Hybrid pillow

Abstract

The hybrid pillow includes a cushioning material defining a recess. A coil panel is disposed within the recess of the cushioning material and is formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer. The upper and lower fabric layers are bonded between the plurality of coil springs and along an outer periphery of the first coil panel. Additionally, a gel layer is disposed within the recess of the cushioning material and over the coil panel. A method of making the pillow includes dispensing a liquid gel into a mold, placing a coil panel in the mold on top of the liquid gel, dispensing a foam precursor into the mold, and foaming the foam precursor to form a cushioning material secured to the coil panel.

Description

[Technical field]

[0001] [Related Applications] This application claims priority to U.S. Provisional Patent Application No. 63 / 214,503, filed June 24, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to a hybrid pillow, and more particularly to a molded hybrid pillow that includes a coil panel and a gel layer embedded within a foam comfort layer. [Background technology]

[0003] The effectiveness and desirability of a support cushion is, in part, a function of how comfortable a user is on the support cushion over time. In this regard, many users find support cushions, especially mattresses, made from flexible foams to be desirable. However, over the life of a body support cushion, such as a mattress or pillow, flexible foams can lose height and firmness. And the reduced durability of the support cushion can result in a decrease in the comfort of the body support cushion.

[0004] Of course, it is desirable for the responsiveness and comfort of the body support cushion to be maintained for as long as possible, and there is a continuing desire to improve the durability, comfort, and responsiveness of these products. Thus, a body support cushion that allows for such improvements in durability, comfort, and responsiveness, and that allows such characteristics to be maintained over an extended period of time, would be highly desirable and beneficial. Summary of the Invention

[0005] The present invention includes hybrid body support cushions, such as hybrid pillows, in some embodiments, the hybrid pillows comprise various layers including one or more coil panels integrally formed into a foam cushion structure with a gel layer that encases the coil panels between the gel and foam.

[0006] In some embodiments of the present invention, an exemplary body support cushion in the form of a pillow includes a cushioning material defining a recess. A coil panel and a gel layer, which collectively form a gel molded spring array, are disposed within the recess.

[0007] In some embodiments, the recess defined in the upper surface of the cushioning material is generally rectangular, however, it is contemplated that the recess may be formed with various perimeter shapes and have various depths depending on the shape and size of the coil panel and gel layer (i.e., the gel molded spring array).

[0008] In some embodiments, the coil panel is formed of a plurality of coil springs deployed in an array or matrix of rows and / or columns. An upper first fabric layer is disposed over an upper end of each coil spring, and a lower second fabric layer is disposed under a lower end of each coil spring. The first and second fabric layers are bonded, e.g., welded, between the coil springs, thereby forming coil pockets. The ends of the coil springs may be in direct contact with the fabric layer, or alternatively, a piece of material, such as a cushion or scrim, may be disposed between the coil springs and the fabric layer. Such intermediate material may prevent the coil springs from protruding or otherwise tearing the fabric layer.

[0009] In some embodiments, the fabric layer can minimize or completely prevent the gel layer from penetrating, submerging, or otherwise contacting the coil spring, and thus in some embodiments the first and second fabric layers can be hydrophobic fabrics, waterproof fabrics, etc.

[0010] In some embodiments, the gel layer is a substantially uniform layer of elastomeric gel-like material that can provide a cooling effect by acting as a heat radiator or heat sink through which heat from the user's body or portions thereof located on the pillow can be dissipated.

[0011] In some embodiments, the gel layer may have an outer surface that is substantially smooth, although the surface shape and texture of the gel may be determined to correspond to the surface of the mold into which the gel is poured. Additionally, the gel may also vary in consistency along the surface of the pillow. The outer edge or perimeter of the gel may be of a regular or irregular shape, and the gel layer may vary in thickness and / or consistency. For example, the thickness of the gel may be greater in the center compared to the area toward the perimeter of the gel.

[0012] In some embodiments, the pillow includes two or more coil panels and / or two or more gel molded spring arrays. For example, there may be multiple gel molded spring arrays disposed across the upper surface of the cushioning, 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.

[0013] 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 coil panel is placed on top of the gel in the mold. After placing the coil panel and gel in the mold, a liquid foam precursor is dispensed into the mold and the liquid precursor is foamed to form the cushioning material.

[0014] According to some other embodiments, rather than forming the gel layer in the same mold as the cushioning, the gel layer may be applied to the cushioning after the gel layer is separately formed. The coil panel may still be provided to the mold prior to providing the foam precursor such that the coil panel is integral with the cushioning. Alternatively, both the coil panel and the gel layer may be applied to the cushioning after it has been formed.

[0015] Further features and advantages of the present invention will become apparent to those skilled in the art after consideration of the description, drawings, and non-limiting examples herein. [Brief description of the drawings]

[0016] [Figure 1] 1 is a perspective view of an exemplary hybrid pillow made in accordance with the present invention; FIG.

[0017] [Diagram 2] FIG. 2 is an exploded perspective view of the hybrid pillow of FIG. 1.

[0018] [Diagram 3] FIG. 3 is an exploded perspective view of the coil panel shown in FIG. 2.

[0019] [Figure 3A] FIG. 3 is a detailed cross-sectional view of the coil panel shown in FIG. 2.

[0020] [Figure 3B] FIG. 3 is a schematic layer diagram of the coil pattern of the coil panel shown in FIG. 2.

[0021] [Figure 4] FIG. 2 is an exploded perspective view of another exemplary hybrid pillow made in accordance with the present invention.

[0022] [Diagram 5] 1 is a flow chart depicting an exemplary method of forming a molded hybrid pillow.

[0023] [Figure 6] FIG. 13 is a schematic layer diagram of another exemplary coil pattern used in a coil panel.

[0024] [Figure 7] FIG. 2 is a top view of an example fabric layer used in a coil panel defining a first pattern of openings.

[0025] [Figure 8] FIG. 13 is a top view of another exemplary fabric layer used in a coil panel defining openings in a plurality of center welds. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] The present invention includes hybrid body support cushions, such as hybrid pillows. In some embodiments, the hybrid pillows include one or more coil panels integrally formed with a foam cushion structure, and include various layers, including a gel layer that encases the coil panels between the gel and the foam. The use of one or more coil panels allows for tuning to adjust various properties to the needs of the user. As a non-limiting example, some users may want a thin pillow, while others may want a thicker pillow. Still further, some users may prefer a firmer feel, while others may prefer a softer feel.

[0027] 1, a perspective view of an exemplary body support cushion 10 is provided, which for purposes of immediate instruction and ease of reference may also be referred to as a pillow or hybrid pillow. However, body support cushions made in accordance with the present invention may be embodied in a variety of configurations that support one or more portions of an end user's body. The term body support cushion can include various types of supports including, by way of non-limiting example, bedding and / or cushions for chairs and furniture, pillows, padding for medical devices and instruments (e.g., wheelchair seat pads, wheelchair pads, medical pads, hospital gurney pads, operating table pads, positioning pads), padding for furniture (e.g., upholstery pads, furniture cushions, furniture pads), padding for athletic equipment and devices (e.g., athletic cushions, sports and athletic pads, gymnastics mats), padding for recreational equipment and devices (e.g., camping and sleeping mats), padding for apparel (e.g., bra straps, shoulder pads, shoe soles, boot soles), padding for household items (e.g., anti-fatigue mats, mattress pads, mattress covers, mattress "toppers" that are the pillow top portion of a pillow top mattress, pillows, etc.), padding accessories (e.g., shoulder straps for briefcases, computer carry cases, wallets, gloves, etc.), pet beds, etc. Thus, any of these types of structures and others can fall within the scope of the term pillow or body support cushion and are used interchangeably.

[0028] Still referring to FIG. 1, the exemplary hybrid pillow 10 has a generally rectangular perimeter shape with an arcuate upper surface 14 and an acicular lower surface 16 that are joined by an arcuate curvature at or around the perimeter 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 about 2-10 inches. In some other embodiments, the height is about 3-5 inches. However, it should be understood that this range is not exhaustive and other sizes may be utilized.

[0029] The exemplary pillow may be arcuate in one or both of the longitudinal (long) and transverse (short) dimensions. Similarly, the exemplary pillow may have generally flat upper and / or lower surfaces joined by straight or arcuate curvatures at or around the perimeter of the pillow, or alternatively the upper and / or lower surfaces may be generally arcuate. As used herein, a "perimeter edge" may be one or more edges that define the shape of the pillow. The exemplary pillow may also have a variety of shapes other than the rectangular shape shown, and thus the shape should not be considered limiting.

[0030] 2, the exemplary pillow 10 includes a cushioning material 30. As previously mentioned, the exemplary pillow 10 has a generally rectangular perimeter shape with acicular upper and lower surfaces 14, 16. Thus, as shown in FIG. 2, the exemplary cushioning material 30 has a rectangular perimeter shape with a curved lower surface 34 and a curved upper surface 35. The upper surface 35 of the cushioning material 30 also defines a recess 36 that receives the coil panel 40 and gel layer 50 that collectively form a gel molded spring array 52, which will be described further below. Of course, the cushioning material of the present invention may have any number of different shapes depending on the application of the body support cushion. For example, in other embodiments, the upper and lower surfaces of the cushioning material may be planar and / or may have surfaces with ribs, protrusions, and other protrusions of any shape and size, grooves, indentations, and other openings that extend partially, nearly completely, or entirely through the cushioning material.

[0031] With regard to the cushioning 30, in the exemplary pillow 10, the cushioning 30 is made of a viscoelastic foam (sometimes called "memory foam" or "memory foam"). However, in other embodiments, the cushioning may be made of a variety of materials without departing from the spirit and scope of the present invention, including, but not limited to, latex foam or reticulated non-viscoelastic foam.

[0032] The cushioning may be formed of a variety of foams throughout the various embodiments, and the following summary is non-exhaustive. For example, open-cell or non-reticulated viscoelastic foams may be used. In some embodiments, temperature-responsive foams may be used. Temperature responsiveness over the range of a user's body temperature (or the range of temperatures to which the pillow 10 is exposed by contact or proximity to a user's body resting thereon) may provide important advantages. As used herein and in the appended claims, a material is considered "responsive" to temperature changes if it exhibits at least a 10% hardness change as measured by International Organization for Standardization (ISO) Standard 3386 through a temperature range of 10°C to 30°C. In other embodiments, it may be desirable for the foam to be substantially insensitive to temperature. As used herein, a material is "substantially insensitive" to temperature changes if it exhibits less than a 10% hardness change as measured by International Organization for Standardization (ISO) Standard 3386 through a temperature range of 10°C to 30°C. In some embodiments, flexible polyurethane foams may be used, and in some embodiments, reticulated foams may be utilized.

[0033] The cushioning of the pillow 10 may be comprised of any of the various mentioned flexible foams capable of distributing pressure from the user's body or portions thereof across the pillow 10, or more generally the body support cushion 10. In some exemplary embodiments, the density of the flexible foam used is generally sufficient to support the neck and shoulders of the user. Such flexible foams may include, but are not limited to, latex foams, reticulated or non-reticulated viscoelastic foams (sometimes referred to as memory foams or memory foams), reticulated or non-reticulated non-viscoelastic foams (sometimes referred to as "conventional" foams), polyurethane high resilience foams, expanded polymer foams (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like, or any combination thereof.

[0034] Exemplary cushioning 30 is a viscoelastic foam having sufficient density and hardness as well as memory resilience to allow pressure to be absorbed uniformly and distributed evenly across the cushioning 30 of the pillow 10. Generally, such viscoelastic foams have a hardness of at least 10N and no more than 80N at about room temperature (e.g., 21°C to 23°C) as measured by exerting a pressure of at least 40% compression of the material's initial thickness from a plate on a sample of the material, where the 40% compression is held for a set time period established by the International Organization for Standardization (ISO) 2439 hardness measurement standard. In some embodiments, the body support cushion or pillow 10 has a hardness of about 70 kg / m 3 ~Approx. 110kg / m 3 A foam may be utilized that is comprised of a viscoelastic foam having a density of about 10 N, about 20 N, about 30 N, about 40 N, about 50 N, about 60 N, about 70 N, or about 80 N to provide the desired comfort and conforming qualities.

[0035] The viscoelastic foam used in the exemplary cushioning 30 of the pillow 10 may also have a density that assists in providing a desired degree of comfort, conforming qualities, as well as an increased degree of material durability. In some embodiments, the viscoelastic foam has a density of about 30 kg / m 3 Above, about 150kg / m 3 In some embodiments, the density of the viscoelastic foam used in the pillow 10 may be about 30 kg / m 3 , about 40kg / m 3 , about 50kg / m 3 , about 60kg / m 3 , about 70kg / m 3 , about 80kg / m 3 , about 90kg / m 3 , about 100kg / m 3 , about 110kg / m 3 , about 120kg / m 3 , about 130kg / m 3 , about 140kg / m 3 , or about 150 kg / m 3 Of course, the selection of a viscoelastic foam having a particular density will affect other properties including the foam's firmness, how the foam responds to pressure, and the overall feel of the foam, but it will be recognized that a viscoelastic foam having a desired density and firmness can be readily selected for a particular application as desired.

[0036] Although the exemplary recess 36 defined in the upper surface 35 of the cushioning material 30 is generally rectangular, it is contemplated that the recess 36 may be formed in various perimeter shapes and have various depths determined, for example, according to the shape and size of the coil 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 cushion 10. For example, in an exemplary embodiment described below with reference to FIG. 5, the cushioning material 30 is made of foam, and the liquid gel and the coil panel are placed in a mold (e.g., in the form of a separately molded sheet including the coil and gel), and a foam precursor is applied such that foaming occurs around the coil panel 40 and the gel. Thus, in such an embodiment, once the liquid gel is set on the gel layer 50 and the foam precursor is set, the resulting cushioning material 30 is displaced around the coil panel 40 and the gel layer 50 during the foaming process to define the recess 36. Alternatively, in some embodiments, the coil / gel sheet may be formed together in a separate mold and, when cured, placed in another mold around which is a liquid precursor of the cushioning material to form the exemplary pillow. As a further embodiment and another alternative, if the cushioning material is formed separately, recesses may also be formed therein or cut after the cushioning material is formed.

[0037] Turning now to the coil panel 40, which is disposed within the recess 36 of the cushioning material 30 and forms part of the gel molded spring array 52, and referring to FIGS. 3-3A, the exemplary coil panel 40 is formed of a plurality of coil springs 44 laid out in an array or matrix of rows and / or columns. An upper first fabric layer 46 is disposed over the upper ends of each coil spring 44, and a lower second fabric layer 47 is disposed under the lower ends of each coil spring 44. The first and second fabric layers 46, 47 are joined, e.g., welded, between the coil springs 44, thereby forming coil pockets. The ends of the coil springs 44 may be in direct contact with the fabric layers 46, 47, or alternatively, a piece of material, such as a cushion or scrim, may be disposed between the coil springs 44 and the fabric layers 46, 47. Such intermediate material may prevent the coil springs 44 from protruding or otherwise tearing the fabric layers 46, 47. The first and second fabric layers 46, 47 are additionally joined, e.g., welded, along the outer periphery 49 of the first and second fabric layers 46, 47 to define the coil panel 40. Additionally, the two fabric layers 46, 47 may be two separate pieces of fabric, or in other embodiments, a single piece of fabric that is folded over the spring and joined at the open end. The space between the coil springs 44 shown in FIG. 3A is illustrative of the weld between the first and second fabric layers 46, 47 and is not intended to be limiting. For example, in some embodiments, the welded joint of the first and second fabric layers 46, 47 may have a width of about 3 mm to about 5 mm. Similarly, the size of the coil pocket formed by the first and second fabric layers 46, 47 may vary based on the size of the coil spring to be housed therein.

[0038] The first and second fabric layers 46, 47 may be made of a variety of materials. Non-limiting examples of materials include nonwovens, warp knits, nylon, rayon, polyester, spacer fabrics, and the like. However, this list is non-exhaustive. As an example, if a nonwoven is used, it may be desirable for the nonwoven to be free of various defects, including, but not limited to, shavings, scabs, holes, and / or scraps. Additionally, in some such examples where a nonwoven may be used, the weight of the nonwoven may be less than about 40 g / m2. 2 ~about 80g / m 2 In other embodiments, the first and second fabric layers 46, 47 may be made of different materials. For example, the first fabric layer 46 may be a spunlace mesh fabric (e.g., about 70 g / m 2 ) and the second fabric layer 47 may be a nonwoven fabric as previously described.

[0039] As discussed above and shown in FIG. 2, the gel layer 50 is disposed adjacent to the coil panel 40. As such, in some embodiments, it may be desirable for the fabric of at least the first fabric layer 46 to be capable of minimizing or entirely preventing the gel layer 50 from penetrating, wicking, or otherwise contacting the coil springs 44. More specifically, such fabric may minimize or prevent the gel from penetrating, wicking, or otherwise contacting the coil springs 44 during winding of the springs, which may bind the springs and / or reduce their functionality. To this end, the first and second fabric layers 46, 47, in some embodiments, are hydrophobic fabrics, waterproof compatible fabrics, or the like.

[0040] In some embodiments, the material of the first and second fabric layers may be limited in air permeability so that air does not easily escape when the coil panel 40 is compressed. Similarly, when the compression force of the pillow is released, expansion of the coil panel 40 may occur slowly due to the slow drawing of air through the first and second fabric layers 46, 47. In some embodiments, the material of the first and second fabric layers may be air impermeable with air permeable portions located at specific locations. By controlling the size, number, and / or location of the air permeable locations, the flow of air into and out of the fabric layers 46, 47 and the coil panel 40 may also be controlled.

[0041] For example, referring now to Figures 7-8, according to some exemplary embodiments, the coil panel may define a number of air flow openings that vary the amount of air flow through the coils and the panel. More specifically, in some embodiments, the first and / or second fabric layers may have varying densities of openings to improve air flow through the respective panels. In Figure 7, an exemplary first fabric layer 446 disposed over a plurality of coil springs 444 defines a number of openings 448 per square inch. Modifying the size and density of the openings in the first and / or second fabric layers will of course adjust the air flow through the coil panel.

[0042] FIG. 8 illustrates another exemplary first fabric layer 546 having an alternative pattern of openings. In this illustrated embodiment, in addition to welding the first fabric layer 546 to the second fabric layer (not shown) between the coil springs 544, the first fabric layer 546 is additionally welded to the second fabric layer at the center portions of the coil springs 544 to form central welds 547 within each coil spring 544. As shown in FIG. 8, openings 548 are defined within these central welds 547 to allow air flow. As a non-limiting example, the diameter of the central welds 547 is about 21 mm to about 25 mm, and the diameter of the openings 548 is about 9 mm to about 10 mm. While the above description of FIGS. 7-8 is directed to the first fabric layer, it should be understood that the second fabric layer may similarly include openings within one or more of the first and second coil panels of the present invention instead of or in addition to the first fabric layer.

[0043] Returning again to FIGS. 3 and 3A, but now focusing on the plurality of coil springs 44 of the coil panel 40, the number of coils per square foot of the exemplary coil panel 40 can range from about 14 to about 250. The coil springs 44 can be of various sizes and numbers within the coil panel 40. In some non-limiting embodiments, for example, the coil springs can be up to about 3 inches in diameter and up to about 3 inches in height at compressed height. The springs can have an unloaded height or a loaded height that is less than the unloaded height, which is the fully relaxed height. As a non-limiting example, a coil mini-spring can be used having an unloaded or coil-free height of about 20 mm to about 26 mm and a loaded or compressed height of about 18 mm to about 20 mm. Alternatively, as a second non-limiting example, a larger coil can be used having an unloaded or coil-free 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. The coil spring may be constructed with 17.5 wire gauge (e.g., about 1.25 mm diameter wire) or 19.5 wire gauge in some embodiments. The coil spring may have a consistent wire size (diameter) or the wire size may vary across the coil spring. The coil spring may be turned approximately 3 and 3 / 4 turns (± 1 / 4 turn) to form the coil in some embodiments. When constructed, each end of the wire forming the coil may be in a coil spring configuration. The coil spring may have a variety of shapes, such as a barrel, cylinder, or hourglass shape. The pitch and diameter may be symmetrical or asymmetrical, allowing the coil spring to have a linear or non-linear response when compressed. However, other sizes, shapes, and variations may be utilized. For example, the coil spring may be a coil-in-coil design where the diameter of one or both coils may vary, such as a conical design. Still further, combinations of coil types may be utilized.

[0044] The coil spring 44 may be loaded by the engagement and bonding of the first and second fabric layers 46, 47. Specifically, the coil spring 44 may be preloaded from about 0.1 lbs. force to about 0.8 lbs. force. The coil spring 44 may also have a varying spring constant. That is, the spring constant of the coil spring 44 may be from about 0.2 lbs / in to about 3.0 lbs / in. Additionally, the spring constant may be the same or in the same range across the surface of the pillow 10, or alternatively, may vary or vary in range from location to location.

[0045] The coil springs 44 may also have a varying spring constant, i.e., the spring constant of the coil springs 44 may be from about 0.2 lbs / in to about 3.0 lbs / in, and the spring constant may be the same or in the same range across the coil panel 40, or alternatively, may vary or have a range that varies from location to location.

[0046] As previously mentioned, the coil spring 44 may have an unloaded height and may have a loaded height that is less than the unloaded height, which is the fully relaxed height. The spring 44 may be loaded by the engagement and joining of the two fabric layers 46, 47. This initial loading of the spring may be provided by an initial support force and / or pushback force of the spring 44.

[0047] 3B, in the exemplary coil panel 40, the coil springs 44 are arranged in rows in the direction Ax and columns in the direction Ay. However, referring now to FIG. 6, in another exemplary coil panel 340, a plurality of coil springs 344 are still arranged in rows in the direction Ax, but the coil springs 344 are not aligned in columns in the direction Ay as in the previous embodiment of FIG. 3B. Instead, every other column is offset a distance O. Other patterns of coil springs are contemplated depending on the design characteristics and considerations of the body support cushion.

[0048] 2 includes only a single coil panel as part of the gel molded spring array 52, it should be understood that the gel molded spring array 52 may have two or more coil panels. Similarly, there may be multiple gel molded spring arrays disposed across the upper surface of the cushioning. The number and location of the gel molded spring arrays and / or coil panels may depend on the size of the body support cushion or other design characteristics and considerations.

[0049] Returning now once again to FIG. 2, as discussed above, disposed above the coil panel 40 is a gel layer 50. More specifically, the exemplary gel layer 50 extends outwardly beyond the outermost coils 44 of the coil panel 40, while the first and second fabric layers 46, 47 of the coil panel 40 extend outwardly beyond the gel layer 50 when the coil panel 40 and the gel layer 50 are adjacent to one another. However, in other embodiments, the gel layer 50 may extend outwardly beyond the first and second fabric layers 46, 47 when the coil panel 40 and the gel layer 50 are adjacent to one another. Additionally, while only one gel layer 50 is shown, it is contemplated that in other embodiments a second gel layer may also be disposed on the lower surface of the cushioning.

[0050] The gel layer 50 included in the pillow 10 may generally be comprised of a substantially uniform layer of an elastomeric gel-like material capable of providing a cooling effect by acting as a heat radiator or heat sink through which heat from the user's body or a portion thereof located on the pillow 10 can be dissipated. For example, in some embodiments, the gel layer 50 may be comprised of a polyurethane-based gel made by combining Hyperlast® LU1046 polyol, Hyperlast® LP5613 isocyanate, and a thermoplastic polyurethane film or talc powder, each manufactured and sold by Dow Chemical Company Corp. (Midland, Mich.), and has a thermal conductivity of 0.1776 W / m*K, a thermal conductivity of 0.1184 mm, and a thermal conductivity of 0.150 W / m*K, as established by the International Organization for Standardization (ISO) 22007-2 volumetric specific heat measurement standard. 2 / s, and a thermal diffusivity of 1.503 MJ / (m 3 The gels may be combined to produce a gel insert having a volumetric specific heat of 0.1 K (K). However, it is also contemplated that numerous other types of gels capable of absorbing amounts of heat and providing a cooling effect may be used in accordance with the present embodiments and may be manufactured to have a desired thermal conductivity, thermal diffusivity, and volumetric specific heat without departing from the spirit and scope of the subject matter described herein.

[0051] In some embodiments, the gel layer 50 may have an outer surface that is substantially smooth, although the surface shape and texture of the gel may be determined to correspond to the surface of the mold into which the gel is poured. Furthermore, the gel may also vary in consistency along the surface of the pillow. As will be appreciated in the following description of an exemplary method of forming the body support cushion of the present invention, the peripheral edge or perimeter of the gel may be of a regular shape or irregular. Furthermore, the gel may also vary in thickness and / or consistency. For example, the thickness of the gel may be greater in the center compared to the area toward the perimeter of the gel.

[0052] In the exemplary pillow 10, the outer surface of the gel layer 50 is substantially flush with the upper surface 35 of the cushioning 30, such that the outer surface of the gel layer 50 and the upper surface 35 of the cushioning 30 collectively form the upper surface 14 of the body support cushion 10. The outer surface of the gel layer 50 may form a shape that is generally symmetrical to the opposite side of the pillow 10 (i.e., the lower surface 16), even though the materials defining the surfaces may be different. However, as previously discussed, other shapes may be utilized.

[0053] However, according to some other embodiments, the gel layer may be surrounded by the cushioning material in a manner such that the material is not flush. For example, the gel layer may be recessed or inset within the surrounding cushioning material, or the gel layer may extend outwardly, in part or in whole, beyond the upper surface of the cushioning material. For example, the outer surface of the gel may define one or more features, such as ribs or bumps, that extend beyond the upper surface of an otherwise generally planar pillow. Similarly, instead of simply being disposed within a recess adjacent the coil panel, additional gel may be disposed within divots in the foam.

[0054] Further with regard to the density and hardness of the pillow 10, as noted above, the density of the gel layer 50 generally differs from the density of the cushioning 30. In the exemplary pillow 10 shown in FIG. 2, the density of the cushioning 30, e.g., viscoelastic foam, is sufficient to support the user's neck and shoulders, while the gel layer 50 has a higher density that is sufficient to support the user's head. More specifically, the exemplary cushioning has a hardness of about 40 kg / m 3 ~about 80kg / m 3 and a hardness of about 25 N to about 50 N, while the exemplary gel layer 50 is constructed of a viscoelastic foam having a density of about 800 kg / m 3 ~Approx. 1200kg / m 3 It is comprised of a very soft polyurethane having a density of about 1000 and a Shore OOO hardness of about 25 to 50. Of course, the specific density and other support characteristics of both the cushioning and gel may vary depending on the design characteristics of the support cushion.

[0055] In some embodiments, one or more of the cushioning material 30, the coil panel 40, and the gel layer 50 may be individually or collectively covered with a netting material (not shown). The netting material may be any fabric in which yarns or fibers are fused, looped, or knotted at their intersections to form a fabric with open spaces between the yarns or fibers. Depending on the type of yarn or filament used to construct the fabric, its properties may vary in durability. The netting material may be formed of single knit jersey, double knit jersey, double rib knit, may be made of fire resistant or non-fire resistant fabrics, and may have a porosity of about 50 to about 850 CFM. Fire resistant fabrics may include, by way of non-limiting examples, fire resistant rayon, modified acrylic, Kevlar, nomax, and others. Non-fire resistant fabrics may include, by way of non-limiting examples, untreated polyester, rayon, or cotton.

[0056] Still referring to FIG. 2, the cover 60 is also disposed around the cushioning material 30 and the gel molded spring array 52. ​​In the exemplary pillow 10, the cover 60 is made of fabric, however, in other embodiments, various materials may be used, including but not limited to, cotton, cotton blends, moisture-wicking fabrics such as 100% polyester fabrics, rayon, nylon, or spandex blend fabrics for enhanced performance and stretchability, or blends of any of the foregoing. This list is non-exhaustive and other materials may be used. The fabric of the cover 20 may be quilted and / or may include various designs, including but not limited to, "hard" side or "soft" side labels. The cover 60 also defines the perimeter of the pillow 10, and thus the shapes of the various layers located within the cover 20 together with the perimeter edge of the cover 20 define the shape of the pillow 10. The cover 60 may also include a phase change material in some embodiments to enhance the cooling sensation to the user. It is contemplated that a pillow case, generally formed of a thin fabric, may be placed over the cover 20, if desired. The exemplary cover 20 is closed around the perimeter edge 18 and includes a closure 62 for accessing the interior of the pillow 10 or alternatively removing the interior contents for cleaning of the cover 60 when desired. The closure 62 may extend along one or more sides of the pillow 10 to facilitate placement of layers therein. The closure 62 may be of various types including, but not limited to, zippers, buttons, snaps, hook-and-loop fasteners, and the like.

[0057] Referring now to FIG. 4, a second exemplary body support cushion 110 constructed in accordance with the present invention similarly includes a gel molded spring array 152 on the upper surface 135 of the cushioning materials 130a, 130b, but also includes a second gel molded spring array 152 on the lower surface 134 of the cushioning materials 130a, 130b.

[0058] Each gel molded spring array 152 includes a coil panel 140 and a gel layer 150 that are substantially similar to the gel molded spring array 52 described above with reference to Figure 2. Specifically, each coil panel 140 includes a plurality of coils or springs 144 encased in first and second fabric layers 146, 147 and that are substantially similar to the coil panel 40 described above with reference to Figures 2 and 3. In the embodiment shown in Figure 4, the coil panels 140 on the upper surface 135 of the cushioning material 130 and the coil panels 140 on the lower surface 134 of the cushioning material 130 may have the same characteristics or may have different characteristics to provide a different feel on the two sides of the body support cushion 110.

[0059] Each gel layer 150 included in the pillow 110 is comprised of a substantially uniform layer of elastomeric gel material that can provide a cooling effect by acting as a heat radiator or heat sink through which heat from the user's body or a portion thereof located on the pillow 110 can be dissipated.

[0060] The coil panel 140 and gel layer 150 are also similarly disposed on the cushioning 130a, 130b in substantially the same manner as described above with reference to Figure 2. As shown in Figure 4, the cushioning 130a, 130b is formed from an upper foam piece 130a and a lower foam piece 130b that are brought together to form the cushioning 130a, 130b. However, according to other embodiments, a similar double-sided pillow may be formed from a single cushioning material.

[0061] 5, an exemplary method for manufacturing a hybrid pillow made in accordance with the present invention begins with a mold, which can vary in shape and size, but in some embodiments has a generally similar perimeter shape as the body support cushion 10 shown in FIG. 2. For example, the mold can be rectangular with curved top and bottom halves that define the crown shape of the exemplary pillows 10, 110 shown in FIGS. 1 and 4. However, any of the shapes and designs of the support cushions described above can be formed in a single mold or tool. The mold can be formed with a first half and a second half, as described below.

[0062] According to an exemplary embodiment, in a first step 210, a liquid gel is dispensed into a mold. The amount of gel may vary depending on the size and / or depth of the mold, as well as the particular design of the hybrid pillow that is ultimately to be molded. As will be further described below, according to some exemplary embodiments, a solid gel, rather than a liquid gel, may also be provided to the mold.

[0063] After the liquid gel is dispensed into the mold, in step 220, the coil panel is placed on top of the gel in the mold. The resulting structure results in a gel layer that is molded to one side of the coil panel to form a gel molded spring array similar to the gel molded spring arrays 52, 152 described above. While the liquid gel and coil panel are applied to the mold separately, in other embodiments, the gel layer and coil panel may be applied to the mold as a combined structure. That is, according to some exemplary embodiments of the present invention, the gel layer may be molded individually and placed into the mold before or after it is applied to the coil panel. In such examples, the gel layer may be formed into a backing that is removed for placement.

[0064] According to some embodiments, the exemplary pillow includes two or more coil panels, for example as described above with reference to the exemplary pillow 110 shown in FIG. 4. Thus, in such embodiments, the method includes the additional step of placing additional coil panels and / or gel layers into the mold. For example, in a mold having two sides that are folded closed, gel (liquid or solid) and a coil panel may be provided on each of the two sides before the mold is closed. Similarly, additional gel layers and coil panels may be provided in a second portion of the mold to provide a support cushion with a plurality of gel molded spring arrays.

[0065] After placing the coil panel and the gel layer in the mold, in step 230, a liquid foam precursor is dispensed into the mold. The mold can then be closed and the liquid precursor is foamed in step 240 to form the cushioning. In other words, a molded form is placed on the gel molded spring array opposite the gel layer. According to an exemplary embodiment, this foaming step 240 connects the coil panel and the gel layer to the resulting cushioning. Specifically, during the foaming step 240, the gel layer and the molded foam are considered to be secured together around the periphery of the coil panel. In this way, the molded foam of the cushioning at least partially surrounds the gel molded spring array with the coil panel completely encased between the gel layer and the molded foam of the cushioning. In embodiments where liquid gel is provided to the mold, it is considered that the gel may solidify before or during the foaming of the liquid precursor. Regardless, once the foaming step is completed, the mold can be opened and the body support cushion is removed.

[0066] According to embodiments where the gel is initially provided as a liquid, the resulting gel layer may vary in thickness across the resulting support cushion. When the gel liquid is poured into a mold and sinks toward the bottom of the mold, the liquid gel, in some embodiments, has a thicker depth at its center and a thinner depth near the perimeter edge. Thus, an exemplary pillow made with liquid gel may have less of the final gel layer toward the edge of the pillow and more of the final gel layer in the crown region of the pillow. Similarly, due to the sinking of the liquid gel, the resulting gel layer may, in some embodiments, have an irregular shape.

[0067] According to other embodiments, rather than forming the gel layer in the same mold as the cushioning so that the concentration of the gel layer varies across the pillow, the gel layer may be applied to the cushioning after the gel layer is individually formed. The coil panel may still be provided to the mold prior to providing the foam precursor so that the coil panel is integral with the cushioning. Alternatively, both the coil panel and the gel layer may be applied to the cushioning after it has been formed.

[0068] Each of the exemplary pillows described above may additionally include additives such as copper to improve moisture properties and inhibit mold growth. Other additives, such as carbon or charcoal additives for filtering, may be provided to improve flame retardancy or improve the foam's odor. Other additives, such as graphite, aluminum, silver, charcoal, gel, etc., may also be included for various benefits known in the art. A further addition to the exemplary pillow may provide far infrared radiation for rejuvenating properties. Still further, one or more layers of the pillow may be coated with nanobiomaterials 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 materials, inorganic materials, solid materials, and biological materials. Additionally, one or more layers may further include biocides, preservatives, odor blocking agents, fragrances, pigments, dyes, stain resistant, antistatic agents, stain resistant agents, waterproofing agents, moisture permeability agents, etc., as known in the art.

[0069] Those skilled in the art will recognize that additional embodiments are possible without departing from the teachings of this invention or the scope of the claims that follow. This detailed description, and in particular the specific details of the exemplary embodiments disclosed herein, are given primarily for clarity of understanding and no unnecessary limitations should be understood therefrom; modifications will become apparent to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the invention as claimed.

Claims

1. A cushioning material defining a recess; a coil panel disposed within the recess of the cushioning material, the coil panel being formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, the upper fabric layer and the lower fabric layer being bonded between the plurality of coil springs and along an outer periphery of the coil panel; a gel layer disposed within the recess of the cushioning material and covering the coil panel; A hybrid pillow that includes:

2. the gel layer is molded onto one side of the coil panel to form a gel molded spring array; The hybrid pillow of claim 1.

3. the cushioning material includes molded foam disposed on the gel molded spring array opposite the gel layer; the molded foam and the gel layer are secured together around an outer periphery of the coil panel. The hybrid pillow of claim 2.

4. the molded foam of the cushioning material at least partially surrounds the gel molded spring array; The hybrid pillow of claim 3.

5. The gel layer extends from the recess of the cushioning material. The hybrid pillow of claim 1.

6. the coil panel is completely encapsulated between the gel layer and the molded foam of the cushioning; The hybrid pillow of claim 3.

7. A first side of the hybrid pillow has a first feel, and a second side of the hybrid pillow has a second feel different from the first feel. The hybrid pillow of claim 1.

8. the gel molded spring array defining a first surface of the hybrid pillow and the molded foam defining a second surface of the hybrid pillow; The first side of the hybrid pillow has a first feel, and the second side of the hybrid pillow has a second feel different from the first feel. The hybrid pillow of claim 3.

9. The upper and lower fabric layers are formed of a nonwoven material or a hydrophobic material. The hybrid pillow of claim 1.

10. The hybrid pillow is a second coil panel disposed in a second recess of the cushioning material opposite the first coil panel, the second coil panel being formed of a plurality of second coil springs, a second upper fabric layer, and a second lower fabric layer, the second upper fabric layer and the second lower fabric layer being bonded between the plurality of second coil springs and along a periphery of the second coil panel; a second gel layer disposed over the second coil panel within the second recess of the cushioning material; The hybrid pillow of claim 1 further comprising:

11. 1. A method of making a hybrid pillow, the method comprising: Dispensing liquid gel into a mold; placing a coil panel over the liquid gel in the mold, the coil panel being formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, the upper fabric layer and the lower fabric layer being bonded between the plurality of coil springs and along a periphery of the first coil panel; dispensing a foam precursor into said mold; expanding the foam precursor to form a cushioning material secured to the coil panel; It has the steps: The method wherein the liquid gel solidifies such that a layer of gel is disposed on the coil panel.

12. The cushioning material and the gel layer are secured to each other around the outer periphery of the coil panel. The method of claim 11.

13. The coil panel is completely encapsulated between the gel layer and the cushioning material. The method of claim 11.

14. The liquid gel solidifies during the step of expanding the foam precursor. The method of claim 11.

15. the liquid gel solidifies prior to the step of expanding the foam precursor such that a gel molded spring array is formed prior to dispensing the foam precursor into the mold; The method of claim 11.

16. A molded hybrid pillow, comprising: A cushioning material defining a recess; a coil panel disposed within the recess of the cushioning material, the coil panel being formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, the upper fabric layer and the lower fabric layer being bonded between the plurality of coil springs and along an outer periphery of the first coil panel; a gel layer disposed within the recess of the cushioning material and covering the coil panel; Equipped with At least one of the upper fabric layer and the lower fabric layer prevents contact between the gel layer and the convolutions of the plurality of coil springs.

17. each of the plurality of springs having a wrapped height of less than 3 inches and a diameter of less than 2 inches; 17. The molded hybrid pillow of claim 16.

18. the gel layer extending outwardly beyond the outermost row of the plurality of springs; 17. The molded hybrid pillow of claim 16.

19. The upper and lower fabric layers extend outwardly beyond the gel layer.

17. The molded hybrid pillow of claim 16.

20. The upper and lower fabric layers are formed of a nonwoven material or a hydrophobic material.

17. The molded hybrid pillow of claim 16.

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