Hybrid pillow

Abstract

The hybrid pillow includes a first coil panel and a second coil panel joined along a perimeter to form an inner shell defining a gap therebetween. The first coil panel is formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, the upper and lower fabric layers being joined between the plurality of coil springs and along the perimeter of the first coil panel. The second coil panel is formed of a plurality of second coil springs, a second upper fabric layer, and a second lower fabric layer, the second upper and lower fabric layers being joined between the plurality of coil springs and along the perimeter of the second coil spring. A support is disposed in the gap of the inner shell, and one or more additional layers are disposed about the inner shell.

Description

[Technical field]

[0001] [Related Applications] This application claims priority to U.S. Provisional Patent Application No. 63 / 214,505, 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 hybrid pillow that includes a coil panel, a foam layer, and an outer shell that may include a cover material or down-fill fabric. [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 a hybrid body support cushion, such as a pillow. In some embodiments, the hybrid pillow comprises various layers including a coil panel, a foam layer, and an outer shell that may include a cover material or down-fill fabric.

[0006] In some embodiments of the invention, a lower first coil panel and an upper second coil panel are joined along their outer periphery to form an inner shell defining a gap therebetween, with a cushioning or support material disposed in the gap.

[0007] In some embodiments, the insulation layer is disposed about the inner shell. Similarly, in some embodiments, the outer shell is disposed outside the insulation layer.

[0008] In some embodiments, the first and second coil panels are each formed of a plurality of coil springs, with an upper first fabric layer disposed over an upper end of each coil spring and a lower second fabric layer 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 a coil pocket. The first and second fabric layers are additionally bonded, e.g., welded, along peripheral edges of the first and second fabric layers to define the first and second coil panels, respectively.

[0009] In some embodiments, the first coil panel and / or the second coil panel may define a number of air flow openings for varying the amount of air flow through the coils and panels.

[0010] In some embodiments, the coil springs in one or both of the coil panels may all have the same configuration, while in other embodiments, the configuration of the coil springs may vary across the coil panels. For example, in some embodiments, the number and / or position of the coils may vary across the coil panels. Similarly, in some embodiments, there are various zones where the coil configurations differ. In some examples, these zones may include soft coil spring zones and hard coil spring zones.

[0011] In some embodiments, the support disposed within the gap defined between the first and second coil panels is a viscoelastic foam plate. In other embodiments, the support is a latex foam plate. Regardless of the particular material, in some embodiments, the foam plate is provided with holes or openings that allow for enhanced airflow and cooling within the pillow. The number of holes or openings may vary depending on the amount of airflow desired and the characteristics of the foam or latex. For example, a thicker foam or a denser foam may have minimal airflow without openings and therefore may require more openings than a thinner or less dense foam. In some embodiments, there are openings in a first region of higher density compared to the remainder of the support.

[0012] In some embodiments, the support material comprises a netting material filled with a chip cushioning material, such as chip foam or chip latex.

[0013] In some embodiments, the outer shell is formed of a first shell material disposed on an outer surface of the first coil panel and a second shell material disposed on an outer surface of the second coil panel. The first and second shell materials are joined along a perimeter edge of the outer shell, thereby surrounding the inner shell, although in some embodiments the outer shell may be open along one side, multiple sides, or may not be completely joined.

[0014] In some embodiments, each of the first and second shell materials is a foam panel. The upper and lower shell materials may be the same type of foam, but may have different thicknesses or properties to provide different feel to the sides of the pillow.

[0015] In some embodiments, the outer shell is made of a down-filled fabric shell that includes a downproof material on its interior surface and may be hermetically closed or may include a closure that allows for removal of the down.

[0016] In some embodiments, the cover is disposed around the outer shell. In some exemplary embodiments, the cover is made of fabric, may be quilted, and / or may include various designs, including, but not limited to, "hard" or "soft" side labels. The cover 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 if desired. Some exemplary covers are closed around the perimeter edge and include a closure for accessing the interior of the pillow or alternatively removing the interior contents for cleaning of the cover when desired. The closure may extend along one or more sides of the pillow to facilitate placement of layers therein.

[0017] 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]

[0018] [Figure 1] 1 is a perspective view of an exemplary hybrid pillow made in accordance with the present invention; FIG.

[0019] [Diagram 2] FIG. 2 is an exploded perspective view of the hybrid pillow of FIG. 1.

[0020] [Figure 2A] FIG. 4 is a detailed cross-sectional view of the coil panel.

[0021] [Diagram 3] FIG. 2 is an exploded perspective view of another exemplary pillow made in accordance with the present invention.

[0022] [Figure 4] FIG. 13 is an exploded perspective view of yet another exemplary pillow made in accordance with the present invention.

[0023] [Figure 5A]FIG. 2 is a top view of one example fabric layer used in a coil panel defining a first pattern of openings.

[0024] [Figure 5B] FIG. 13 is a top view of a second exemplary fabric layer used in a coil panel defining a second dense pattern of a plurality of openings.

[0025] [Figure 5C] FIG. 13 is a top view of a third exemplary fabric layer used in a coil panel defining openings in a plurality of central welds.

[0026] [Figure 6A] FIG. 2 is a schematic layer diagram of one exemplary coil pattern used in a coil panel.

[0027] [Figure 6B] FIG. 13 is a schematic layer diagram of another exemplary coil pattern used in a coil panel.

[0028] [Figure 6C] FIG. 13 is a schematic layer diagram of another exemplary coil pattern used in a coil panel.

[0029] [Figure 6D] FIG. 13 is a schematic layer diagram of another exemplary coil pattern used in a coil panel.

[0030] [Figure 6E] FIG. 13 is a schematic layer diagram of another exemplary coil pattern used in a coil panel.

[0031] [Figure 6F] FIG. 13 is a schematic layer diagram of another exemplary coil pattern used in a coil panel.

[0032] [Figure 6G] FIG. 13 is a schematic layer diagram of another exemplary coil pattern used in a coil panel.

[0033] [Figure 6H] FIG. 13 is a schematic layer diagram of another exemplary coil pattern used in a coil panel.

[0034] [Figure 7A] FIG. 2 is a top view of an exemplary foam plate defining a first pattern of openings.

[0035] [Figure 7B] FIG. 13 is a top view of another exemplary foam plate defining a second pattern of openings.

[0036] [Figure 7C] FIG. 13 is a top view of another exemplary foam plate defining a third pattern of a plurality of openings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] The present invention includes a hybrid body support cushion, such as a pillow. In some embodiments, the hybrid pillow comprises various layers including foam and coil springs, and additional layers or structures to provide a desired feel for the end user, such as a firmer or softer feel or other properties. The various layers can be tuned to adjust the various properties to the desires 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. All of these properties and others can be "tuned" or changed to provide the most preferred pillow feel for the end user.

[0038] 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, for non-limiting examples, 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.

[0039] Still referring to FIG. 1, the exemplary hybrid pillow 10 has a generally rectangular perimeter shape with an arcuate upper surface 12 and an acicular lower surface 14 joined by an arcuate curvature at or around the perimeter edge 16 of the pillow 10. The pillow 10 also includes a cover 20 having at least one closure 18 along one or more sides thereof. The closure 18 can be of various types including, but not limited to, zippers, buttons, snaps, and hook-and-loop fasteners. The closure 18 allows the cover 20 of the pillow 10 to be opened to change the internal components, for example, if a user desires to change the characteristics of the pillow (e.g., to fit the pillow to the back, side, or stomach of a sleeper). Also, with removal of the internal components, the cover 20 can be periodically washed.

[0040] 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 edge of the pillow 10, 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 10. 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.

[0041] 2-2A, the exemplary hybrid pillow 10 includes multiple layers that provide certain properties, as described below. Specifically, the exemplary pillow 10 shown in FIG. 2-2A includes a lower first coil panel 30 and an upper second coil panel 32 that are joined along the outer periphery 39 of the first and second coil panels 30, 32 to form an inner shell 31 that defines a gap 40 between the first and second coil panels 30, 32. In the exemplary hybrid pillow 10, a cushioning or support material 42 is disposed in the gap 40, although in other embodiments, the support material 42 may be omitted or replaced with other materials without departing from the spirit and scope of the present invention. The first and second coil panels 30, 32 may be joined together by ultrasonic welding (i.e., welding), sewing, and / or other forms of fasteners to form the inner shell 31. The joined first and second coil panels 30, 32, or other inner shell 31, may be completely closed around the entire perimeter, or in some embodiments, may be provided with an opening along one side. The opening may include various types of closures (not shown), including but not limited to zippers, buttons, snaps, and hook-and-loop fasteners. The opening allows for the support 42 to be placed therein and for the support 42 to be later removed, if desired.

[0042] 2, an insulation layer 50 is disposed about the inner shell 31, i.e., there is an insulation layer 50 extending along the outer surface of the first coil panel 30 and another insulation layer 50 extending along the outer surface of the second coil panel 32. However, in other embodiments, an insulation layer may only be disposed over the outer surface of only one of the first coil panel 30 or the second coil panel 32, or the insulation layer may be omitted entirely. Also shown outside the insulation layer 50 are outer shells 60, 62, as well as the cover 20 outside the outer shells 60, 62, each of which will be further described below.

[0043] Still referring to FIG. 2-2A, but now focusing on the first and second coil panels 30, 32 of the exemplary pillow 10, each of the first and second coil panels 30, 32 is formed with a plurality of coil springs 34 (shown in FIG. 2A) deployed in an array or matrix of rows and / or columns. In the embodiment shown in FIG. 2-2A, the plurality of coil springs 34 are arranged in rows and columns, although other configurations are contemplated. For example, rather than the plurality of coil springs being aligned in two perpendicular dimensions as shown in FIG. 2, the plurality of coil springs may be aligned in one dimension and offset in the other dimension. The number of coil springs per row and column may also vary. Similarly, the size of the matrix may vary depending on the size of the first and second coil panels 30, 32.

[0044] As shown in FIG. 2A, the exemplary first coil panel 30 includes an upper first fabric layer 35 disposed over an upper end of each coil spring 34 and a lower second fabric layer 37 disposed under a lower end of each coil spring 34. The first and second fabric layers 35, 37 are bonded, e.g., welded, between the coil springs 34, thereby forming a coil pocket. The first and second fabric layers are additionally bonded, e.g., welded, along the outer periphery 39 of the first and second fabric layers 35, 37 to define the first coil panel 30 and the second coil panel 32, respectively. The space between the coil springs 34 shown in FIG. 2A is illustrative of the weld between the first and second fabric layers 35, 37 and is not intended to be limiting. For example, in some embodiments, the welded bond of the first and second fabric layers 35, 37 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 35, 37 may vary based on the size of the coil spring contained therein. Although not expressly shown, the second coil panel 32 is similarly constructed of an upper first fabric layer and a lower second fabric layer that are joined between the coil springs and along the outer periphery of the first and second fabric layers to form a coil pocket around the coil springs.

[0045] The first and second fabric layers 35, 37 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 35, 37 may be made of different materials. For example, the first fabric layer 35 may be a spunlace mesh fabric (e.g., about 70 g / m 2 ) and the second fabric layer 37 may be a nonwoven fabric as previously described.

[0046] 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 first and second coil panels 30, 32 are compressed. Similarly, when the compression force of the pillow is released, expansion of the first and second coil panels 30, 32 may occur slowly due to the slow drawing of air through the first and second fabric layers 35, 37. 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 and the first and second coil panels 30, 32 may also be controlled.

[0047] For example, referring now to Figures 5A-5C, according to some exemplary embodiments, the first coil panel and / or the second coil panel may define a number of air flow openings that vary the amount of air flow through the coils and panels. More specifically, in some embodiments, the first and / or second fabric layers may have different densities of openings to improve air flow through the respective panels. In Figure 5A, an exemplary first fabric layer 435 disposed over a plurality of coil springs 434 defines a large number of openings 437 per square inch, and in comparison, in Figure 5B, another exemplary first fabric layer 535 disposed over a plurality of coil springs 534 defines a larger number of openings 537 per square inch. Thus, the size and density of the openings may be varied to vary the air flow through the device.

[0048] FIG. 5C illustrates another exemplary first fabric layer 635 having an alternative pattern of openings. In this illustrated embodiment, in addition to welding the first fabric layer 635 to the second fabric layer (not shown) between the coil springs 634, the first fabric layer 635 is additionally welded to the second fabric layer at the center portions of the coil springs 634 to form central welds 645 within each coil spring 634. As shown in FIG. 5C, openings 647 are defined within these central welds 645 to allow air flow. As a non-limiting example, the diameter of the central welds 645 is about 21 mm to about 25 mm, and the diameter of the openings 647 is about 9 mm to about 10 mm. While the above description of FIGS. 5A-5C 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.

[0049] Returning again to FIGS. 2 and 2A, but now focusing on the plurality of coil springs 34 in the first and second coil panels 30, 32, the number of coils per square foot in the exemplary first and second coil panels 30, 32 can be in the range of about 14 to about 250. The coil springs 34 may be of various sizes and numbers within the first and second coil panels 30, 32. In some non-limiting embodiments, for example, the coil springs may be up to about 3 inches in diameter and up to about 3 inches in height at the compressed height. The springs may have an unloaded height and may have 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 may 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 may 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 about 3 and 3 / 4 turns (± 1 / 4 turn) to configure the coil in some embodiments. When configured, each end of the wire that forms 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, a combination of coil types may be utilized.

[0050] The coil spring 34 may be loaded by the engagement and bonding of the first and second fabric layers. As previously mentioned, in some embodiments, the coil spring 34 may be preloaded to a height of about 18 mm to about 20 mm, thereby providing coil pockets of approximately the same height. Additionally, the coil spring 34 may be preloaded to about 0.09 lbf to about 0.8 lbf and may have a compression of about 0.45 lbf to about 1.85 lbf at 0.5 inches.

[0051] According to some exemplary embodiments, the coil springs in one or both of the coil panels may all have the same configuration, or in other embodiments, the configuration of the coil springs may vary across the coil panels. Similarly, the density of the coil springs may vary across the coil panels. Additionally, the coil springs may vary in spring constant. That is, the spring constant of the coil springs may be from about 0.3 lbs / in to about 3.0 lbs / in. Also, the spring constant may be the same or in the same range across the coil panels, or alternatively, may vary in range or vary from location to location. Thus, an exemplary pillow may have firmer regions and less firmer regions. Similarly, an exemplary pillow may have an upper surface with one or more coil characteristics based on an underlying upper coil panel, and a lower surface with the same or different set of coil characteristics based on an underlying lower coil panel. Thus, an exemplary pillow made in accordance with the present invention may have one feel on one side of the pillow and a different feel on a second side of the pillow.

[0052] With additional brief reference to Figures 6A-6H, various schematic diagrams are provided illustrating various patterns of coils that may be used within the coil panels of the present invention. Each diagram illustrates other exemplary coil panels 730, 830, 930, 1030, 1130, 1230, 1330, 1430 that may be used as the first coil panel 30, the second coil panel 32, or both the first and second coil panels 30, 32 of the exemplary pillow 10. As shown in Figures 6A-6H, the coil panels 730, 830, 930, 1030, 1130, 1230, 1330, 1430 may have various coil patterns, represented by circles in the diagrams.

[0053] According to some embodiments, as depicted in Figures 6A-6E, the number and / or location of coils may vary across a coil panel. Referring initially to Figure 6A, an exemplary coil panel 730 includes coils 734 that form stripes in both x and y coordinate directions (i.e., rows and columns). These rows and columns may correspond to head-to-toe and / or side-to-side directions. Referring to Figure 6B, an exemplary coil panel 830 includes coils 834 arranged in groups 833 with channels 835 defined between the groups 833 and extending in the x and / or y directions. In the exemplary coil panel 830, the groups 833 are substantially square, but may be defined by a variety of shapes, and in some embodiments may be rectangular, circular, or any other desired shape. Referring to Figure 6C, an exemplary coil panel 930 includes coils 934 arranged in a checkerboard arrangement. With reference to FIG. 6D, an exemplary coil panel 1030 includes coils 1034 arranged in a pattern of squares 1035, for example with a hollow area 1037 in the center of the square 1035 where there are no coils. Of course, other shapes other than squares 1035 may be used. With reference to FIG. 6E, an exemplary coil panel 1130 includes coils 1134 arranged in a pattern in which a coil is removed every nth position 1137. For example, in the exemplary coil panel 1130, every third coil is removed with an offset of one coil between the coils along each row. However, in other embodiments, coils may be removed at other frequencies in either the x or y direction or both.

[0054] In further embodiments, as depicted in Figures 6F-6H, there are various zones with different coil configurations. In some examples, these zones can include soft coil spring zones and hard coil spring zones. With specific reference to Figure 6F, the exemplary coil panel 1230 includes a central zone 1237 of coil springs and a peripheral zone 1239 of coil springs, each having coil springs with different configurations and therefore different characteristics, such as the spring constant of the coil springs. As a non-limiting example, a first portion of the plurality of coil springs in the peripheral zone 1239 can be constructed with 17.25 wire gauge to provide a first spring constant, while a second portion of the plurality of coil springs in the central zone 1237 can be constructed with 19.5 wire gauge to provide a second spring constant different from the first spring constant. Similarly, the peripheral and central coil springs can be preloaded differently. As a non-limiting example, the coil springs in the central zone 1237 may be unpreloaded, while the coil springs in the perimeter zone 1239 may be preloaded from about 0.09 lbf to about 0.23 lbf and may have a compression of about 0.45 lbf to about 0.55 lbf at 0.5 inches. With reference to FIG. 6G, an exemplary coil panel 1330 includes a middle zone 1337 that may be soft or hard, while the top and bottom ends or zones 1339 may be the other of soft or hard. With reference to FIG. 6H, an exemplary coil panel 1430 includes a hard perimeter or edge zone 1439 and a plurality of interior zones 1437 that are softer compared to the edge zones 1439.

[0055] 2 and 2A, as previously described, the outer perimeter edges 39 of the first and second coil panels 30, 32 are joined to define a gap 40 between the first and second coil panels 30, 32 with a support 42 disposed therein. In an instant embodiment, the support 42 includes a foam plate 43 disposed within the gap 40. The foam plate 43 may be formed from a variety of materials including, but not limited to, viscoelastic foam (sometimes referred to as "memory foam" or "memory foam"). In other embodiments, latex foam may be utilized or non-reticulated, non-viscoelastic foam may be used, as described further herein.

[0056] Various foams may be utilized throughout the various embodiments, and the following summary is non-exhaustive. For example, open-cell, 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.

[0057] The support 42 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. In some exemplary embodiments, the density of the flexible foam used in the outer portion generally has a density sufficient to support the user's neck and shoulders. Such flexible foams may include, but are not limited to, latex foam, reticulated or non-reticulated viscoelastic foam (sometimes referred to as memory foam or memory foam), reticulated or non-reticulated 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), and the like. In the embodiment shown in FIG. 2, the foam plate 43 is comprised of a viscoelastic foam having sufficient density and hardness as well as memory resilience to allow pressure to be absorbed evenly and distributed evenly across the foam plate 43 of the pillow 10. Generally, such viscoelastic foams have a hardness of at least 10 N and no more than 80 N at about room temperature (e.g., 21° C.-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. An exemplary foam plate 43 has a hardness of about 70 kg / m 3 ~Approx. 110kg / m 3 and a hardness of about 25 N to about 50 N. In some other exemplary embodiments, the viscoelastic foam has a hardness 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.

[0058] The viscoelastic foams described herein for use in 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 density of the viscoelastic foam used in the foam plate 43 is about 30 kg / m3 Above, about 150kg / m 3 In some embodiments, the density of the viscoelastic foam used in the foam plate 43 of the pillow 10 is 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.

[0059] Additionally, while the exemplary foam plate 43 is generally flat in shape, it is contemplated that in other embodiments the surfaces may be planar or of other shapes. For example, in other embodiments the top and bottom surfaces of the foam plate may be non-planar, including but not limited to surfaces having ribs, protrusions, and other protrusions of any shape and size, surfaces having grooves, indentations, and other openings that extend partially, nearly completely, or entirely through the foam plate.

[0060] Regardless of the particular material of the foam plate 43, in some embodiments, the foam plate 43 may or may not be 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.

[0061] 7A-C, additional embodiments of supports 1542, 1642, 1742 made in accordance with the present invention are depicted. These exemplary supports are foam plates 43 similar to the exemplary foam plates 43 described above with respect to FIG. 2 and may be used as such in the exemplary pillow 10. However, in these embodiments, the supports 1542, 1642, 1742 are provided with holes or openings to allow for increased airflow and cooling within the pillow 10. The number of holes or openings may vary depending on the amount of airflow desired and the properties of the foam or latex. In the exemplary support 1542 shown in FIG. 7A, two rows 1544 of openings 1545 are provided in a non-limiting example. However, in the exemplary support 1642 shown in FIG. 7B, the number of rows 1644 and the number of openings 1645 are increased and may depend on the properties of the foam, its thickness, the density of the foam, and the amount of airflow that may move through the unopened foam. For example, thicker or denser foams may have minimal airflow without openings and therefore may require more openings than thinner or less dense foams. Additionally, compared to openings 1545 in support 1542 shown in FIG. 7A, openings 1645 in support 1642 in FIG. 7B are larger in size. In other words, the support of the present invention has a resistance of about 1.1 to 6.7 lb / ft 3The foam plate may have a density in the range of 0.1 mm to 0.5 mm and / or may have holes of different sizes. It may be desirable to provide increased airflow in that the number of openings may be increased or the size may be increased. This may also result in a softer support. Alternatively, if less airflow is desired, the number of openings may be decreased, resulting in a firmer support. As shown in the example support 1742 shown in FIG. 7C, there may be openings 1745 in a first region 1750 of higher density compared to the remainder of the support 1742. In some examples, the first region 1750 may correspond to the foot region of the mattress, but this should not be understood as limiting, as there may be a higher concentration of openings associated with a particular region of the pillow. In other embodiments, there may be a higher concentration of openings along the perimeter of the support, or alternatively, there may be a higher concentration of openings within the center of the support. Additionally, the placement and concentration of the openings may vary based on the intended use, for example, the location, concentration, and / or size of the openings may vary depending on whether the pillow is for side sleepers, back sleepers, and / or stomach sleepers.

[0062] The size or shape of the holes or openings may also vary. Although the openings 1545, 1645, 1745 shown in Figures 7A-7C are all circular, this should not be understood as limiting. In some embodiments, the openings may be hexagonal, octagonal, square, triangular, or any shape opening that allows air flow therethrough. Similarly, the size (e.g., diameter) of the openings may also vary. For example, the diameter of the openings may vary from about 1 / 8 inch to about 1 inch. In some embodiments, all of the openings may be the same size, while in other embodiments, the openings may vary in size across the support. For example, the openings may be larger along the perimeter of the support, or alternatively, the openings may be larger in the center of the support. In other examples, there may be an asymmetric distribution of openings of various sizes.

[0063] Returning once again to FIG. 2, as previously described, the insulation layer 50 is disposed on both the outer surface of the first coil panel 30 and the outer surface of the second coil panel 32. However, in other embodiments, the insulation layer 50 may be disposed only over the outer surface of either the first coil panel 30 or the second coil panel 32, or may be omitted entirely without departing from the spirit and scope of the present invention. The insulation layer 50 may be formed of a variety of materials. In some embodiments, the insulation layer 50 may be a fibrous material, a spacer fabric, a foam, or other material having insulating properties. In some examples, the spacer fabric may be formed of a bi-directionally stretchable fabric, meaning that it is stretchable in two dimensions, such as horizontally, e.g., head-to-toe, and laterally, side-to-side, relative to the bed. The spacer fabric may include a woven or knitted material, and / or an extruded plastic material, including polyethylene, polyester, other plastics, or any combination thereof. In some embodiments, the insulation layer 50 may be formed of a non-woven material or a high loft material. The term "nonwoven" is used in the textile industry to refer to fabrics that are neither woven nor knitted. Nonwoven fabrics are generally engineered fabrics made by bundling small fibers together in a sheet or web form and bonding them together through chemical, mechanical, heat, or solvent treatments. The term "non-dense" refers to fibers that are not bonded together by melting and resolidifying the bonded fibers. "High loft" is a term given to a fiber structure that contains more air than the fibers. Generally, high loft fibers retain more warmth. Such high loft materials are high, low density materials used in such applications as fiberfill, insulation, and the like. The fibers can be made of materials with smooth or slippery surfaces, including, but not limited to, polyester, polypropylene, nylon, silk, acrylic, acetate, and / or rayon. In other examples, the insulation layer 50 can be natural fibers, such as wool, down, and the like. In some embodiments, the insulation layer 50 further includes a netting material that contains other loose materials.

[0064] Still referring to FIG. 2, as previously described, outer shells 60, 62 are also shown outside the insulation layer 50. More specifically, the first shell material 60 is disposed on the outer surface side of the first coil panel 30, and the second shell material 62 is disposed on the outer surface side of the second coil panel 32. Although the exemplary first and second shells 60, 62 are bonded along the perimeter of the outer shells 60, 62, thereby surrounding the insulation layer 50 and the inner shell 31, in some embodiments, the outer shells 60, 62 may be open along one side, open along multiple sides, or may not be completely bonded. The openings allow various layers to be placed therein and later removed if desired. The first and second shell materials 60, 62 may be bonded together by welding, sewing, and / or other forms of fasteners to form the outer shells 60, 62.

[0065] In the exemplary pillow 10, each of the first and second shell materials 60, 62 is a foam panel, with the lower first shell material 60 being relatively thick and the upper second shell material 62 being relatively thin, to provide different feel to the sides of the pillow 10. In an instant embodiment, the outer shells 60, 62 may be formed of any of the foams previously described, including but not limited to polyurethane foam or latex foam. Additionally, the upper and lower shell materials 62, 60 may be the same type of foam, but may have different properties to provide different feel to the sides of the pillow, and in addition or instead, the thickness of the first and second shell materials 60, 62 may be varied. Of course, the foam properties may be the same to provide an equal feel to both sides of the pillow. Regardless of the particular material of the first and second shell materials 60, 62, in some embodiments, the first and second shell materials 60, 62 may or may not be covered with a netting material (not shown). The netting material may be any woven fabric in which yarns or fibers are fused, looped, or knotted at their intersections to result in 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. According to some embodiments, the outer shells 60, 62 may be used in addition to or instead of the insulation layer 50 on one or both sides of the inner shell 31.

[0066] Still referring to FIG. 2, the cover 20 is disposed around the outer shell 60, 62 as previously described. In the exemplary pillow 10, the cover 20 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 above. 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 20 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 20 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 16 and includes a closure 18 for accessing the interior of the pillow 10 or alternatively for removing the interior contents for cleaning of the cover 20 when desired. The closure 18 may extend along one or more sides of the pillow 10 to facilitate placement of layers therein.

[0067] As previously mentioned, the upper and lower surfaces 12, 14, which are joined along the perimeter 16, may be utilized by the user by flipping the pillow 10 onto either side, respectively. By adjusting the properties of one or more of the components described above, the upper and lower surfaces 12, 14 of the pillow 10 may provide different feel, or may provide the same feel on both sides. For example, one side of the exemplary pillow may be firmer or softer than the other side. Still further, one side of the exemplary pillow may have the same cooling capacity as the other side, or may have more or less cooling capacity than the other side. The exemplary pillow may also include a gusset (not shown) along its perimeter, allowing for a taller, thicker pillow.

[0068] Referring now to FIG. 3, another exemplary pillow 110 made in accordance with the present invention includes first and second coil panels 130, 132 substantially similar to the first and second coil panels 30, 32 described above with respect to FIG. 2-2A, with a gap 140 defined between the first and second coil panels 130, 132 and a support material 142 disposed within the gap 140. However, in the exemplary pillow 110 shown in FIG. 3, the support material 142 includes a latex plate 143, as compared to the foam plate 43 made of viscoelastic foam described above with reference to FIG. 2. The exemplary latex plate 143 may additionally have other additives to improve moisture, odor, or other properties that may sometimes be unpleasant. Furthermore, the latex plate 143 may also be surrounded by a netting material (not shown) to help reduce slippage, sticking, bunching, etc. between adjacent layers.

[0069] The exemplary pillow 110 also includes an outer shell 180 made of a down-filled fabric shell 182 that includes a downproof material on its interior surface and may be hermetically closed or may include a closure to allow removal of the down. Similar to the exemplary pillow 10 shown in FIG. 2, the pillow 110 shown in FIG. 3 also includes a cover 170 in addition to the down-filled fabric shell.

[0070] Also similar to the pillow 10 described above with reference to Figures 2-2A, in this embodiment there is an outer shell 180 defined by a down-fill fabric shell 182, and an inner shell 131 formed by first and second coil panels 130, 132 joined along their periphery. Thus, a similar outer shell and inner shell arrangement is provided as described above.

[0071] 4, another exemplary pillow 210 made in accordance with the present invention includes first and second coil panels 230, 232 substantially similar to the first and second coil panels 30, 32 described above with respect to FIGS. 2-2A, with a gap 240 defined between the panels 230, 232 and a support material 242 disposed within the gap 240. However, in the exemplary pillow 210 shown in FIG. 4, the support material 242 includes a net material 243 filled with a chip cushioning material 244, such as chip foam or chip latex. In contrast to the previous embodiment in which a continuous foam plate or latex plate structure was utilized, the instant embodiment utilizes chip cushioning material to provide a more distinct feel for the pillow 210. The chip cushioning material 244 may range in size from about 1 / 4 inch to about 1-1 / 2 inches and may be of consistent firmness or may contain foam of varying firmness.

[0072] Additionally, unlike the previous pillows 10, 110, in the exemplary pillow 210 shown in Figure 4, the cover 270 is disposed directly around the inner shell 231 formed by the first and second coil panels 230, 232. Thus, in this exemplary embodiment, the cover 270 itself may be considered an outer shell.

[0073] 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.

[0074] 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 first coil panel 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 joined between the plurality of coil springs and along a periphery of the first coil panel; a second coil panel formed of a plurality of second coil springs, a second upper fabric layer, and a second lower fabric layer, wherein the second upper fabric layer and the second lower fabric layer are joined between the plurality of coil springs and along a periphery of the second coil panel; the first coil panel and the second coil panel are joined along the outer periphery to form an inner shell defining a gap therebetween; a support disposed in the gap of the inner shell; one or more additional layers disposed about the inner shell; A hybrid pillow that includes:

2. the one or more additional layers include a layer of insulation extending along an outer surface of the first coil panel, an outer surface of the second coil panel, or an outer surface of each of the first coil panel and the second coil panel. The hybrid pillow of claim 1.

3. The one or more additional layers include an outer shell formed of a first shell material disposed on an outer surface side of the first coil panel and a second shell material disposed on an outer surface side of the second coil panel, wherein the first shell material and the second shell material are joined along an outer periphery of the outer shell to surround the inner shell, a cover disposed around the outer shell; The hybrid pillow of claim 1 ,

4. The first coil panel and the second coil panel are joined by ultrasonic welding or sewing along the outer periphery. The hybrid pillow of claim 1.

5. the outer periphery of the first coil panel and the second coil panel are joined by at least one zipper. The hybrid pillow of claim 1.

6. The insulation layer is formed of a fiber material, a foam material, or a combination thereof. The hybrid pillow of claim 1.

7. The insulation layer includes a net material. The hybrid pillow of claim 6.

8. The first shell material and the second shell material are formed of foam. The hybrid pillow of claim 1.

9. The first shell material and the second shell material include down. The hybrid pillow of claim 1.

10. The first shell material and the second shell material further include a downproof material. The hybrid pillow of claim 9.

11. The support is a foam plate. The hybrid pillow of claim 1.

12. The support is formed of polyurethane foam or latex foam. The hybrid pillow of claim 11.

13. The polyurethane foam is a viscoelastic foam. The hybrid pillow of claim 12.

14. The foam plate defines a plurality of openings. The hybrid pillow of claim 11.

15. The support material includes a net material filled with a chip cushion material. The hybrid pillow of claim 1.

16. At least one of the first upper fabric layer, the second upper fabric layer, the first lower fabric layer, and the second lower fabric layer defines a plurality of openings. The hybrid pillow of claim 1.

17. At least one of the first coil panel and the second coil panel includes a first portion of the plurality of coil springs having a first spring constant and a second portion of the plurality of coil springs having a second spring constant different from the first spring constant. The hybrid pillow of claim 1.

18. At least one of the first shell material and the second shell material is covered with a net material. The hybrid pillow of claim 1.

19. a first coil panel formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, the upper and lower fabric layers being joined between the plurality of coil springs and along a periphery of the first panel, the upper and lower fabric layers defining a plurality of openings; a second coil panel formed of a plurality of second coil springs, a second upper fabric layer, and a second lower fabric layer, wherein the second upper fabric layer and the second lower fabric layer are joined between the plurality of second coil springs and along a periphery of the second panel, and the second upper fabric layer and the second lower fabric layer define a plurality of openings; the first coil panel and the second coil panel are joined along the outer periphery to define a gap therebetween; a support formed of polyurethane or latex and disposed in the gap between the first panel and the second panel; and an outer shell formed of a first shell material disposed on an outer surface side of the first coil panel and a second shell material disposed on an outer surface side of the second coil panel, wherein the first shell material and the second shell material are joined together along an outer peripheral edge of the outer shell to surround the first coil panel and the second coil panel; a cover disposed around the outer shell; A hybrid pillow that includes:

20. The first shell material and the second shell material include down.

20. The hybrid pillow of claim 19.

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