Approximately 140 kg / m 3 or approximately 150 kg / m 3 Of course, choosing a viscoelastic foam with a specific density will affect other properties of the foam, including its hardness, how the foam responds to pressure, and the overall feel of the foam. However, it should be understood that viscoelastic foams with the desired density and hardness can be easily selected for specific applications as needed.

[0037] The exemplary recess 36 defined in the upper surface 35 of the padding material 30 is typically rectangular; however, it is contemplated that the recess 36 may be formed of various peripheral shapes and have various depths, for example, determined by the shape and size of the helical spring panel 40 and the gel layer 50 (i.e., the gel-molded spring array 52). The recess 36 may be formed in various ways depending on the method of forming the body support padding 10. For example, see below for reference. Figure 5In the exemplary embodiments discussed, the padding material 30 is made of foam, the liquid gel and the helical spring panel are placed in a mold (e.g., in the form of a separately molded sheet comprising the helical spring and the gel), and a foam precursor is applied such that foaming occurs around the helical spring panel 40 and the gel. Thus, in such embodiments, once the liquid gel solidifies into the gel layer 50 and the foam precursor solidifies, the resulting padding material 30 shifts around the helical spring panel 40 and the gel layer 50 during the foaming process to define the recess 36. Alternatively, in some embodiments, the helical spring / gel sheet can be formed together in a separate mold and, once cured, can be placed in another mold in which the liquid precursor of the padding material surrounds to form an exemplary pillow. In other embodiments and as another alternative, if the padding material is formed independently, the recess can also be formed therein or cut out after the padding material is formed.

[0038] Turning now to the coil spring panel 40, which is disposed within the recess 36 of the padding material 30 and forms part of the gel-molded spring array 52, and now referring to Figures 3 to 3A An exemplary helical spring panel 40 is formed of a plurality of helical springs 44 arranged in an array or matrix of rows and / or columns. An upper first fabric layer 46 is disposed above the upper end of each helical spring 44, and a lower second fabric layer 47 is disposed below the lower end of each helical spring 44. The first fabric layer 46 and the second fabric layer 47 are bonded between the helical springs 44, for example, by welding, to form a helical spring pocket. The ends of the helical springs 44 may be in direct contact with the fabric layers 46, 47, or alternatively, a piece of material (such as padding or sparse fabric) may be disposed between the helical springs 44 and the fabric layers 46, 47. This intermediate material may prevent the helical springs 44 from passing through or otherwise tearing the fabric layers 46, 47. The first fabric layer 46 and the second fabric layer 47 are also bonded, for example, by welding, along their outer peripheral edges 49 to define the helical spring panel 40. In addition, the two fabric layers 46 and 47 can be two different fabric pieces, or in some embodiments, they can be a single fabric piece folded onto the spring and joined at the open end. Figure 3A The space between the helical springs 44 illustrates the weld between the first fabric layer 46 and the second fabric layer 47 and is not intended to be limiting. For example, in some embodiments, the weld joining the first fabric layer 46 and the second fabric layer 47 can have a width of about 3 mm to about 5 mm. Similarly, the size of the helical spring bag formed by the first fabric layer 46 and the second fabric layer 47 can vary based on the size of the helical spring contained therein.

[0039] The first fabric layer 46 and the second fabric layer 47 can be made of various materials. Non-limiting examples of materials include nonwoven fabrics, warp-knitted fabrics, nylon, rayon, polyester, spacer fabrics, etc. However, this list is not exhaustive. As an example, when using nonwoven fabrics, it may be desirable that the nonwoven fabric be free of various defects, including but not limited to scratches, blemishes, holes, and / or waste. Additionally, in some such cases, where nonwoven fabrics are available, the nonwoven fabric may have a density between approximately 40 g / m³. 2 and approximately 80g / m 2 The weight between them. In other cases, the first fabric layer 46 and the second fabric layer 47 can be made of different materials. For example, the first fabric layer 46 can be a mesh fabric (e.g., having about 70 g / m²). 2 (weight), while the second fabric layer 47 can be a nonwoven fabric as described above.

[0040] As mentioned above and as Figure 2 As shown, the gel layer 50 is disposed adjacent to the helical spring panel 40. Therefore, in some embodiments, it may be desirable that the fabric of at least the first fabric layer 46 minimizes or completely prevents the gel layer 50 from penetrating, creeping, or otherwise contacting the helical spring 44. More specifically, such fabric can minimize or prevent gel penetration, creep, or other contact between the spring windings, which could cause the springs to stick and / or reduce their functionality. For this purpose, in some embodiments, the first fabric layer 46 and the second fabric layer 47 are hydrophobic fabrics, waterproof fabrics, etc.

[0041] In some embodiments, the materials of the first and second fabric layers can restrict air permeability, making it difficult for air to escape when the coil spring panel 40 is compressed. Similarly, when the compressive force on the pillow is released, the expansion of the coil spring panel 40 may occur slowly due to the slow pulling of air through the first fabric layer 46 and the second fabric layer 47. In some other embodiments, the materials of the first and second fabric layers may be airtight, with breathable portions located at specific locations. Airflow into and out of the fabric layers 46, 47 and the coil spring panel 40 can also be controlled by controlling the size, number, and / or location of the breathable portions.

[0042] For example, and now refer to Figures 7 to 8 According to some exemplary embodiments, the coil spring panel may define a plurality of airflow holes to vary the amount of airflow through the coil spring and the panel. More specifically, in some embodiments, the first fabric layer and / or the second fabric layer may have varying pore densities to improve airflow through each panel. Figure 7In this example, an exemplary first fabric layer 446, arranged above a plurality of helical springs 444, defines a plurality of holes 448 per square inch. Of course, modifying the hole size and density in the first and / or second fabric layers will regulate the airflow through the helical spring panels.

[0043] Figure 8 Another exemplary first fabric layer 546 with an alternative hole pattern is shown. In this illustrated embodiment, in addition to welding the first fabric layer 546 to a second fabric layer (not shown) between the coil springs 544, the first fabric layer 546 is also welded to the second fabric layer in the central portion of the coil springs 544 to form a central welded portion 547 within each coil spring 544. Figure 8 As shown, holes 548 are then defined within these center weld portions 547 to allow airflow. As a non-limiting example, the center weld portion 547 has a diameter of approximately 21 mm to approximately 25 mm, and the hole 548 has a diameter of approximately 9 mm to approximately 10 mm. Although Figures 7 to 8 The above description relates to the first fabric layer, but it should be understood that the second fabric layer may also include holes in place of the first fabric layer in one or more of the first and second helical spring panels of the present invention, or in addition to the first fabric layer in one or more of the first and second helical spring panels of the present invention.

[0044] Back to Figure 3 and Figure 3AHowever, focus now is on the plurality of coil springs 44 of the coil spring panel 40, the number of coil springs per square foot of the exemplary coil spring panel 40 ranging from about 14 to about 250. The coil springs 44 can have various sizes and numbers within the coil spring panel 40. In some non-limiting embodiments, for example, the diameter of the coil springs can be up to about 3 inches, and the compression height can be up to about 3 inches. The springs can have an unloaded height and can also have a loaded height that is shorter than the unloaded fully relaxed height. As a non-limiting example, miniature coil springs with an unloaded or uncoiled height of about 20 mm to about 26 mm and a loaded or compressed height of about 18 mm to about 20 mm can be used. Alternatively, as a second non-limiting example, larger coil springs with an unloaded or uncoiled height of about 90 mm to about 110 mm and a loaded or compressed height of about 27.5 mm to about 32.5 mm can be used. In some cases, coil springs can be constructed from 17.5 gauge wire (e.g., wire with a diameter of approximately 1.25 mm) or 19.5 gauge wire. Coil springs can have a consistent wire size (diameter), or the wire size can vary across the coil spring. In some cases, the coil spring can be constructed by rotating approximately three and three-quarters (positive or negative quarter turns) times. When constructed, each end of the wire forming the coil spring can be inside the coil spring structure. Coil springs can be of various shapes, such as barrel, cylindrical, or hourglass. The pitch and diameter can be symmetrical or asymmetrical, allowing the coil spring to have a linear or non-linear response when compressed. However, other sizes, shapes, and variations can be utilized. For example, a coil spring can be a coil spring within a coil spring design, where the diameters of one or both coil springs can vary, such as a conical design. Further combinations of coil spring types can be utilized.

[0045] The coil spring 44 can be loaded by joining and bonding the first fabric layer 46 and the second fabric layer 47. Specifically, the coil spring 44 can be preloaded to about 0.1 psi to about 0.8 psi. The spring constant of the coil spring 44 can also be varied. That is, the coil spring 44 can have a spring constant of about 0.2 psi to about 3.0 psi. Moreover, the spring constant can be the same or the same range across the entire surface of the pillow 10, or alternatively, it can vary in range or depending on the location.

[0046] The spring constant of the helical spring 44 can also be varied. That is, the helical spring 44 can have a spring constant of about 0.2 psi to about 3.0 psi. Moreover, the spring constant can be the same or the same range across the entire helical spring panel 40, or alternatively, it can vary across a range or vary depending on the location.

[0047] As previously described, the coil spring 44 can have an unloaded height and can also have a loaded height shorter than the fully relaxed unloaded height. The spring 44 can be loaded by the joining and binding of two fabrics 46, 47. This initial loading of the spring can provide initial support and / or a push-back force to the spring 44.

[0048] Now for reference Figure 3B In the exemplary helical spring panel 40, the helical springs 44 are arranged in rows in direction Ax and in columns in direction Ay. However, now referring to... Figure 6 In another exemplary coil spring panel 340, although multiple coil springs 344 are still arranged in a row in the direction Ax, the coil springs 344 are not like... Figure 3B As in the previous embodiment, the columns are aligned in direction Ay. Instead, they are offset by a distance O every other row. Other patterns of the helical springs have also been considered based on the design characteristics and considerations of the body support pad.

[0049] Although Figure 2 The exemplary pillow 10 shown includes only a single helical spring panel 40 as part of a gel-molded spring array 52; however, it should be understood that the gel-molded spring array 52 may include two or more helical spring panels. Similarly, multiple gel-molded spring arrays may be positioned across the upper surface of the padding material. The number and location of the gel-molded spring arrays and / or helical spring panels may depend on the size of the body support pad or other design characteristics and considerations.

[0050] Now let's go back again Figure 2 As previously described, a gel layer 50 is disposed above the helical spring panel 40. More specifically, the exemplary gel layer 50 extends outward beyond the outermost helical spring 44 of the helical spring panel 40, but when the helical spring panel 40 and the gel layer 50 are adjacent to each other, the first fabric 46 and the second fabric 47 of the helical spring panel 40 extend outward beyond the gel layer 50. However, in other embodiments, when the helical spring panel 40 and the gel layer 50 are adjacent to each other, the gel layer 50 may extend outward beyond the first fabric 46 and the second fabric 47. Furthermore, although only one gel layer 50 is shown, it is conceivable that in other embodiments, a second gel layer may also be disposed on the lower surface of the padding material.

[0051] The gel layer 50 included in the pillow 10 can typically be composed of a substantially uniform layer of elastomeric gel-like material capable of providing a cooling effect by acting as a heat collector or radiator, into which heat from the user's body or parts thereof located on the pillow 10 can be dissipated. For example, in some embodiments, the gel layer 50 can be composed of a polyurethane-based gel, which is combined with... LU 1046 polyols LP 5613 isocyanate and thermoplastic polyurethane film or talc are used, each of which is manufactured and sold by Dow Chemical Company Corp. (Midland, Michigan), and these components can be combined to produce a gel insert having a thermal conductivity of 0.1776 W / m*K and a thickness of 0.1184 mm². 2 The thermal diffusivity is 1.503 MJ / (m³K), and the volumetric specific heat is 1.503 MJ / (m³K), as established by the International Organization for Standardization (ISO) 22007-2 standard for the measurement of volumetric specific heat. However, it is also conceivable that, according to embodiments of the invention, many other types of gels capable of absorbing a certain amount of heat and providing a cooling effect can be used, and they can be produced with the desired thermal conductivity, thermal diffusivity, and volumetric specific heat without departing from the spirit and scope of the subject matter described herein.

[0052] In some embodiments, the gel layer 50 may have a substantially smooth outer surface, but the surface shape and texture of the gel may be determined by the corresponding surface of the mold in which the gel is poured. Furthermore, the density of the gel may also vary along the surface of the pillow. The outer peripheral edges or periphery of the gel may be a regular shape or may be irregular, as will be understood after the discussion of exemplary methods for forming the body support liner of the present invention. Additionally, the thickness and / or density of the gel may also vary. For example, the gel thickness may be greater in the center compared to the area towards the periphery of the gel.

[0053] In the exemplary pillow 10, the outer surface of the gel layer 50 is substantially flush with the upper surface 35 of the padding material 30, such that the outer surface of the gel layer 50 and the upper surface 35 of the padding material 30 together form the upper surface 14 of the body support padding 10. The outer surface of the gel layer 50 can be formed into a shape that is substantially symmetrical to the opposite side (i.e., the lower surface 16) of the pillow 10, even if the materials defining the sides are different. However, as previously mentioned, other shapes can be utilized.

[0054] However, according to some other embodiments, the gel layer may be surrounded by the padding material in an uneven manner. For example, the gel layer may be embedded or recessed within the surrounding padding material, or the gel layer may extend partially or entirely outward beyond the upper surface of the padding material. For example, the outer surface of the gel may define one or more features, such as ribs or bumps, extending beyond another generally flat upper surface of the pillow. Similarly, instead of being positioned merely within a recess adjacent to the coil spring panel, additional gel may be disposed within a divot of the foam.

[0055] Regarding the density and firmness of pillow 10 further, as mentioned above, the density of gel layer 50 is generally different from the density of padding material 30. Figure 2 In the exemplary pillow 10 shown, the padding material 30 (e.g., viscoelastic foam) has a density sufficient to support the user's neck and shoulders, but the gel layer 50 has a greater density suitable for supporting the user's head. More specifically, the exemplary padding material is composed of viscoelastic foam with a density of approximately 40 kg / m³. 3 Approximately 80 kg / m 3 The density and hardness are approximately 25 N to approximately 50 N, while the exemplary gel layer 50 is composed of a very soft polyurethane gel having a density of approximately 800 kg / m³. 3 Approximately 1200 kg / m 3 It has a density and a hardness of approximately 25-50 Shore A. Of course, the specific density and other support properties of both the padding material and the gel can vary depending on the design characteristics of the support pad.

[0056] In some embodiments, one or more of the padding material 30, the helical spring panel 40, and the gel layer 50 may be individually or collectively covered with a mesh material (not shown). The mesh material can be any textile in which yarns or fibers fuse, loop, or knot at their intersections, resulting in a fabric with open spaces between the yarns or fibers. Its properties can vary in durability depending on the type of yarn or filament used to constitute the textile. The mesh material can be formed by single-knit plain knit, double-knit plain knit, or double-rib knit, and can be made of fire-resistant or non-fire-resistant textiles, and can have a porosity of about 50 to about 850 CFM. As a non-limiting example, fire-resistant textiles may include fire-resistant rayon, modified acrylics, Kevlar, Nomax, etc. As a non-limiting example, non-fire-resistant textiles may include untreated polyester, rayon, or cotton.

[0057] Still referencing Figure 2The cover 60 is also disposed around the padding material 30 and the gel-molded spring array 52. ​​In the exemplary pillow 10, the cover 60 is made of fabric, but in other embodiments, a variety of materials may be used, including but not limited to cotton, cotton blends, moisture-wicking fabrics such as 100% polyester fabric, rayon, nylon or spandex blends to improve performance and tensile strength, or any mixture of the foregoing materials. This list is not exhaustive, and other materials may be used. The cover 20 fabric may be quilted and / or may include various designs, including but not limited to labels for the “hard” or “soft” side. The cover 60 also defines the outer perimeter of the pillow 10, and thus the shapes of the various layers located within the cover 20, together with the outer peripheral edges of the cover 20, define the shape of the pillow 10. In some embodiments, the cover 60 may also include a phase change material to enhance the cooling sensation to the user. If desired, it is conceivable that a pillowcase, typically formed of thin fabric, may be placed on the cover 20. The exemplary cover 20 closes around the outer peripheral edge 18 and includes a closure 62 to access the interior of the pillow 10, or alternatively, to remove the internal contents for cleaning the cover 60 when needed. The closure 62 may extend along one or more sides of the pillow 10 to facilitate the placement of layers therein. The closure 62 may be of various types, including but not limited to zippers, buttons, snaps, hook-and-loop fasteners, etc.

[0058] Now for reference Figure 4 The second exemplary body support pad 110 manufactured according to the present invention similarly includes an array of gel-molded springs 152 on the upper surface 135 of the padding materials 130a, 130b, but also includes a second array of gel-molded springs 152 on the lower surface 134 of the padding materials 130a, 130b.

[0059] Each gel-molded spring array 152 includes the above reference. Figure 2 The described gel-molded spring array 52 is substantially identical to the helical spring panel 140 and gel layer 150. Specifically, each helical spring panel 140 includes a plurality of helical springs or springs 144 encapsulated in a first fabric layer 146 and a second fabric layer 147, substantially the same as those referenced above. Figure 2 and Figure 3 The described coil spring panel 40 is the same. Figure 4 In the illustrated embodiment, the helical spring panel 140 on the upper surface 135 of the padding material 130 and the helical spring panel 140 on the lower surface 134 of the padding material 130 may have the same characteristics or may have different characteristics to provide different tactile sensations on both sides of the body support padding 110.

[0060] Each of the gel layers 150 included in the pillow 110 is composed of a substantially uniform layer of elastomeric gel material that can provide a cooling effect by acting as a heat collector or radiator, into which heat from the user's body or parts thereof, located on the pillow 110, can be dissipated.

[0061] The spiral spring panel 140 and the gel layer 150 are also in accordance with the above reference. Figure 2 The essentially same manner described is similarly applied in padding materials 130a and 130b. For example... Figure 4 As shown, the padding materials 130a and 130b are formed from an upper foam member 130a and a lower foam member 130b, which are placed together to form the padding materials 130a and 130b. However, according to other embodiments, similar double-sided pillows can be formed from a single padding material.

[0062] Now for reference Figure 5 An exemplary method of manufacturing a hybrid pillow according to the present invention begins with a mold, the shape and size of which may vary, but in some embodiments may have a generally similar shape. Figure 2 The peripheral shape of the body support pad 10 is shown. For example, the mold can be a rectangle with curved upper and lower halves, which defines... Figure 1 and Figure 4 The exemplary pillows 10 and 110 are shown in a crown shape. However, any shape and design of the aforementioned support pad can be formed in a single mold or tool. As described below, the mold can be formed from a first half and a second half.

[0063] According to an exemplary embodiment, in the first step 210, a liquid gel is dispensed into the mold. The amount of gel can vary depending on the size and / or depth of the mold and the specific design of the final molded hybrid pillow. As discussed further below, according to some other exemplary embodiments, a solid gel, instead of a liquid gel, may also be provided in the mold.

[0064] After the liquid gel is dispensed into the mold, in step 220, a helical spring panel is positioned in the mold on top of the gel. The resulting configuration produces a gel layer molded on one side of the helical spring panel to form a gel-molded spring array, similar to the gel-molded spring arrays 52, 152 described above. While the liquid gel and the helical spring panel can be applied to the mold separately, in other embodiments, the gel layer and the helical spring panel can be applied to the mold as a combined structure. That is, according to some exemplary embodiments of the invention, the gel layer can be molded separately and then positioned in the mold before or after it is applied to the helical spring panel. In this case, the gel layer can be formed on a backing and then the backing can be removed for placement.

[0065] According to some embodiments, the exemplary pillow contains two or more helical spring panels, for example, as referenced above. Figure 4 As illustrated in the exemplary pillow 110. Therefore, in such embodiments, the method may include the additional step of placing additional helical spring panels and / or gel layers within the mold. For example, in a mold that folds closed on both sides, gel (liquid or solid) and helical spring panels may be provided on each of the two sides before the mold is closed. Similarly, additional gel layers and helical spring panels may be provided in a second portion of the mold to provide a support liner in which a plurality of gel-molded spring arrays are present.

[0066] After positioning the helical spring panel and gel layer into the mold, in step 230, a liquid foam precursor is dispensed into the mold. Then, in step 240, the mold can be closed and the liquid precursor foamed to form a padding material. In other words, the molded form is arranged on the gel-molded spring array in the opposite direction to the gel layer. According to an exemplary embodiment, this foaming step 240 attaches the helical spring panel and gel layer to the resulting padding material. Specifically, it is envisioned that during foaming step 240, the gel layer and the molded foam are fixed to each other around the periphery of the helical spring panel. In this way, the molded foam of the padding material at least partially encloses the gel-molded spring array, wherein the helical spring panel is completely enclosed between the gel layer and the molded foam of the padding material. In embodiments where the liquid gel is provided in the mold, the gel may solidify before or during the foaming of the liquid precursor. In any case, once the foaming step is complete, the mold can be opened and the body support padding removed.

[0067] Depending on the embodiment in which the gel is initially provided as a liquid, the density of the resulting gel layer can vary across the resulting support liner. In some embodiments, as the liquid gel is poured into a mold and settles toward the bottom of the mold, the liquid gel can have a thicker depth at its center and a thinner depth near the outer peripheral edges. Therefore, an exemplary pillow made with the liquid gel can have a smaller final gel layer toward the pillow edges and a larger final gel layer in the crown region of the pillow. Similarly, due to the settling of the liquid gel, in some embodiments, the resulting gel layer can have an irregular shape.

[0068] In other embodiments, instead of forming the gel layer in the same mold as the padding material to allow for variations in gel layer density across the pillow, the gel layer can be applied to the padding material after it has been formed separately. The helical spring panel can still be provided in the mold before the foam precursor is provided, allowing the helical spring panel to be integrated into the padding material. Alternatively, both the helical spring panel and the gel layer can be applied to the padding material after their formation.

[0069] Each of the exemplary pillows described above may further include additives such as copper to improve properties relative to moisture content and inhibit mold growth. Other additives may be provided to improve flame retardancy or the odor of the foam, such as carbon or charcoal additives for filtration. Other additives may also be included, such as graphite, aluminum, silver, charcoal, gels, etc., to obtain various benefits known in the art. Further additions to the exemplary pillows may provide far-infrared radiation for restoring properties. Furthermore, one or more layers of the pillow may be coated with nano-biomimetic materials or phase change materials (PCMs) to enhance the cooling sensation to the user. These phase change materials (PCMs) may be coatings, including but not limited to commercially available organic, inorganic, solid, and biological materials. Additionally, one or more layers may also include biocides, preservatives, odor inhibitors, fragrances, pigments, dyes, anti-stain agents, antistatic agents, anti-fouling agents, waterproofing agents, hygroscopic agents, etc., as known in the art.

[0070] Those skilled in the art will recognize that additional embodiments are possible without departing from the teachings of the invention or the scope of the appended claims. This detailed description, particularly the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding and should not be construed as limiting unnecessarily, as modifications will become apparent to those skilled in the art upon reading this disclosure and can be made without departing from the spirit or scope of the claimed invention.

Claims

1. A hybrid pillow, comprising: A padding material, wherein the padding material defines a recess; A first helical spring panel is positioned within a recess in the padding material. The first helical spring panel is formed of a plurality of helical springs, an upper fabric layer, and a lower fabric layer, the upper fabric layer and the lower fabric layer being joined between the plurality of helical springs and along the outer peripheral edge of the first helical spring panel. as well as A gel layer, positioned within the recess of the padding material and above the first helical spring panel. The gel layer is molded on one side of the first helical spring panel to form a gel-molded spring array. The padding material includes molded foam, which is disposed on the gel-molded spring array opposite to the gel layer, and The molded foam and the gel layer are fixed to each other around the periphery of the first helical spring panel.

2. The hybrid pillow according to claim 1, wherein, The molded foam of the padding material at least partially encloses the array of gel-molded springs.

3. The hybrid pillow according to claim 1, wherein, The gel layer extends from the recess in the padding material.

4. The hybrid pillow according to claim 1, wherein, The first helical spring panel is completely enclosed between the gel layer and the molded foam of the padding material.

5. The hybrid pillow according to claim 1, wherein, The first side of the hybrid pillow has a first tactile feel, and the second side of the hybrid pillow has a second tactile feel that is different from the first tactile feel.

6. The hybrid pillow according to claim 1, wherein, The gel-molded spring array defines a first surface of the hybrid pillow, and the molded foam defines a second surface of the hybrid pillow. The first surface of the hybrid pillow has a first tactile feel, and the second surface of the hybrid pillow has a second tactile feel, which is different from the first tactile feel.

7. The hybrid pillow according to claim 1, wherein, The upper and lower fabric layers are formed of nonwoven or hydrophobic materials.

8. The hybrid pillow according to claim 1, further comprising: The second helical spring panel is positioned in a second recess of the padding material opposite to the first helical spring panel. The second helical spring panel is formed by a second plurality of helical springs, a second upper fabric layer and a second lower fabric layer. The second upper fabric layer and the second lower fabric layer are joined between the second plurality of helical springs and along the outer peripheral edge of the second helical spring panel. as well as The second gel layer is positioned within the second recess of the padding material and above the second helical spring panel.

9. A method for manufacturing a hybrid pillow, the method comprising the following steps: Dispense the liquid gel into the mold; A helical spring panel is positioned in the mold and on top of the liquid gel. The helical spring panel is formed of a plurality of helical springs, an upper fabric layer and a lower fabric layer, the upper fabric layer and the lower fabric layer being joined between the plurality of helical springs and along the outer peripheral edge of the helical spring panel. Dispense the foam precursor into the mold; as well as The foam precursor is foamed to form a padding material, which is then attached to the helical spring panel. The liquid gel solidifies into a gel layer located on the helical spring panel.

10. The method according to claim 9, wherein, The padding material and the gel layer are fixed to each other around the periphery of the helical spring panel.

11. The method according to claim 9, wherein, The helical spring panel is completely enclosed between the gel layer and the padding material.

12. The method according to claim 9, wherein, The liquid gel solidifies during the step of foaming the foam precursor.

13. The method according to claim 9, wherein, The liquid gel solidifies prior to the step of foaming the foam precursor, thereby forming a gel-molded spring array before the foam precursor is dispensed into the mold.

14. A molded hybrid pillow, comprising: A padding material, wherein the padding material defines a recess; A helical spring panel, the helical spring panel being positioned within the recess of the padding material, the helical spring panel being formed of a plurality of helical springs, an upper fabric layer and a lower fabric layer, the upper fabric layer and the lower fabric layer being joined between the plurality of helical springs and along the outer peripheral edge of the helical spring panel; as well as A gel layer, positioned within the recess of the padding material and above the helical spring panel. The gel layer is molded on one side of the helical spring panel to form a gel-molded spring array. The padding material includes molded foam, which is disposed on the gel-molded spring array opposite to the gel layer. The molded foam and the gel layer are fixed to each other around the periphery of the helical spring panel, and Wherein, at least one of the upper and lower fabric layers prevents contact between the gel layer and the winding of the plurality of helical springs.

15. The molded hybrid pillow according to claim 14, wherein, Each of the plurality of springs has an encapsulation height of less than three inches and a diameter of less than two inches.

16. The molded hybrid pillow according to claim 14, wherein, The gel layer extends outward beyond the outermost row of the plurality of springs.

17. The molded hybrid pillow according to claim 14, wherein, The upper fabric layer and the lower fabric layer extend outward beyond the gel layer.

18. The molded hybrid pillow according to claim 14, wherein, The upper and lower fabrics are formed of nonwoven or hydrophobic materials.

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