Cushioned covers for cushions

Abstract

To provide a cover having a panel which includes a secondary cushion element.SOLUTION: A cover for a cushion includes: a first panel; a second panel; and a primary receptacle defined between the first panel and the second panel. The primary receptacle may receive a primary cushioning element such as a pillow, a pillow insert or a fill material. At least one of the first panel and the second panel includes a secondary cushioning element. The secondary cushioning element may be defined from a compressible, resilient elastomeric material. The elastomeric material defines a plurality of thin interconnected walls, and the interconnected walls in turn define an array of open cells or columns. Each cell or column may have a hexagonal shape, imparting the array of open cells or columns with a honeycomb appearance. Methods for assembling a primary cushioning element with such a cover are also disclosed.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS Priority is hereby claimed to U.S. Provisional Patent Application No. 62 / 861,138, entitled "PILLOWS AND COVERS" (the "'138 Provisional Application"), filed June 13, 2019. The entire disclosure of the '138 Application is hereby incorporated herein.

[0002] The present disclosure relates generally to covers for pillows and other primary cushioning elements, and more particularly to covers having panels containing secondary cushioning elements. Even more particularly, the present disclosure relates to covers having a central pocket for receiving a cushioning element, such as a pillow or pillow insert, between a pair of secondary cushioning elements of the cover. The present disclosure also relates to cushions, such as pillows, including such covers, as well as methods of making and using covers for pillows and other primary cushioning elements. Summary of the Invention [Means for solving the problem]

[0003] A cover according to the present disclosure can have a configuration that allows it to receive a primary cushioning element, such as a pillow insert or pillow. The cover can include a first panel that carries a secondary cushioning element, a second panel, and a primary receptacle or pocket defined between the first and second panels. The pocket can receive the primary cushioning element. In some embodiments, the second panel can also carry a secondary cushioning element.

[0004] The secondary cushioning element of the first panel can include any suitable type of cushioning element. In certain embodiments, the secondary cushioning element can include a compressible, resilient, elastomeric material defining a plurality of thin, interconnected walls that define an array of cells or columns. Even more specifically, the compressible, resilient, elastomeric material can define a plurality of thin walls that, in turn, define an array of hexagonal cells in a so-called "honeycomb" structure. Such a secondary cushioning element can be secured (e.g., formed, bonded, adhered, etc.) to a portion of the first panel.

[0005] The first panel can include an outer layer and an inner layer with a secondary receptacle defined therebetween. In some embodiments, the periphery of the inner layer can be secured to the inner surface of the outer layer and / or to the periphery of the outer layer. The inner layer can be secured directly to the outer layer. Alternatively, the inner layer can be secured to the inner edge of a gusset, the outer edge of which is then secured to the outer layer, the gusset separating the inner and outer layers from each other. The secondary receptacle between the inner and outer layers can receive or carry a secondary cushioning element. In some embodiments, the secondary cushioning element can be secured to one or both of the outer and inner layers of the first panel. The secondary cushioning element can be permanently secured within the secondary receptacle in a manner that prevents access to the secondary cushioning element.

[0006] In embodiments in which the second panel includes a secondary cushioning element, the secondary cushioning element of the second panel can also include any suitable type of cushioning element, including, without limitation, a cushioning element comprising a compressible, resilient, elastomeric material defining a plurality of thin, interconnected walls that in turn define an array of cells or columns. In such embodiments, the second panel can also include an outer layer and an inner layer, and a secondary receiver defined between the outer and inner layers. In such embodiments, the periphery of the inner layer can be secured to the inner surface of the outer layer and / or to the periphery of the outer layer. The inner layer can be secured directly to the outer layer. Alternatively, the inner layer can be secured to the inner edge of a gusset, and the outer edge of the gusset can then be secured to the outer layer, which in turn secures the gusset. The seat separates the inner and outer layers from one another. A secondary receptacle between the inner and outer layers can receive or support a secondary cushioning element of the second panel. The secondary cushioning element of the second panel can be secured to one or both of the outer and inner layers of the second panel. The secondary cushioning element can be permanently secured within the secondary receptacle, preventing access to the secondary cushioning element.

[0007] The peripheral edges of the first and second panels of the cover can be secured to one another in a manner that defines a primary receiver between the first and second panels. In some embodiments, the peripheral portions of the first and second panels that are inseparably secured to one another can be directly secured to one another. In other embodiments, the peripheral portions of the first and second panels that are inseparably secured to one another can be indirectly secured to one another. As an example, the peripheral edge of the first panel (e.g., top panel, etc.) of the cover can be secured to a first edge (e.g., top edge, etc.) of the gusset, and the peripheral edge of the second panel (e.g., bottom panel, etc.) of the cover can be secured to a second edge (e.g., bottom edge, etc.) of the gusset, the gusset defining the perimeter of the cover and thus referred to herein as a "perimeter gusset." In embodiments where the first panel includes an inner layer and an outer layer and the second panel includes an inner layer and an outer layer, the inner layers of the first panel and the second panel can at least partially define the primary receptacle. In embodiments where the cover further includes a peripheral gusset, the peripheral gusset can also define a portion of the primary receptacle.

[0008] The cover can also include a primary opening, providing access to the primary receptacle. The primary opening can be defined by edges of the cover that can be separated from one another. For example, edge portions defining the primary opening can be separated from one another to open the primary opening and provide access to the primary receptacle of the cover. As another example, a zipper between edge portions defining the primary opening can be selectively unzipped to open the primary opening to the primary receptacle. As yet another example, a button or other fastener securing edge portions defining the primary opening together can be unbuttoned or otherwise unzipped to open the primary opening and provide access to the primary receptacle.

[0009] When the primary opening in the cover is open, the primary receptacle can receive a primary cushion element. More specifically, the primary opening in the cover can facilitate the introduction (and removal) of a primary cushion element, such as pillow filler, pillow insert, pillow, or the like, into (or out of) the primary receptacle. The primary receptacle can receive the primary cushion element such that each secondary cushion element at least partially or more completely covers a corresponding surface of the primary cushion element.

[0010] In another aspect, a cushion, such as a pillow, is disclosed that includes a cover according to the present disclosure and a cushioning element within the interior of the cover.

[0011] Also disclosed is a method for enhancing the cushioning of a cushioning element. A primary cushioning element, such as a pillow filler, pillow insert, existing pillow, or the like, can be introduced into a primary receptacle of a cover that includes a secondary cushioning element on one or both panels (i.e., major surfaces) thereof. When the primary cushioning elements are introduced into the primary receptacle, each secondary cushioning element of the cover can be at least partially overlapped by the pillow or filler. The resulting cushion can then be used to support a body part (e.g., an individual's head, back, legs, etc.). The overlapping of the secondary cushioning element over at least a portion of the primary cushioning element can change or enhance the manner in which the primary cushioning element cushions the body part.

[0012] Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosed subject matter, will become apparent to those skilled in the art through consideration of the ensuing disclosure, the accompanying drawings, and the appended claims. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is an exploded perspective view of an embodiment of a cushion and cushion cover according to the present disclosure, wherein the cover includes a first panel carrying a secondary cushioning element and a second panel carrying a secondary cushioning element, and wherein a primary cushioning element can be positioned between the first panel and the second panel. [Figure 1A] FIG. 2 is a top view of the cushion and cover shown in FIG. 1. [Figure 1B] 2 shows the cushion and cover shown in FIG. 1 from the side thereof. [Figure 2] 10 is a cross-sectional view of a variation of the cover of FIG. 1 in which the secondary cushioning elements of the first panel of the cover and the second panel of the cover are offset relative to one another. [Figure 3] 3 is a cross-sectional view of an embodiment of a secondary cushioning element of a panel of the cover variation shown in FIG. 2, showing that the secondary cushioning element is thicker at its center than at its periphery. [Figure 3A] 4A-4C show an embodiment of the surface of the secondary cushioning element of the embodiment shown in FIG. 3. [Figure 4] 10 is a cross-sectional view of another variation of the cover of FIG. 1, in which the secondary cushioning elements of the first panel of the cover and the second panel of the cover are substantially aligned with one another. [Figure 5] FIG. 2 is a cross-sectional view of yet another variation of the cover of FIG. 1, in which the individual secondary cushion elements of the first panel of the cover and the second panel of the cover include halves that define opposing surfaces of the secondary cushion elements and have patterns that are offset relative to one another. [Figure 6] A cross-sectional view of a first option for the secondary cushioning element of the cover variation shown in Figure 5, in which one half of the secondary cushioning element is thicker at its center than at its periphery, while the other half of the secondary cushioning element has a substantially uniform thickness. [Figure 7] 6 is a cross-sectional view of a second option for the secondary cushioning element of the cover variation shown in FIG. 5, in which both halves of the secondary cushioning element are thicker at their centers than at their peripheries. [Figure 8] 10 is a cross-sectional view of yet another variation of the cover of FIG. 1, in which the secondary cushioning elements of the first panel of the cover and the second panel of the cover have a substantially uniform thickness. [Figure 9] 9 is a cross-sectional view of a secondary cushioning element of a panel of the cover variation shown in FIG. 8. [Figure 10] 10 is a cross-sectional view of another embodiment of a cover for a cushion according to the present disclosure, in which a first panel and a second panel are secured to each other but spaced apart from each other via a peripheral gusset. [Figure 11] 1 is a perspective view of an embodiment of a cushion with a cover according to the present disclosure. FIG. [Figure 12] 10A-10C are diagrams of alternative embodiments of a pillow or pillowcase with a top panel, a bottom panel, a cushion insert, and a first cushioning element. DETAILED DESCRIPTION OF THE INVENTION

[0014] 1, 1A, and 1B, one embodiment of a cushion 10 according to the present disclosure is shown. The cushion 10 may comprise a pillow or any other type of cushion. The cushion 10 includes a cover 20 having a first panel 40, a second panel 60, and a primary receptacle 80 between the first panel 40 and the second panel 60. The first panel 40 and the second panel 60 may comprise opposing sides (e.g., top and bottom) of the cover 20. The primary receptacle 80, sometimes referred to herein as a "pocket," is configured to receive a primary cushioning element 100.

[0015] The first panel 40 can support or otherwise include a secondary cushioning element 50. The second panel 60 can also support or otherwise include a secondary cushioning element 70. Each secondary cushioning element 50, 70 can include any suitable cushioning material. The secondary cushioning elements 50 and 70 can be relatively thin. In various embodiments, the secondary cushioning elements 50 and 70 have a maximum thickness and a minimum thickness. The maximum thickness may be toward the center 56, 76 (FIG. 3) of the secondary cushioning element 50, 70 and the minimum thickness may be toward the periphery 58, 78 of the secondary cushioning element 50, 70.

[0016] As a non-limiting example, each secondary cushioning element 50, 70 can comprise a compressible, resilient elastomeric material (such as those described by U.S. Pat. Nos. 5,994,450, 6,797,765, and 7,964,664, the entire disclosures of which are incorporated herein by reference), which defines a plurality of thin interconnected walls 52, 72 that in turn define an array of cells or columns 54, 74 (such as those described by U.S. Pat. Nos. 5,749,111 and 6,026,527, the entire disclosures of which are incorporated herein by reference). The cells or columns 54, 74 of each secondary cushioning element 50, 70 can be hexagonally shaped, as illustrated by FIGS. 3 and 3A, although any circular or polygonal shape (e.g., square, diamond, triangle, etc.) is contemplated as being within the scope of the present disclosure. Secondary cushioning elements 50, 70 having other shapes or configurations are within the scope of this disclosure (e.g., solid sheets, bonded multi-component structures, etc.) Other materials may also be used to define each secondary cushioning element 50, 70, including, without limitation, other oil-extended block copolymers, foamed rubbers (e.g., natural latex, polyurethane, viscoelastic foams, etc.), and the like.

[0017] In some embodiments, the primary receptacle 80 may have a configuration that allows a consumer to place the primary cushioning element 100 in the primary receptacle 80 and remove the primary cushioning element 100 from the primary receptacle 80. Such a primary receptacle 80 may be accessible through a primary opening 90 in the cover 20, thus allowing the primary cushioning element 100 to be inserted into the primary receptacle 80 and the primary cushioning element 100 to be removed from the primary receptacle 80. In other embodiments, the primary cushioning element 100 may be permanently fixed within the primary receptacle 80.

[0018] As shown in FIG. 1A , the cover 20, in some embodiments, can include a pair of long sides 24 and 25 and a pair of short sides 26 and 27. As shown in FIG. 1B , a primary opening 90 providing access to the primary receptacle 80 of the cover 20 can extend along the entire length of the short side 26 of the cover 20. Alternatively, the primary opening 80 can extend along the long side 24 or multiple edges (including corners) of the cover 20 that can provide easy access to the primary receptacle 80, thus allowing the primary cushioning element 100 to be easily introduced into and removed from the primary receptacle 80 of the cover 20. In some embodiments, the primary opening 90 can be expandable as the material defining the primary opening 90 allows (e.g., via its elasticity, stretchability, etc.). A fastener 95 (e.g., a zipper, button, VELCRO® fastener, etc., which may be visible or hidden under one or more flap materials) may be associated with the primary opening 90 to enable closing of the primary opening 90 as well as its reopening.

[0019] 1, 1A, and 1B, the primary receptacle 80 can be inaccessible or even hidden when the primary opening 90 of the cover 20 is closed (e.g., zipped, fastened, folded over, etc.). The primary receptacle 80 can allow the secondary cushioning elements 50, 70 of the first panel 40 and the second panel 60, respectively, to at least partially cover corresponding surfaces of the primary cushioning element 100. In some embodiments, the secondary cushioning elements 50, 70 can extend the entire length and width of the primary cushioning element 100, providing an additional cushioning layer over each surface 105, 107 of the primary cushioning element 100, respectively.

[0020] The cover 20 can be rectangular, although it can have any number of suitable shapes (e.g., a regular polygon). Shapes such as squares, irregular polygons, stars, rounded shapes (e.g., circles, ovals, ellipses, etc.), and other shapes are also within the scope of this disclosure. In embodiments in which cover 20 has a rectangular shape, the periphery of three sides of first panel 40 can be secured to the periphery of three corresponding sides of second panel 60, while the corresponding periphery of the fourth side of first panel 40 and the fourth side of the second panel can define primary opening 90 (FIG. 1B). Primary opening 90 can remain continuously open and / or be selectively closeable (e.g., via a fastener (e.g., a button, zipper, etc.) that allows for closure and reopening, etc.). The dimensions of the first panel 40 and second panel 60 of such a cover 20 may vary, but may be approximately 20 inches (approximately 51 cm) by 26 inches (approximately 66 cm), i.e., the dimensions of a standard-sized pillow case or pillowcase, with reasonable deviations. However, other dimensions are contemplated and intended for larger pillows (i.e., queen-size pillows (20 inches by 30 inches, i.e., approximately 51 cm by 76 cm), king-size pillows (20 inches by 36 inches, i.e., approximately 51 cm by 91 cm), Euro pillows (26 inches by 26 inches, i.e., approximately 66 cm by 66 cm), and smaller pillows.

[0021] Primary cushioning element 100 can include any suitable cushioning element. In embodiments in which cushion 10 (FIGS. 1, 1A, and 1B) includes a pillow, primary cushioning element 100 can include filler material, a pillow insert, or a standard pillow. In some embodiments, an individual can select the particular primary cushioning element 100 they want to place within primary receptacle 80 of cover 20 to provide a customized cushion 10 that achieves a particular or desired cushioning effect.

[0022] FIG. 1 illustrates a specific embodiment of a primary cushioning element 100. The primary cushioning element 100 can be formed from a compressible, resilient foam material. By way of non-limiting example, the primary cushioning element 100 can be formed from a foam rubber, such as natural latex foam (e.g., Talalay latex foam, etc.), polyurethane foam, or the like. An array of channels 102 can extend through the thickness of the primary cushioning element 100. The channels 102 can facilitate airflow through the primary cushioning element 100 and the cushion 10 of which the primary cushioning element 100 is a part. Alternatively, the primary cushioning element 100 can include a compressible, resilient elastomeric material (e.g., materials described by U.S. Pat. Nos. 5,994,450, 6,797,765, and 7,964,664, the entire disclosures of which are hereby incorporated by reference). The elastomeric material defines a plurality of thin interconnected walls, which in turn define an array of cells or columns (e.g., cushioning elements such as those described by U.S. Pat. Nos. 5,749,111 and 6,026,527 and U.S. Patent Application Publication No. 2018 / 0305199 A1, the disclosures of which are incorporated herein in their entireties).

[0023] In embodiments in which the primary cushioning element 100 includes a filler material, the filler material may include any material suitable for use as a cushion, such as a pillow (e.g., for use in cushioning an individual's head, back, legs, etc.). The filler material may be introduced directly into the primary receptacle 80 to define the primary cushioning element 100 of the cushion 10. Alternatively, the filler material may be contained within a separate cover that, together with the filler material, defines the primary cushioning element 100 (e.g., an existing pillow, etc.) prior to its placement in the primary receptacle 80.

[0024] Turning now to Figure 2, the first panel 40 and second panel 60 of a particular embodiment of the cover 20 are illustrated in further detail. The first panel 40 can include an outer layer 42 and an inner layer 46. The outer layer 42 and the inner layer 46 can include thin layers secured to one another about their respective outer perimeters 44, 48. As illustrated in Figure 2, the outer perimeters 44, 48 of the outer layer 42 and the inner layer 46, respectively, can be secured directly to one another (e.g., by stitching, bonding, etc.). Alternatively, the outer peripheries 44, 48 of the outer and inner layers 42, 46, respectively, can be secured to corresponding edges of gussets (not shown in FIG. 2) that indirectly secure the outer and inner layers 42, 46 to one another.

[0025] The second panel 60 may similarly include an outer layer 62 and an inner layer 66. The outer layer 62 and the inner layer 66 may include thin layers secured to one another about their respective perimeters 64, 68. As illustrated in Figure 2, the perimeters 64, 68 of the outer layer 62 and the inner layer 66 may be secured to one another directly (e.g., with stitching, bonding, etc.). Alternatively, the outer layer 62 and the inner layer 66 may be secured to one another indirectly by securing the perimeters 64, 68 of the outer layer 62 and the inner layer 66 to corresponding edges of a gusset (not shown in Figure 2).

[0026] In some embodiments, the outer layer 42, 62 and the inner layer 46, 66 can be breathable, or allow air to flow therethrough. The outer layer 42, 62 and the inner layer 46, 66 can be formed from a flexible material, such as a fabric. The fabric can be elastically stretchable (e.g., the fabric can contain up to 10% spandex, elastane, or the like). The fabric can include a moisture-wicking material, which can provide a cooling effect when the body portion is placed against it. Without limitation, the outer layer 42, 62 can be formed from a stretch nylon, which can include visible perforations therethrough (i.e., nylon mesh), while the inner layer 46, 66 can be formed from a soft, lightly lofted fabric, such as cotton or a cotton-polyester blend. Other examples of fabrics that can be used to define the outer layers 42, 62 and inner layers 46, 66 include, but are not limited to, cotton fabrics, cotton blend fabrics, rayon, polyester, other synthetic fabrics, and bamboo fabrics, to name just a few.

[0027] In the first panel 40 of the cover 20, the secondary cushioning element 50 can be positioned between the outer layer 42 and the inner layer 46. The second panel 60 of the cover 20 can similarly include a secondary cushioning element 70 positioned between the outer layer 62 and the inner layer 66 of the second panel 60. Each secondary cushioning element 50, 70 can include a compressible, resilient elastomeric material that defines a plurality of thin interconnected walls 52, 72 that in turn define an array of cells or columns 54, 74. The thin interconnected walls 52 and array of cells or columns 54 of the secondary cushioning element 50 of the first panel 40 can be offset relative to the thin interconnected walls 72 and array of cells or columns 74 of the secondary cushioning element 70 of the second panel 60.

[0028] As depicted by FIG. 3 , each secondary cushioning element 50, 70 can include a larger-profile center 56, 76 and a smaller-profile perimeter 58, 78. The cushioning element 50, 70 can have longer or taller cells or columns 54, 74 at and around the center 56, 76 and shorter cells or columns 54, 74 at and near the perimeter 58, 78. In some embodiments, the outer surface 51, 71 of the secondary cushioning element 50, 70 can gradually taper from its center 56, 76 or central portion 57, 77 downward to its perimeter 58, 78. Such a taper can be linear or curved. Stated another way, the length or height of the cells or columns 54, 74 can form a gradient, decreasing from the center 56, 76 to the perimeter 58, 78 or increasing from the perimeter 58, 78 to the center 56, 76. Such cushioning embodiments are exemplified by U.S. Design Patent Application Nos. 29 / 694,846 and 29 / 694,851, the disclosures of which are incorporated herein in their entireties. Such a configuration can enable the center 56, 76 or central portion 57, 77 of the secondary cushioning element 50, 70 to provide greater support and cushioning than is provided by the peripheral locations and peripheries 58, 78 of the secondary cushioning element 50, 70. By way of non-limiting example, the thickness of each secondary cushioning element 50, 70 at its center 56, 76 can be from about 1 / 2 inch (about 1 1 / 4 cm) to about 2 inches (about 5 cm), while the thickness of each secondary cushioning element at its periphery 58, 78 can be from about 1 / 2 inch (about 1 1 / 4 cm) to about 2 inches (about 5 cm). The thickness of 50, 70 can be from about 1 / 16 inch (about 1.5875 mm) to about 1 inch (about 2.54 cm). In a more specific embodiment, the thickness of each secondary cushioning element 50, 70 at its center 56, 76 can be about 1 inch (about 2.54 cm), while the thickness of each secondary cushioning element 50, 70 at its periphery 58, 78 can be about 1 / 8 inch (about 3.175 mm). Such secondary cushioning elements 50, 70 can taper outward from anywhere on the periphery 58, 78 toward the center 56, 76 over a distance of about 5 3 / 4 inches (about 14.6 cm). Thus, the central portion 57, 77 of the secondary cushioning element 50, 70, having a substantially uniform thickness, can be longer than it is wide, meaning that the area of ​​maximum thickness can have substantially the same shape as the secondary cushioning element 50, 70. Even in a standard size pillow having dimensions of approximately 20 inches by 26 inches (approximately 51 cm by approximately 66 cm), the central portion 57, 77 having a substantially uniform thickness can include most of the area of ​​the secondary cushioning elements 50, 70.

[0029] 2, each secondary cushioning element 50, 70 can be secured to the corresponding inner layer 46, 66 of its corresponding panel (i.e., the first panel 40 or the second panel 60, respectively). The secondary cushioning elements 50 and 70 can be manufactured simultaneously by placing overlapping layers of fabric or scrim between two sides of a mold and then molding each secondary cushioning element 50, 70 onto the corresponding scrim. Once the secondary cushioning elements 50, 70 are molded, each scrim can remain attached to its respective secondary cushioning element 50, 70, while each of the corresponding inner layers 46, 66 can be removed from attachment to each other and thus function as the inner layers 46, 66 of the panels (i.e., the first panel 40 and the second panel 60, respectively) of the cover 20. Alternatively, the secondary cushioning elements 50, 70 can be secured to one or both of their respective outer and inner layers 42, 62, 46, 66 by any other suitable technique (e.g., heating and melting an elastomeric material, ultrasonic welding, adhesive bonding, stitching, etc.). Furthermore, the first cushioning element 14 can be secured to the top panel 18 via similar means. It will be appreciated that open knit or woven fabrics can be utilized as scrims or other fabric portions to allow for breathability and air flow.

[0030] 2, the plurality of interconnected walls 52 and array of cells or columns 54 of the secondary cushioning element 50 can be laterally offset from the plurality of interconnected walls 72 and array of cells or columns 74 of the secondary cushioning element 70. Such secondary cushioning element embodiments are illustrated in U.S. Design Patent Application Nos. 29 / 694,846 and 29 / 694,851.

[0031] Figure 4 illustrates an embodiment of cover 20', which may include many or all of the same features and elements as the embodiment of cover 20 shown in Figure 2. The primary difference between cover 20' and cover 20 is that the plurality of interconnected walls 52' and array of cells or columns 54' of the secondary cushioning element 50' of the first panel 40' of cover 20' substantially align with the plurality of interconnected walls 72' and array of cells or columns 74', respectively, of the secondary cushioning element 70' of the second panel 60' of cover 20'.

[0032] FIG. 5 illustrates an embodiment of a cover 20″ in which each secondary cushioning element 50″, 70″ includes a first half 50a″, 70a″ and a second half 50b″, 70b″. The halves 50a″ and 50b″, 70a″ and 70b″ define opposing surfaces of the secondary cushioning element 50″, 70″. The first half 50a″, 70a″ includes a compressible, resilient elastomeric material that defines a plurality of thin, interconnected walls 52a″, 72a″ that in turn define an array of cells or columns 54a″, 74a″ and a second half 50b″, 70b″. The second half 50b″, 70b″ also includes a compressible, resilient elastomeric material that defines another plurality of thin, interconnected walls 52a″, 72a″. The first half 50a", 70a" and the second half 50b", 70b" have patterns that are offset from one another. More specifically, the plurality of thin interconnecting walls 52a", 72a" of the first half 50a", 70a" can be laterally offset from the other plurality of thin interconnecting walls 52b", 72b" of the second half 50b", 70b", and thus the array of cells or columns 54a", 74a" of the first half 50a", 70a" can be laterally offset from the other array of cells or columns 54b", 74b" of the second half 50b", 70b", as illustrated by FIG. 5, as well as by FIG. 3A and U.S. Design Patent Application Nos. 29 / 694,846 and 29 / 694,851. Alternatively, the plurality of thin interconnecting walls 52a", 72a" and array of cells or columns 54a", 74a" of the first half 50a", 70a" can be aligned with the other plurality of thin interconnecting walls 52b", 72b" and other array of cells or columns 54b", 74b" of the second half 50b", 70b".

[0033] FIG. 6 shows an example of a secondary cushioning element 50", 70" in which a first half 50a", 70a" has a variable thickness from its central location 57a", 77a" to its outer periphery 58a", 78a", such as the taper described earlier in this specification with reference to FIG. 3. The second half 50b", 70b" of such a secondary cushioning element 50", 70" can have a substantially uniform thickness throughout the area occupied by the second half 50b", 70b".

[0034] FIG. 7 shows another example of a secondary cushioning element 50", 70", where a first half 50a", 70a" has a variable thickness from its central location 57a", 77a" to its outer periphery 58a", 78a", such as the taper described earlier in this specification with reference to FIG. 3. A second half 50b", 70b" of such a secondary cushioning element 50", 70" similarly has a variable thickness from its central location 57b", 77b" to its outer periphery 58b", 78b". Thus, both halves 50a", 50b", 70a", and 70b" of each secondary cushioning element 50", 70" of a cover 20" can be thicker at the center than at their peripheries.

[0035] Secondary cushioning elements 50", 70" with an offset arrangement such as that illustrated by FIGS. 5-7 can provide greater support than other embodiments of the secondary cushioning element while allowing air to flow through the secondary cushioning element 50", 70". A fabric or scrim can be molded into place between the first half 50a", 70a" and the second half 50b", 70b" of each secondary cushioning element 50", 70", and the halves 50a" and 50b", 70a" and 70b" can be secured to their respective scrim. The scrim can comprise a single, complete piece of fabric extending through the thickness of the secondary cushioning element 50", 70", across the entire area occupied by the secondary cushioning element 50", 70". The scrim can be perforated, cut, or modified to enhance the breathability, support, and / or stability of the secondary cushioning element 50", 70". The scrim can also have an effect on the cushioning properties of the secondary cushioning element 50", 70", for example, the stretch and resilience of the scrim can contribute to the feel of the secondary cushioning element 50", 70" on all of its outer surfaces.

[0036] Other than the configuration of secondary cushioning elements 50'" and 70'", the embodiment of cover 20"' illustrated by FIG. 8 can include many or all of the same elements and features as the embodiment of cover 20 illustrated by FIG. 2, the embodiment of cover 20' illustrated by FIG. 4, and the embodiment of cover 20" illustrated by FIG. 5. With additional reference to FIG. 9, each secondary cushioning element 50"', 70"' of cover 20"' can have a substantially uniform thickness throughout the area it occupies, i.e., from its center 56"', 76"' across its central location 57"', 77"' to its outer periphery 58"', 78"'.

[0037] 10 provides a cross-sectional view of another embodiment of a cushion cover 120 according to the present disclosure, in which a first panel 140 including a secondary cushioning element 150 and a second panel 140 including a secondary cushioning element 170 are secured to each other but spaced apart via a peripheral gusset 130. The peripheral gusset 130 may comprise an elongated flexible element (e.g., a strip of breathable material, a strip of fabric, etc.) and includes a first edge 134 along the length of the peripheral gusset 130 and a second edge 136 along the length of the peripheral gusset 130. The first edge 134 and the second edge 136 may face each other. The first edge 134 of the peripheral gusset 130 may be secured to an outer periphery 141 of the first panel 140, and the second edge 136 of the peripheral gusset 130 may be secured to an outer periphery 161 of the second panel 160.

[0038] The peripheral gusset 30 can carry at least a portion of a fastener (not shown in FIG. 10) to provide selective access to the primary opening 90 (FIG. 1B) in the cover 120.

[0039] While FIGS. 4, 5, 8, and 10 illustrate embodiments of covers 20', 20", 20'", and 120, respectively, the secondary cushioning elements 50' and 70', 50" and 70", 50"' and 70"', and 150 and 170 are substantially the same as or identical to one another, embodiments of cover 20 including combinations of different cushioning elements 50 and 70 are also within the scope of this disclosure, as illustrated only to a limited extent in FIG. 2. The use of cushioning elements 50, 70 that differ in softness, thickness, material, or other characteristics can provide for individual use of cover 20 relative to primary cushioning element 10 with the ability to experience different cushioning effects with the same cushion 10 (FIGS. 1, 1A, and 1B).

[0040] FIG. 11 shows an embodiment of an assembled cushion 10 including any embodiment of a cover 20 according to the present disclosure, with a secondary cushioning element 50 visible through the cover 20.

[0041] Referring to FIG. 12 , another embodiment of a cushion 210 is illustrated. The cushion's cover 220 includes a first panel 240 and a second panel 260 with a primary receptacle 280 therebetween. Only the first panel 240 of the cover 220 includes a secondary cushioning element 250. The first panel 240 and its secondary cushioning element can be configured in any suitable manner, including those previously described herein. The second panel 260 can include one or more layers of flexible material, such as fabric (e.g., breathable fabric, moisture-wicking fabric, etc.). The primary receptacle 280 can receive the primary cushioning element 100.

[0042] Although the cushion embodiments described herein include a primary receptacle that can removably receive a primary cushion element, a closure system that includes a cover according to the present disclosure, and the primary cushion element permanently secured therein, the lack of modularity is also considered to be within the scope of the present disclosure.

[0043] While the above description contains many specifics, they should not be construed as limiting the scope of the invention as set forth by any of the appended claims, but merely as providing information relevant to some specific embodiments that may fall within the scope of the appended claims. Features from different embodiments may be combined and employed. Additionally, other embodiments may also fall within the scope of the appended claims. All additions, deletions, and modifications of the disclosed subject matter that fall within the scope of the claims are to be embraced within the scope of the claims.

Claims

1. a first panel including an outer layer, an inner layer, and a secondary cushioning element between the outer layer and the inner layer; a second panel overlaid on the first panel, the second panel including an outer layer and an inner layer, and an outer periphery of the second panel secured to a corresponding outer periphery of the first panel; a primary receiver defined between the first panel and the second panel for receiving a primary cushioning element; Includes a cover for the cushion.

2. The cover of claim 1 , wherein the secondary cushioning element comprises a compressible, resilient, elastomeric material defining a plurality of interconnecting walls that define an array of cells.

3. The cover of claim 2 , wherein a central region of the secondary cushioning element is thicker than a periphery of the secondary cushioning element.

4. The secondary cushioning element comprises: a first half defining a first major surface of the secondary cushioning element and including a first plurality of interconnected walls defining a first array of cells; a second half defining a second major surface of the secondary cushioning element and including a second plurality of interconnected walls defining a second array of cells; The cover of claim 1 or 2, comprising:

5. The cover of claim 4 , wherein the second plurality of interconnecting walls and the second array of cells are laterally offset from the first plurality of interconnecting walls and the first array of cells.

6. The cover of claim 4 , wherein the second plurality of interconnecting walls and the second array of cells are aligned with the first plurality of interconnecting walls and the first array of cells.

7. The cover of any one of claims 4 to 6, wherein the secondary cushioning element further comprises a scrim positioned between the first half and the second half.

8. The cover of any one of claims 1 to 7, wherein the second panel includes an inner layer, an outer layer, and another secondary cushioning element between the inner and outer layers.

9. 9. The cover of claim 1, further comprising a primary opening providing access to the primary receptacle, the primary opening allowing introduction of the primary cushioning element into the primary receptacle.

10. 10. The cover of claim 9, wherein the first panel, the second panel, the primary cushioning element, and the secondary cushioning element are substantially rectangular in shape.

11. The cover of claim 10 , wherein at least a portion of three outer perimeter edges of the first panel are secured to at least a portion of three corresponding outer perimeter edges of the second panel.

12. The cover of any preceding claim, wherein the outer periphery of the first panel is sewn to the corresponding outer periphery of the second panel.

13. a first panel including an outer surface, an inner surface, and a secondary cushioning element between the outer surface and the inner surface; a second panel overlaid on the first panel, the peripheral edge of the first panel being secured to a corresponding peripheral edge of the second panel; a primary receiver defined between the first panel and the second panel; a primary cushioning element positionable within the primary receptacle; Cushion including cover.

14. 14. The cushion of claim 13, comprising a pillow.

15. 15. The cushion of claim 14, wherein the primary cushion element comprises a standard pillow removable from and replaceable within the primary receptacle.

16. A cushion according to any one of claims 13 to 15, wherein the secondary cushioning element comprises a compressible, resilient, elastomeric material defining a plurality of interconnecting walls defining an array of cells.

17. 17. The cushion of claim 16, wherein at least some of the plurality of interconnected walls include buckling walls that define buckling cells.

18. The secondary cushioning element comprises: a first half defining a first major surface of the secondary cushioning element and including a first plurality of interconnected walls defining a first array of cells; a second half defining a second major surface of the secondary cushioning element and including a second plurality of interconnected walls defining a second array of cells; 18. The cushion of claim 16 or 17, comprising:

19. 20. The cushion of claim 18, wherein the second plurality of interconnected walls and the second array of cells are laterally offset from the first plurality of interconnected walls and the first array of cells.

20. 20. The cushion of claim 18, wherein the second plurality of interconnected walls and the second array of cells are aligned with the first plurality of interconnected walls and the first array of cells.

21. The cushion of any of claims 18 to 20, wherein the secondary cushioning element further comprises a scrim located between the first half and the second half.

22. The cushion of any of claims 13 to 21, wherein the second panel of the cover includes an outer surface, an inner surface, and a secondary cushioning element between the outer surface and the inner surface.

23. introducing a primary cushioning element into the primary receptacle of the cover according to any one of claims 1 to 12, The primary receptacle is defined between a first panel of the cover and a second panel of the cover, and the method for assembling the cushion includes stacking a secondary cushion element of the first panel onto a first surface of the primary cushion element.

24. 25. The method of claim 23 or 24, wherein the introducing step further comprises overlaying another secondary cushioning element of the second panel onto the second side of the primary cushioning element.

25. removing the primary cushioning element from the primary receptacle; introducing another primary cushioning element into the primary receptacle; 24. The method of claim 23, further comprising:

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