PERSONAL SUPPORT DEVICE HAVING ELONGATED INSERT - Patent application

Abstract

The present invention relates to a comfort device having multiple elongated inserts. The comfort device has one or more compartments for receiving the elongated inserts. The multiple elongated inserts have a length and a cross-section, the cross-section having a cross-sectional area and multiple cross-sectional dimensions. The length of the insert is at least 8 inches long and is at least 8 times the maximum cross-sectional dimension. The comfort device has one or more openings and a fastening mechanism corresponding to the one or more openings. The elongated inserts generate a tensile force in response to a force applied to the comfort device, thereby improving the stretchability of the comfort device.

Description

[Technical field]

[0001] SUMMARY The present disclosure relates to personal support devices, such as pillows and other types of cushions, that are filled with multiple elongated inserts of resilient material. [Background technology]

[0002] Personal support devices such as pillows and cushions are used to provide comfort to users when sitting or lying down. Such pillows and cushions are filled with different types of inserts having different material properties and properties to provide different levels of support and comfort to the user. Summary of the Invention [Problem to be solved by the invention]

[0003] It would be desirable to have an insert that is breathable and washable, yet maintains its volume and cushioning over time. Various configurations, materials and shapes have been proposed or implemented to provide sufficient support and comfort to the user. [Means for solving the problem]

[0004] The present disclosure includes embodiments of systems, devices, and methods for manufacturing a cushion having multiple elongate inserts for providing physiological support to a user.

[0005] At least one aspect of the embodiments disclosed herein may provide unexpected benefits from the use of long ribbons of elastic material as filler for personal cushioning devices. For example, in this context, it is important to note that some conventional personal cushioning devices, such as pillows, are often filled with small randomly sized pieces of foam scraps. Foam scraps such as those shown in FIG. 1 have a size of about 1 / 2 to about 1 1 / 2 inches in diameter. Such pieces have random shapes, and thus, although the size of the pieces is characterized herein as a diameter, such pieces are not necessarily spherical or even circular. Rather, such pieces may be of many different random sizes and shapes.

[0006] Another aspect of at least one of the inventions disclosed herein includes the recognition that such small, randomly shaped pieces of elastic material are subject to large loads in compression or shear during use and also suffer from durability issues, resulting in breakage and dust emission. For example, a conventional personal cushioning device filled with such small, randomly sized pieces of material is compressed under load when a user places their head on the pillow. Under such compression, the small, randomly sized pieces of material are subject to large loads only in compression and shear. The resulting stress on such small, randomly sized pieces of material, typically cellular foam, results in undesirable breakage and dust emission. This is due to the greatly reduced effective cross-sectional area resulting from concentrating the forces caused by the load on a small cross-sectional area, resulting in a grinding or crushing process that further concentrates the resulting stresses and increases the likelihood of damage (breakage).

[0007] At least some embodiments of the invention disclosed herein provide an improved personal cushioning device by filling the personal cushioning device with pieces of elastic material having a length greater than about 6 inches. For example, a personal cushioning device can be filled with pieces of elastic material having a length greater than about 6 inches and arranged in a random intertwined orientation, thereby increasing the likelihood that some of the pieces of material will be partially loaded in tension during use. For example, elongated pieces of elastic material, when used as filler for a personal cushioning device such as a pillow and arranged in a random orientation, will intertwine with each other. As a result of such intertwining, a first end of some pieces may intertwine with another piece located near the periphery of the cushion and a second end may intertwine with another piece located closer to the center of the cushion. When the cushion is crushed in the center, the second end of the elongated piece is pulled down with the central piece and the first end remains substantially stationary with the surrounding pieces. In this manner, the elongated pieces may be loaded in tension. This lengthening is similar to the loading of a spring around a trampoline and can therefore cause a reactive stretching / loading of the elongated ribbon of the personal cushioning device. Such tensile loading of the elongated ribbon can result in a greater elastic elongation than is possible under compressive loading resulting from small particle filler compositions used in known pillows. Thus, in some embodiments, a different cushioning property can be achieved compared to cushions filled with small randomly sized pieces.

[0008] Another aspect of at least one of the inventions disclosed herein, when elongated ribbons are used as filler for a personal cushioning device, can provide better airflow through the cushion during use. For example, at least one aspect of one of the inventions disclosed herein includes the recognition that when elongated elastic members having lengths greater than, for example, about 6 inches are used as filler for a personal cushioning device, the elongated members intertwine similarly to strands of spaghetti in a bowl of spaghetti. The elongated members are often in an orientation that extends through rounded curves, thereby forming voids between adjacent elongated members. The voids formed in portions of the cushion that are not compressed define open air passages therebetween and support some airflow therein. Airflow through the pillow is useful and desirable for some users who prefer a "cooler" pillow or cushion.

[0009] Another aspect of at least one of the inventions disclosed herein includes the recognition that elongated elastic members used as filling materials for personal cushioning devices can be more easily manufactured when they have a shape with an outer surface that can be aligned in a continuous plane when stacked. For example, some known pillows include elongated filling members with a rounded cross-section. Elongated members with such cross-sectional shapes are typically stamped or punched from foam material. Alternatively, other substantially rounded cross-sectional shapes (e.g., pentagons, hexagons, heptagons, octagons, etc.) can be formed by cutting with a cutting tool that moves through the virgin material in a non-linear cut. However, such cutting techniques are difficult to perform, more time consuming, and produce additional waste. In contrast, according to at least one embodiment disclosed herein, elongated elastic members can be formed with a cross-section with sides that can be aligned in a continuous plane when stacked. Such cross-sections can be rectangular, square, or triangular. Elongated members with such cross-sectional shapes can be cut from a block of virgin material using a plurality of linear planar cuts. This results in a significantly faster, cheaper and less wasteful manufacturing process.

[0010] Another aspect of at least one of the inventions disclosed herein includes the recognition that elastic members used as filler in personal cushioning devices may deteriorate over time due in part to tearing. Tearing of elastic members used as filler in personal cushioning devices occurs when the stress on such elastic members exceeds the ultimate tensile or compressive strength of the members. Loading of foams, particularly open-cell foams, results in all stresses being concentrated in the remaining cell walls within the internal structure of the foam.

[0011] At least one aspect of the invention disclosed herein involves the recognition that loads, including shear and tensile forces, on elastic pieces of material in personal cushioning devices may be sufficient to tear such foam pieces when the cross-sectional area of ​​such foam pieces is less than 1 / 16 square inch. It has been discovered that when such elastic members are molded with cross-sectional areas greater than approximately 1 / 16 square inch, they can withstand the loads encountered during use in personal cushioning devices for a significantly longer life without tearing. Thus, such personal cushioning devices including elongated filler material having lengths of at least about 6 inches and cross-sectional areas of at least 1 / 16 square inch have a significantly longer life without tearing and generate less dust.

[0012] In some embodiments, the comfort device can include: (i) an outer cover having an upper sidewall and a lower sidewall; (ii) a first interior compartment in the cover between the upper sidewall and the lower sidewall; (iii) an opening in the outer cover that opens to the interior compartment of the outer cover; (iv) a fastening assembly in the opening that has at least a first fastening element, the fastening element being movable between an open position and a closed position; and (v) a plurality of elongate inserts in the first interior compartment of the outer cover. The plurality of elongate inserts comprises an open cell foam material, a first end, a second end, a middle portion, and a length between the first end and the second end. The plurality of elongate inserts have a length of at least 8 inches. The plurality of elongate inserts have a cross-section extending perpendicular to a length of the plurality of elongate inserts, the cross-section defining a cross-sectional area of ​​at least one-sixteenth of an inch, the cross-section also having at least a plurality of cross-sectional dimensions. The length is at least 8 times the largest cross-sectional dimension of the plurality of cross-sectional dimensions. Additionally, at least one aspect of the invention disclosed herein includes the recognition that limiting the cross-sectional area of ​​the elongate member can provide an associated comfort device with a smoother appearance with fewer indentations. Thus, in some embodiments, the elongate member has a cross-sectional area of ​​1 square inch or less, 3 / 4 square inch or less, 1 / 2 square inch or less, 3 / 8 square inch or less, 1 / 4 square inch or less, 1 / 8 square inch or less, 1 / 16 square inch or less, or less. For example, a square cross-section elongate member with a 3 / 4 inch long side would have a cross-sectional area of ​​0.5635 square inches, which is approximately 1 / 2 square inch.

[0013] In some embodiments, the comfort device may further include one or more of the following features in any combination: (a) the plurality of elongate inserts have a load deflection modulus between 10 ILD and 40 ILD and a density between 0.5 pcf and 8.0 pcf, (b) one or more of the plurality of inserts have a uniform cross-section along its length, and (c) one or more of the plurality of inserts have a non-uniform cross-section along its length, e.g., a first end has a first cross-section, a second end has a second cross-section, and an intermediate portion has a third cross-section, wherein the first cross-section and the second cross-section have the same cross-sectional shape and the third cross-section has a different cross-sectional shape than the first cross-section and the second cross-section. (d) the plurality of elongated inserts have varying lengths; (e) a first end, a second end and an intermediate portion of the plurality of elongated inserts have a rectangular cross-sectional shape; (f) the outer cover of the comfort device comprises one or more compartments; (g) the one or more compartments have different volumes and shapes; (h) the one or more compartments accommodate elongated inserts having different stretch properties; and (i) the fastening mechanism utilizes at least one of the following mechanisms: zippers, hooks, ties, Velcro®, clips, buttons, clasps, straps, and pins.

[0014] In some embodiments, a comfort device may include: (i) an outer cover having an upper sidewall and a lower sidewall, (ii) a first interior compartment within the cover between the upper sidewall and the lower sidewall, (iii) an opening within the outer cover that opens into the interior compartment of the outer cover, and (iv) a plurality of elongated inserts within the first compartment of the outer cover, the plurality of elongated inserts comprising an open cell foam material, a first end, a second end, an intermediate portion, and a length between the first end and the second end, the plurality of elongated inserts having a cross-section defining a cross-sectional area of ​​at least one-sixteenth of an inch, the cross-section also comprising at least a plurality of cross-sectional dimensions, the length being at least eight times the largest cross-sectional dimension of the plurality of cross-sectional dimensions.

[0015] In some embodiments, a method for batch manufacturing pillows filled with a plurality of elongated inserts can be made from a block of foam cut into batches. For example, the method can include: (i) placing the block of foam in a cutting machine; (ii) cutting a first batch of elongated inserts, the first batch having a first volume sufficient for a first pillow, collecting the first batch of elongated inserts on a first conveyor belt; (iii) moving the first batch of elongated inserts away from the block of foam; (iv) cutting a second batch of elongated inserts from the block of foam, the second batch having a second volume equal to a total volume of several elongated inserts required for a second pillow, collecting the second batch of elongated inserts on the first conveyor belt; and (v) spacing the first batch of elongated inserts away from the second batch of elongated inserts.

[0016] Another aspect of at least one of the inventions disclosed herein includes the recognition that a comfort device, such as a cushion or pillow, may be manufactured more efficiently by, for example, mixing layers of different cushioning materials into a larger block of cushioning material before cutting the block of cushion into its final shape. For example, in some embodiments, a block of cushioning material may comprise multiple layers of different types of materials. Thus, when further cuts are made on the block of material, the cut piece comprises a mixture of the different materials of the layers. The concentration of the amount of the first and second materials may be altered by adjusting the number and size of each of the multiple layers.

[0017] In some embodiments, the block of material can be cut to create at least partially mixed batches of cushioning members, with a subgroup of cushioning members made from a first material and a second subgroup of cushioning members made from a second, different material. In some embodiments, after an appropriate number of batches of cushioning members have been cut from such a multi-layered, multi-material block, the cushioning members are mixed to further mix and randomize their distribution. One or more batches of cushioning members can then be inserted into the cushion shell.

[0018] In some embodiments, a block of mixed cushioning material can include groups of layers of different materials. For example, a block of cushioning material with layers of two different materials can be arranged such that all of the layers of one material are adjacent to each other and all of the layers of the second material are adjacent to each other, thereby dividing the block into two groups that are independent and adjacent to each other. The two groups of layers can be in direct contact, one on top of the other or adjacent to each other.

[0019] In some embodiments, the different layers of the multi-material block can be intermixed with each other before being cut into the final shape. For example, a block of cushioning material can include multiple layers of different materials, with the layers arranged in an alternating pattern. Thus, when the cushioning member is cut from the multi-layer block, some intermixing of the cushioning member has already been achieved due to the alternating arrangement of the layers of material. Such fully or partially premixed cushioning members can optionally be mixed using a downstream mixing device prior to insertion into the cushion shell.

[0020] For purposes of summarizing the disclosure, certain aspects, advantages, and novel features have been described herein. Of course, it should be understood that not necessarily all such aspects, advantages, or features may be embodied in any particular embodiment. [Brief description of the drawings]

[0021] [Figure 1] FIG. 1 illustrates two different types of foam scraps used in prior art pillows. [Diagram 2] FIG. 1 shows a prior art monoblock type foam insert for a pillow. [Figure 3A] FIG. 2 is a schematic diagram of a pillow having multiple pillow inserts. [Figure 3B] 3B is a top, right and left perspective view of the pillow embodiment of FIG. 3A. [Figure 4A] FIG. 4 is a perspective view of a variation of the embodiment of FIG. 3 in the form of a sleep pillow having multiple elongated pillow inserts. [Figure 4B] 4B is a schematic diagram of a variation of the pillow of FIG. 4A having a first arrangement of internal compartments. [Figure 4C] 4B is a schematic diagram of a variation of the pillow of FIG. 4A having a second arrangement of the interior compartments. [Figure 4D] 4B is a schematic diagram of another variation of the pillow of FIG. 4A having a third arrangement of the interior compartments. [Figure 4E] 4B is a schematic diagram of yet another variation of the pillow of FIG. 4A having a fourth arrangement of the interior compartments. [Diagram 5] 1A-1D are perspective views of three embodiments of elongated pillow inserts that may be used with the embodiments of the personal cushioning device disclosed herein. [Figure 6] 1 is a schematic perspective view of an embodiment of an elongated insert having a rectangular cross section; [Figure 7] 7 is a schematic perspective view of a variation of the elongated insert of FIG. 6 having a different triangular cross section. [Figure 8] FIG. 13 is another perspective view of an embodiment of a pillow having multiple elongated pillow inserts, showing further details of the interaction between the elongated pillow inserts. [Figure 9] 1 is a schematic side partial cutaway view of an embodiment of a pillow in a relaxed state showing intertwined groups of elongate members, one group near the center of the cushion and another group closer to the edge of the cushion. FIG. [Figure 10]10 is a schematic side partial cutaway view of the cushion of FIG. 9 in which a group of elongate members near the center of the cushion is compressed, creating tension in the elongate members extending between the two groups. [Figure 11] 13 is a perspective view of a sheet material that can be used to form another embodiment of an elongate member that can be used to fill another embodiment of a cushion. FIG. [Figure 12] FIG. 1 is a perspective view of a block of virgin elastic material with optional cut lines for cutting the block into groups of elongated members for filling the cushion. [Figure 13A] FIG. 13 is a perspective view of the block of virgin elastomeric material of FIG. 12 showing further detail of a lower portion of the block of virgin elastomeric material. [Figure 13B] FIG. 2 is a schematic end view of a group of elongated members having circular cross sections stacked on top of one another with star-shaped gaps between them. [Figure 13C] FIG. 2 is a schematic end view of a group of elongated members having hexagonal cross sections stacked on top of one another. [Figure 13D] FIG. 2 is a schematic end view of a group of elongated members having rectangular cross sections stacked on top of one another. [Figure 13E] FIG. 2 is a schematic end view of a group of elongate members having triangular cross sections stacked on top of one another. [Figure 14] FIG. 13 is a perspective view of a cutting machine with a conveyor belt illustrating an optional procedure for cutting a block of virgin elastomeric material into groups of elongated members for filling the cushions. [Figure 15] FIG. 1 is a perspective view of an assembly of two different layers of virgin elastic material with optional cut lines for cutting the assembly into groups of elongated members for filling the cushion. [Figure 16] FIG. 16 is a perspective view of the assembly shown in FIG. 15, with the layers interleaved. [Figure 17] FIG. 1 is a perspective view of an assembly of four different layers of virgin elastic material with optional cut lines for cutting the assembly into groups of elongated members for filling the cushion. [Figure 18] FIG. 18 is a perspective view of the assembly shown in FIG. 17, with an optional further alternating layer arrangement. [Figure 19] FIG. 13 is a perspective view of a cutter with a conveyor belt, illustrating an optional step for cutting a block of virgin elastic material into groups of elongated members and mixing the cut groups prior to insertion into the cushion. [Figure 20] 1 is a flow diagram of an embodiment of a method for manufacturing a personal cushioning device. [Figure 21] 11 is a flow diagram of another embodiment of a method for manufacturing a personal cushioning device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] The embodiments disclosed herein are described in the context of a pillow used as bedding to support a user's head while lying down, as it has particular utility in that context, however, the invention disclosed herein can also be used in other contexts such as, for example but not limited to, as a cushion for sitting on couches, chairs, animal bedding, bean bags and other types of furniture.

[0023] Some of the currently available types of pillow inserts include, but are not limited to, down inserts, feather inserts, polyester fiberfill inserts, shredded foam inserts, buckwheat hull inserts, microbead inserts, and kapok pillow inserts. These types of inserts suffer from various types of drawbacks. For example, down and feather inserts require constant fluffing, can be expensive, and can provide inconsistent levels of support. Polyester fiberfill inserts can easily clump, which can be potentially dangerous, and are not very breathable. Buckwheat hull inserts can be heavy and too hard for some users. Microbead inserts can have an unpleasant chemical odor and can release potentially dangerous chemical fumes. Microbeads can deteriorate and collapse with repeated use, shortening their lifespan. Kapok inserts do not hold their shape and tend to clump easily, thus requiring frequent reconditioning.

[0024] FIG. 1 shows examples of different types of shredded foam inserts 102 used in some prior art pillows. The shredded foam inserts 102 can be manufactured using a shredder, for example, by grinding or cutting foam pieces into random sized pieces. Some known pillows are manufactured using scrap foam left over from other manufacturing processes. Such cutting can be irregular, resulting in shredded foam inserts 102 of different shapes and sizes that can be difficult and time consuming to manufacture.

[0025] Additionally, the shredded foam insert 102 is prone to tearing. At least one aspect of the embodiments disclosed herein includes the recognition that the shredded foam insert may have a cross-sectional area that is so small that stresses occurring during use may tear such a shredded foam insert. Thus, the shredded foam insert 102 often does not maintain its initial volume and shape after repeated use. It loses its ability to maintain air spaces / pockets as it tears and breaks over time. As the shredded foam pieces 102 lose the air space between them, they tend to lose their ability to maintain their initial volume and / or shape, and therefore may not provide the same level of comfort.

[0026] 2 shows a different type of prior art pillow insert 104 that is essentially a single block of foam with an opening 108 punched or drilled into it. In some known pillows of this type, the insert 104 is made from one of a number of materials including, but not limited to, polyurethane foam, memory foam, gel foam, latex rubber foam, convolute phone, evlon foam, reflex foam, high density foam, high resilience phone, Supreme™ foam, rebonded foam, closed cell foam, or dry fast foam. Typically, as shown in FIG. 2, the opening 108 typically has a circular cross section.

[0027] However, pillow inserts 104 made from a block of foam, as shown in FIG. 2, can be quite heavy and expensive. Creating openings 108 in the pillow insert 104 can result in short, small cross-sectional noodle-like foam scraps that can be used as inserts for other types of pillows. However, such noodles tend to be much shorter and have a smaller cross-sectional area than the pillow inserts disclosed herein. Due to the size and manufacturing method of such inserts, it would be necessary to manufacture many pillow inserts of the single block type shown in FIG. 2 in order to generate a sufficient number of such long lengths of foam scraps (or noodles) to fill a single pillow of a smaller size. Also, such pillow inserts 104 can provide a sufficient level of comfort to the user, but can be significantly heavier than the chopped pillow inserts 102.

[0028] 3A and 3B are schematic diagrams showing an embodiment of a comfort device 100. The comfort device 100 may comprise a cover 160 and a number of elongate members 110. The comfort device 100 may be a sleeping pillow for supporting the user's head while lying down. However, with proper sizing, the comfort device 100 may be configured to serve as a pillow or bed for pets, a form of furniture commonly known as a "bean bag", a sofa, a seat cushion, a back cushion, or for other applications including, but not limited to, automobiles, office furniture, flotation devices, or sporting goods.

[0029] The cover 160 can be made from a variety of materials, including, but not limited to, cotton, nylon, polyester, linen, silk, or other materials. In some embodiments, the cover 160 is made from a breathable material. In some embodiments, the cover 160 is made from a stretchable material. The cover 160 can be substantially rectangular or circular. In another embodiment, the cover 160 can be spherical. In the context of a comfort device that is a "bean bag" type furniture configuration, the cover can be substantially spherical or partially spherical and partially seat shaped. In some embodiments, the cover 160 can be configured to take on and maintain different types of shapes.

[0030] As shown in Figures 3A and 3B, the comfort device 100 is a sleeping pillow for supporting a user's head while lying down. The cover 160 is substantially rectangular and / or bag-shaped, such as the shape of a conventional pillow used as sleeping equipment. The cover 160 can include a first side 170, a second side 172, a third side 174, a fourth side 176, a first surface 180, and a second surface 182. The first side 170 can be located distal or opposite to the third side 174, and the second side 172 can be located distal or opposite to the fourth side 176. The first side 170 and the third side 174 can be opposite to each other, and the second side 172 and the fourth side 176 can be opposite to each other. The first side 170, the second side 172, the third side 174, and the fourth side 176 may be configured to define boundaries for a first surface 180 and a second surface 182. The first surface 180 and the second surface 182 may be arcuate. In some embodiments, the first surface 180 and the second surface 182 are substantially flat. The generally illustrated configuration of sides and surfaces is only one example of a pillow cover that may be used to form the comfort device 100. Other configurations may be used.

[0031] In some embodiments, the first surface 180 is the top surface of the comfort device 100 and the second surface 182 is the bottom surface. During use, the user may flip the comfort device 100 to switch the orientation of the surfaces 180, 182. Thus, the comfort device of Figures 3A and 3B is configured to be used in any orientation.

[0032] The first surface 180 and the second surface 182 can extend between the first side 170 and the third side 174 of the cover 160, and the first surface 180 and the second surface 182 extend between the second side 172 and the fourth side 176 of the cover 160. The first surface 180 and the second surface 182 can be substantially rectangular, each having four sides bordering the first side 170, the second side 172, the third side 174, and the fourth side 176 of the cover 160. The first surface 180 and the second surface 182 can be configured such that the inner sides face each other and the outer sides face opposite each other. In some embodiments, the first surface 180 is an upper sidewall and the second surface 182 is a lower sidewall.

[0033] In another embodiment, the cover 160 includes more than four sides. In some embodiments, the cover 160 includes fewer than four sides. In another embodiment, the cover 160 is substantially a rectangular parallelepiped having six sides. The cover 160 may be circular or elliptical. In some embodiments, the cover 160 may be substantially spherical.

[0034] The cover 160 can include one or more interior compartments 168 defined within the sides 170, 172, 174, 176 and the top 180 and bottom 182. The embodiment of the comfort device 100 shown in Figures 3A and 3B includes a single interior compartment. Thus, the first side 170, the second side 172, the third side 174, the fourth side 176, the first surface 180, and the second surface 182 of the cover 160 can define the boundaries of the compartment 168. In some embodiments, various combinations of the first side 170, the second side 172, the third side 174, the fourth side 176, the first surface 180, and the second surface 182 of the cover 160 can define the boundaries of the compartment 168.

[0035] In some embodiments, the compartment 168 of the cover 160 can contain multiple elongate members 110. The elongate members 110 can have one or more different cross-sectional shapes and cross-sectional areas. In some embodiments, the length of the inserts can vary. In other embodiments, all, most, or a substantial number of the elongate members 110 have the same length. The elongate members 110 can be disposed within the compartment 168 of the cover 160 through an opening 162. The opening 162 can be associated with either a side or a surface of the cover 160.

[0036] Figure 4A shows another embodiment of the comfort device 100 of Figure 3, generally identified by the reference number 100a. Parts, components and features of the comfort device 100a are identified using the same reference numbers as the corresponding parts, components and features of the comfort device 100, except for the addition of the letter "a". The illustrated embodiment of the comfort device 100a includes a cover 160a and an elongate member 110a.

[0037] As shown in FIG. 4A, the cover 160a can include an opening 162a and a fastening mechanism associated with the opening 162a. The cover can include a first side 170a, a second side 172a, a third side 174a, and a fourth side 176a. The first side 170a, the second side 172a, the third side 174a, and the fourth side 176a can define a boundary of a first surface 180a and a second surface 182b (not shown). As mentioned above, the first surface 180a and the second surface 182a can be positioned such that the inner surfaces of the first surface 180a and the second surface 182a face each other. The cover 160a can be made of materials as described above. The cover 160a can be of different shapes, including but not limited to a cylindrical shape, such as those commonly used for bedding pillows, a substantially rectangular shape, a circular shape, or a bag shape, or any other shape. The cover 160a can have a cross-section of different shapes. For example, the cross-section of the cover 160a can be oval or substantially rectangular. The cover 160a can include different types of surface indentations to provide additional comfort and / or support to the user.

[0038] For example, as shown in FIG. 4A, the cover 160a has one or more divots and / or protrusions to provide additional comfort and / or support. The protrusions shown in FIG. 4A may include different elements to provide cushioning / energy absorption. In some embodiments, such divots and / or protrusions are provided on the outer surface of the cover 160a. In other embodiments, such divots and / or protrusions are provided on the inner surface of the cover 160a.

[0039] In some embodiments, the opening 162a can be associated with either the first side 170a or the third side 174a of the cover 160a. The opening 162a is sized such that its length is equal to or less than the length of either the first side 170a or the second side 172a of the cover 160a, as is typical for a generally rectangular sleeping pillow.

[0040] The fastening mechanism of the cover 160a is configured to interact with the opening 162a of the cover 160a to allow a user or manufacturer to open or close the opening 162a. The fastening mechanism can have two positions that correspond to states of the opening 162a. For example, the fastening mechanism can have an open position in which the opening 162a is open. When the fastening mechanism is in a closed position, the opening 162a is closed. In some embodiments, the fastening mechanism has three or more positions.

[0041] The fastening mechanism can be associated with either the first side 170a or the third side 174a of the cover 160a. The fastening mechanism can incorporate various types of mechanisms including, but not limited to, zippers, hooks, ties, Velcro, clips, buttons, clasps, straps, or pins. In some embodiments, the fastening mechanism is not associated with either the first side 170a or the second side 172a of the cover 160a. In some embodiments, the fastening mechanism 180 is associated with the opening 162 of the cover 160.

[0042] In some embodiments, the cover 160a may include one or more compartments 168a sized to contain multiple elongate members 110a. In some embodiments, each of the compartments 168a is associated with at least one opening to allow a user to place a desired number of elongate members 110a in each of the compartments 168a. Optionally, having separate compartments 168a in the comfort device 100a allows a user to insert elongate members 110a having different characteristics (e.g., size, density, and / or length) in different compartments 168a. For example, high density elongate members 110a may be placed in the compartments 168a located near the ends 170, 174 and the cover 160a, and low density elongate members 110a may be placed in the compartments 168a located away from the ends 170, 174.

[0043] Figures 4B-4E show another embodiment of the cover 160 of the comfort device 100 of Figures 3A and 3B, generally identified by the reference numbers 160b, 160c, 160d, 160e. Parts, components and features of the covers 160b, 160c, 160d, 160e are identified using the same reference numbers as the corresponding parts, components and features of the comfort device 100, except for the addition of the letters "b", "c", "d", "e".

[0044] As shown in FIG. 4B, in some embodiments, the cover 160b has two compartments 168b separated by a partition 190. As described above, the cover 160b can have a first side 170b, a second side 172b, a third side 174b, and a fourth side 176b. The first compartment can be associated with the first opening, and the second compartment can be associated with the second opening. In some embodiments, the compartments 168b are equal in size and volume. In other embodiments, the first compartment is larger in size and volume than the second compartment. The first and second compartments can be positioned adjacent to each other. In some embodiments, the compartments 168b can be positioned such that the first compartment is located above the second compartment. In some embodiments, the cover 160b has more than one compartment 168b.

[0045] 4C shows an embodiment of a cover 160c including three compartments 168c separated by a divider 190c. As described above, the cover 160c can have a first side 170c, a second side 172c, a third side 174c, and a fourth side 176c. The first compartment 168c can be associated with a first opening 162c, and the second compartment 168c can be associated with a second opening 162c. In some embodiments, the third compartment can have an opening 162c associated with the side 176c of the cover 160c or an internal divider 190c such that the third compartment 168c opens to an adjacent compartment 168c and can therefore be emptied or filled through the adjacent compartment 168c. Optionally, in some embodiments, the compartments 168c are equal in size and volume. The compartments 168c can also have different sizes and volumes. The compartments 168c can be arranged adjacent to one another as shown in FIG. 4C. However, the compartments 168cs can also be arranged such that a first compartment is adjacent to a top surface of the cover 160c, a second compartment is adjacent to a bottom surface of the cover 160c, and a third compartment is located between the first and second compartments. In some embodiments, the compartments 168c are stacked on top of one another.

[0046] 4D shows the cover 160d including four compartments 168d separated by dividers 190d. As mentioned above, the cover 160d can have a first side 170d, a second side 172d, a third side 174d, and a fourth side 176d. The first and second compartments can be associated with the first opening 162d, and the third and fourth compartments can be associated with the second opening 162d. In some embodiments, the compartments 168d are equal in size and volume. Optionally, the compartments 168d can also have different sizes and volumes. In some embodiments, the compartments 168d are arranged such that each of the four compartments 168d is generally located in the four quadrants of the cover 160d. However, the compartments 168d can also be arranged such that a first compartment is adjacent to the top surface of the cover 160d, a second compartment is adjacent to the bottom surface of the cover 160d, and the third and fourth compartments 168d are located between the first and second compartments. In some embodiments, the compartments 168d are stacked on top of each other, as shown in FIG. 4E.

[0047] 5 illustrates a perspective view of an embodiment of an elongate member 110a. The elongate member 110a can include a first end 120a, a second end 130a, and an intermediate portion 140a. The elongate member 110a can have a cross-section of any shape, including but not limited to a square, circle, triangle, rectangle, polygon, or other shape.

[0048] Optionally, in some embodiments, the elongate members 110a have cross-sectional shapes that define sides that can be aligned in a continuous plane. For example, triangular, rectangular, parallelogram, diamond, and rectangular cross sections define sides that can be aligned in a continuous plane when such inserts are stacked on top of each other. Other cross sections do not provide this structural relationship. For example, when elongate members having circular, elliptical, pentagonal, or hexagonal cross sections are stacked, the sides of adjacent members do not align along a continuous plane. Rather, the sides are spaced apart from each other with non-uniform gaps or follow a zigzag path. The non-planar alignment of the sides of such elongate members when stacked is a result of these elongate members being manufactured with more complex and restrictive processes.

[0049] In contrast, if elongate members 110 include alignable sides that extend continuously along a plane, such elongate members may benefit from the optional advantage of being manufactured by linearly cutting a block of virgin material, such as foam. An exemplary manufacturing process is described below with reference to Figures 14-17.

[0050] With respect to the overall shape of the elongate member 110a, the first end 120a, the second end 130a, and the middle portion 140a of the elongate member 110a can have the same cross-section. In some embodiments, the first end 120a, the second end 130a, and the middle portion 140a have different cross-sections. In some embodiments, the elongate member 110a is made from a virgin elastic material, such as, but not limited to, open cell foam, which can provide higher breathability, lower density, and lighter overall weight than closed cell foam.

[0051] Figures 6 and 7 are schematic diagrams of variations of elongate member 110 detailing the uniformity and / or variation in cross-section along its length. The variations of Figures 6 and 7 are identified by reference numerals 110b and 110c. Parts, components and features of covers 110b and 110c are identified using the same reference numerals as the corresponding parts, components and features of elongate member 110a, except for the addition of the letters "b" and "c."

[0052] 6, the elongate member 110b can include a first end 120b, a second end 130b, and an intermediate portion 140b. The first end 120b can include a first cross-section 122b having a width 124b and a depth 126b, and the second end 130b can include a second cross-section 132b having a width 134b and a depth 136b. The intermediate portion 140b can include a third cross-section 142b having a width 144b and a depth 146b. The widths 124b, 134b, 144b and the depths 126b, 136b, 146b can be the same or different from each other. In some embodiments, the widths 124b, 134b, 144b and the depths 126b, 136b, 146b can be manufactured using a cutting tool with a straight blade, but vary due to normal cutting tool operation. In other embodiments, the widths 124b, 134b, 144b and depths 126b, 136b, 146b may vary by design.

[0053] The first end 120b, the second end 130b, and the middle portion 140b of the elongate member 110b can have different cross-sectional shapes, including, but not limited to, a square (FIG. 6), a circle, an oval, a triangle (FIG. 7), or a hexagon. In some embodiments, the first cross-section 122b, the second cross-section 132b, and the third cross-section 142b have different cross-sectional shapes. In other embodiments, the first cross-section 122b, the second cross-section 132b, and the third cross-section 142b have the same cross-sectional shape. In other embodiments, the first cross-section 122b and the second cross-section 132b have different cross-sectional shapes. In some embodiments, the first cross-section 122b and the second cross-section 132b have the same shape, and the third cross-section 142b has a different shape than the first and second cross-sections 122b, 132b.

[0054] The elongate member 110b can have a length 150b defined between the first end 120b and the second end 130b. Varying the length 150b can result in different stretch and compression responses of the elongate member 110b. For example, an elongate member 110b having a length between 4 and 6 inches may be less flexible and unable to create and maintain a larger air gap than an elongate member 110b having a length greater than about 6 inches or more. In some embodiments, the comfort device 100 includes elongate members 110b having different lengths 150b.

[0055] In some embodiments, the length 150 of the elongate member 110b is between about 6 inches and 14 inches, between about 10 inches and 14 inches, between about 8 inches and 12 inches, between about 5 inches and 10 inches, or about 7 inches, 8 inches, 9 inches, 10 inches, 11 inches, 12 inches, 13 inches, 14 inches, or a range including any two of the foregoing values. In some embodiments, the length 150 of the elongate member 110 can be at least 6 inches. In other embodiments, the length 150 of the elongate member 110 can be at least 8 inches.

[0056] The length 150b of the elongate member 110b may be at least 15 times the width 124b, 134b, 144b or the depth 126b, 1365b, 146b of the elongate member 110b. In some embodiments, the length 150b of the elongate member 110b is at least 20 times the width or depth of the elongate member 110b. Some embodiments of the elongate member 110b may include a circular cross-section. In such cases, the length 150b of the elongate member 110b may be at least 20 times the diameter of the elongate member 110b.

[0057] The first cross section 122b, second cross section 132b, and third cross section 142b of the elongate member 110b are associated with cross-sectional areas 128b, 138b, 148b, which may be between about 0.0625 square inches and 0.25 square inches, between about 0.09 square inches and 0.5625 square inches, between about 0.25 square inches and 0.445 square inches, between about 0.4 square inches and 1 square inch, or a range including about 0.0625 square inches, 0.09 square inches, 0.25 square inches, 0.4 square inches, 0.445 square inches, 0.5625 square inches, 1 square inch, or any two of the foregoing values. In some embodiments, the elongate member 110b has a cross-sectional area of ​​at least one-sixteenth of an inch. The elongate member 110b of the comfort device 100 may be subjected to various types and levels of tensile, compressive, shear and / or bending moments during normal use of the comfort device 100. The cross-sectional areas 128b, 138b, 148b and material properties of the elongate member 110b may affect the ability of the elongate member 110b to better withstand the tensile, compressive, shear and bending moments resulting from normal use of the comfort device 100.

[0058] 8-10, the elongated member 110b of the comfort device 100 may be subjected to various types and levels of tensile stress, shear stress and / or bending moment from normal use of the comfort device 100. The length 150b and material properties of the elongated member 110b may affect the ability of the elongated member 110b to withstand the shear stress, bending moment and / or torque resulting from normal use of the comfort device 100. Furthermore, the length 150b of the elongated member 110b may also affect the stretchability and / or compression response of a pillow filled with the elongated member 110b. For example, a longer length 150b of the elongated member 110b may provide a better compression response of the comfort device 100a.

[0059] Figure 8 illustrates an embodiment of the comfort device 100a of Figure 4A showing further details of the elongate members 110a. The elongate members 110a as shown in Figure 8 can interact with each other and with the cover 160a to provide beneficial or desirable effects. Some such effects are associated with longer elongate members.

[0060] In some embodiments, the elongate member 110b has a density that may be between about 0.5 pounds per cubic foot (pcf) and 5 pcf, between about 1.5 pcf and 3.5 pcf, between about 2.0 pcf and 3.0 pcf, or between about 0.5 pcf, 1.0 pcf, 1.5 pcf, 2.0 pcf, 2.5 pcf, 3.0 pcf, 3.5 pcf, 4.0 pcf, 4.5 pcf, 5.0 pcf, or a range including any two of the aforementioned values. The elongate member 110b of the comfort device 100 may provide different levels of comfort and support to the user depending on the density of the elongate member 110b. The elongate member 110b may have different compression responses and / or stretching properties depending on the density of the elongate member 110b.

[0061] In some embodiments, the volume ratio of the total volume of the elongate member 110b in an uncompressed state to the total volume of the comfort device 100 is between about 0.5 and 0.95, between about 0.6 and 0.8, between about 0.7 and 0.75, or between about 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, or a range including any two of the foregoing values.

[0062] As discussed above, when the elongate members 110b are inserted into the cover 160, they may be arranged in a random orientation, bend, and / or wrap around themselves and / or each other, resembling a tangled strand of spaghetti. Thus, when the elongate members 110b are inserted into the cover 160, they are not typically arranged in a tight, compact configuration extending parallel to one another. Rather, the random, tangled orientation results in a significant amount of gaps and air spaces between the elongate members 110b. Such gaps and spaces improve the breathability of the comfort device 100. Additionally, at least one aspect of the invention disclosed herein includes the recognition that longer members 110 improve the creation and maintenance of such gaps and spaces. A shorter member, for example, about 6 inches or less, creates a smaller amount of gaps and spaces. However, a member that is about 6 inches or more in length can form more arcuate bends and more complete loops, thereby creating significantly more gaps and spaces in the cover 160 of the comfort device 100.

[0063] Varying the volume ratio can provide different levels of comfort and support to the user. For example, a lower volume ratio provides less support to the user, whereas a higher volume ratio provides more support to the user. In some embodiments, based on personal observations, a volume ratio between 0.75 and 0.9 provides an optimal level of support and comfort to the user.

[0064] As shown in Figures 9 and 10, the end of the elongate member 110b may be intertwined with other elongate members 110b within the comfort device 100b. For the purpose of illustrating one possible mode of tensile loading of the elongate member 110b, Figures 9 and 10 separately show that the end of one elongate member 110b may be intertwined with another insert in two different regions of the comfort device 100b, one end intertwined in a region towards the center C of the comfort device 100b and the other end intertwined in a region closer to the edge E of the comfort device 100b.

[0065] With this assumed orientation, when a load is applied to the top surface of the central region C of the cushion during use, the elongate member and the portion located in the central region are compressed downward in the direction of the arrow. Thus, one end of the separated elongate member 110b is pulled downward as the central region C is crushed. However, the second end, which is intertwined with the non-compressed portion of the comfort device 100 near the edge E, remains relatively more stationary. Thus, the elongate member 110b may be loaded in tension as one end is pulled away from the other end. The tensile loading of the elongate member 110b can create a different response of the comfort device to a load during use, such as a trampoline, which is a different loading mechanics than a foam that is loaded in compression only. Importantly, such loading is different from loading mechanisms that are typically only subjected to compression with small randomly sized filling materials, such as those shown in Figures 1 and 2.

[0066] As mentioned above, comfort devices 100 having pieces of elastic material with lengths greater than about 6 inches can provide improved comfort devices 100, and more specifically comfort devices 100 having elongated members 110 of 8 inches or more. For example, the comfort device 100 can be filled with elongated pieces of elastic material having lengths greater than about 6 inches, arranged in a random orientation, and the elongated pieces of elastic material (e.g., elongated members 110a) can intertwine with each other. In such a configuration, some elongated pieces of elastic material can have first ends that intertwine with elongated pieces located at the periphery of the comfort device 100 and second ends that intertwine with elongated pieces located near the center of the comfort device 100. This is just one illustrative example of an orientation that can result in tensile loading of the elongated members 110. However, as mentioned above, the elongated members 110 will be randomly oriented within the comfort device 100. In this manner, the collective loading of the longer elongate members 110 results in a greater tensile loading of the elongate members 110 compared to the loading of the shorter elongate members 110. Thus, generally speaking, longer elongate members 110 may be loaded in compression and greater tension, while shorter elongate members 110 tend to be loaded only in more compression and less tension.

[0067] Thus, when a load is applied near the center of the comfort device 100, the elongated piece located near the center is pushed downward and the second end of the elongated piece is pulled downward. Thus, tension may be generated between the relatively stationary first end and the second end being pulled downward, stretching the elongated piece. This tension and stretching may be similar to the load of a spring around a trampoline, and thus may cause a reactive stretching / loading of the elongated piece of the personal cushioning device 100. Such tensile loading of the elongated piece may result in a greater elastic elongation than is possible under a compressive load resulting from the small particle filler composition. Thus, in some embodiments, a different desirable cushioning property may be achieved as compared to a cushion filled with smaller, shorter and / or randomly sized pieces.

[0068] More specifically, when a force is applied to the elongate member 110b in a first direction, the first end of the elongate member 110b can move in the first direction while the second end of the elongate member 110b can remain substantially stationary. The second end, in some embodiments, is intertwined within the complex macrostructure of the insert 100b and therefore does not move or moves only slightly when a force is applied. In such a configuration, the first end of the elongate member 110b can stretch away from the fixed end, creating tension between the first and second ends of the elongate member 110b. This tension can create a resilient trampoline-like effect.

[0069] The magnitude of the tensile force may be proportional to and / or related to one or more properties, including but not limited to the material of the elongated member 110b, the length of the elongated member 110b, the cross-sectional area of ​​the elongated member 110b, the magnitude of the force, the volume ratio of the total volume of the elongated member 110b to the total volume of the comfort device 100b, the weight ratio of the total weight of the elongated member 110b to the total weight of the comfort device 100b, the average amount of air space and / or volume between the elongated members 110b, the length of the free ends, the length of the fixed ends, or the amount of force generated through friction between the elongated members 110b.

[0070] Having a smaller or limited cross-sectional area of ​​the elongate member 110 can be advantageous because such a configuration can provide a more uniform "feel" to the user of the comfort device. For example, a smaller cross-sectional shape of the elongate member can result in a smoother and less rugged feel or appearance of the comfort device 100. However, tensile loads of a longer elongate member 110b, in addition to compressive loads, can result in higher stresses on the elongate member 110b. Thus, in some embodiments, limiting the cross-sectional area to a certain range can provide an optional advantage of balancing the improved durability that can be obtained from a larger cross-section with a smoother appearance and the feel that can be obtained from a smaller cross-section. For example, the minimum cross-sectional area of ​​the elongate foam elongate member 110 can be a predetermined number, such as, for example, about 1 / 16 inch or more. When the elongate member 110b is made of open-cell foam, a minimum cross-sectional area of ​​about 1 / 16 inch for elongate members 110b with lengths greater than about 6 inches has resulted in improved reduction in tearing and therefore better durability. Using an elongate member 110 having a minimum cross-sectional area of ​​about ¼ inch results in a significant additional improvement, especially when the length of the elongate member 110 is about 8 inches or greater. The longer elongate member 110 is subjected to greater tension, and therefore the greater minimum cross-sectional area associated with the longer elongate member 100 can provide significantly improved resistance to tearing and greater durability.

[0071] In some embodiments, the minimum cross-sectional area is calculated using at least one of the variables including, but not limited to, the length of the elongate member 110, the material of the elongate member 110, the cell structure of the elongate member 110, the maximum cross-sectional dimension of the elongate member 110, and the volume ratio between the elongate members 110 of the comfort device 100.

[0072] As noted above, having a minimum cross-sectional area of ​​at least 1 / 16, 1 / 8, or 1 / 4 inch can improve the performance and durability of the elongate member 110. Additionally, limiting the cross-sectional area of ​​the elongate member 110 can provide an associated comfort device 100 with a smoother appearance with fewer irregularities. Thus, in some embodiments, the elongate member has a cross-sectional area of ​​1 square inch, 3 / 4 inch, 1 / 2 inch, 3 / 8 inch, or 1 / 4 inch or less.

[0073] As mentioned above, in some embodiments, the elongated member 110b can be made from open cell foam rather than closed cell foam. Open cell foam has small cells that are filled with air and are not completely closed. Closed cell foam, on the other hand, has cells that are completely closed. The structural differences between open cell foam and closed cell foam result in different levels of durability and stretchability. Closed cell foams are more stretchable than closed cell foams, but they are less durable. For this reason, in some embodiments, it may be beneficial to have a minimum cross-sectional area, as listed above, for elongated foam members 110b made from open cell foam to reduce structural deterioration and / or dusting from repeated use.

[0074] Figure 11 is a schematic diagram of materials that can be used to form variations of the elongated insert for the comfort device 100. As shown in Figure 11, the insert material 210 can include an outer surface 220 and an inner portion 230. The outer surface 220 can include one or more openings 222 that allow air to flow through the outer surface 220 and the inner portion 230. In some embodiments, the openings 222 are the same size. In other embodiments, the openings 222 vary in size.

[0075] The inner portion 230, e.g., the area between the outer surfaces 230, can include a webbing 232 that can comprise a complex structure made of one or more fibers 234. The fibers 234 can be made from a variety of durable yet flexible materials. In some embodiments, the fibers 234 can comprise a first end and a second end, the first end attached to the first outer surface 220 and the second end attached to the second outer surface 220. In some embodiments, the fibers 234 generally define a longitudinal axis between the outer surfaces 220. In some embodiments, the fibers 234 are substantially perpendicular to the outer surfaces 220. In some embodiments, the fibers 234 are angled such that one end of the fibers 234 is at an obtuse angle to the outer surface 230 and the other end of the fibers 234 is at an acute angle to the outer surface 230.

[0076] 12-14 show steps of an embodiment of a method for producing an elongate member 110 from a block of virgin foam 300. As used herein, the term "virgin" refers to foam in bulk form that has been formed in large pieces and not previously cut into smaller pieces and glued back together, for example, by gluing.

[0077] The block 300 can be made from a variety of materials, including, but not limited to, polyurethane foam, memory foam, gel foam, latex rubber foam, convolute phone, Evlon foam, reflex foam, high density foam, high resilience phone, Supreme foam, rebond foam, closed cell foam, or dryfast foam. The block 300 can be of different shapes. In some embodiments, the block 300 can be a cube, or a large roll with quadrilateral sides, as shown in FIG. 12. Some forms of bulk foam blocks can be as large as a truck or a school bus. In any of these forms, the block 300 can be considered a "virgin" material or foam as used herein.

[0078] For purposes of this description, the block 300 can be considered to have a length indicated as A in FIG. 12, which can be at least about 10 inches, with some blocks being as long as 200 inches, or even 100 feet (commercially available in compressed rolls). In some embodiments, the length of the block 300 is an integer multiple of a dimension of the elongate member 110, such that there are no scrap segments of the block 300 after all cuts have been made. For example, the length A of the block 300 may be 20 times longer than the length 150b, width 124b, or depth 126b (FIG. 6) of the elongate member 110b being produced.

[0079] The block 300 can also be considered to have a width, designated B in FIG. 12, which can be between about 10 inches and 200 inches. In some embodiments, the width B of the block 300 can be a multiple of a dimension of the elongate member 110 such that there are no scrap segments of the block 300 after the cuts 310 are made. For example, the width B of the block 300 can be 20 times longer than the length 150b, width 124b, or depth 126b (FIG. 6) of the elongate member 110.

[0080] The block 300 can also be considered to have a height, shown as C in FIG. 12, which can be up to about 200 inches, or another size. In some embodiments, the height of the block 300 is a multiple of a dimension of the elongate member 110 such that there are no scrap segments of the block 300 after the cuts 310 are made. For example, the height C of the block 300 can be 20 times longer than the length 150b, width 124b, or depth 126b (FIG. 6) of the elongate member 110.

[0081] In some embodiments, the first step may include cutting the bulk block 300 to a desired width B, height C and / or length A such that these dimensions are integer multiples of the length 150b, width 124b, or depth 126b (FIG. 6) of the elongated members 110 planned to be manufactured from the block 300. In some embodiments, due to practical limitations of the equipment used to cut the elongated members 110 from the block 300, pieces of the block 300 may remain that cannot be cut using the same technique or equipment.

[0082] For example, a foam cutting machine having both vertical and horizontal saw blades and two conveyor belts, all of which are digitally controlled for their precise movement, is described in more detail below, however, some such machines are not capable of actually or accurately cutting small pieces of material.

[0083] 12 is a schematic perspective view of a block of foam 300 with some initial layout of cuts that may be made into the block 300 to form multiple elongate members 110. The cuts 310 may be made using various types of mechanisms including, but not limited to, a laser, a jigsaw, a circular saw, or pressurized water. In some embodiments, the cuts 310 are made for each individual elongate member 110. In other embodiments, the cuts 310 are made in such a way that two or more elongate members 110 may be formed in a batch.

[0084] In some embodiments, the cuts 310 can be vertical or horizontal. For example, the horizontal cuts 310h are made to have a cut surface substantially parallel to the xy axes. In addition, the vertical cuts 310v can be made to have a cut surface substantially parallel to the xz axes. Furthermore, the longitudinal cuts 310l can be made to have a cut surface substantially parallel to the yz axes.

[0085] In some embodiments, horizontal cuts 310h can be made to cut block 300 into horizontal sheets 301, 302, 303, 304 having xy-axis parallel flat surfaces. Similarly, longitudinal cuts 310l can be used to split the sheet into two or more parallel sheets. Also, vertical cuts 310v can be used to cut multiple fully formed elongated members 110 from block 300, for example in a single pass.

[0086] In some embodiments, the cuts 310 are linear. In other embodiments, the cuts 310 are not linear. For example, the cuts 310 may comprise one or more arcuate, stepped, and / or discontinuous cut surfaces. The cuts 310 can be made on the block 300 to produce elongate members 110 having different cross sections. For example, as described above, cuts 310 having cut surfaces parallel to the xy, xz, and yz axes can produce elongate members 110 that are substantially rectangular parallelepipeds with six quadrilateral faces. On the other hand, cuts 310 made while maintaining a constant distance from an axis parallel to either the x, y, or z axes can produce elongate members 110 that are cylindrical in shape.

[0087] 13A shows a layout of a series of horizontal, longitudinal and vertical cut lines showing that incisions 310h, 310l, 310v are made to cut the fully formed elongate member 110b from the block 300 without leaving any beads. Although not shown, in use, scrap may remain after the final cut, for example, when the last remaining piece of the block 300 falls over or is too small to be cut by the machine 400. Such a series of cuts may provide important other optional advantages. For example, at least one aspect of the invention disclosed herein involves the recognition that elongate members having sides alignable in successive planes may be cut more efficiently than elongate members having more complex shapes.

[0088] For example, Figures 13B and 13C are schematic end views of stacked elongate members 110o (having a rounded cross-section) and 110p (having a pentagonal cross-section). In both figures, elongate members 110o, 110p are stacked as tightly as possible on top of one another. However, the edges of elongate members 110o, 110p cannot align in a continuous plane. Rather, the edges of member 110o only meet tangentially, leaving star-shaped gaps G between them. Meanwhile, pentagonal member 110p meets along flat edges, but the edges cannot align in a continuous plane. Rather, the edges of member 110p fall along a zigzag path Z.

[0089] Cutting any of these types of members 110o, 110p is more difficult because it requires punching, punching, or chopping. Such techniques become more difficult for longer elongated members, especially for smaller cross-sections. In other words, elongated foam pieces are more difficult to manufacture using punching, punching, or chopping techniques, especially when it is desirable to provide a controlled or uniform cross-sectional shape along their length. For example, soft foam materials can collapse and / or crush during chopping or punching, making it more difficult to accurately punch or chop elongated members. Drilling or hollowing is also difficult, as soft foam materials also collapse and are prone to twisting, tearing, and / or failure when forming elongated elongated members.

[0090] In contrast, elongated members with sides that can be aligned in successive planes can be manufactured more easily, accurately and efficiently. For example, Figures 13D and 13E are schematic end views of stacked rectangular elongated members 110r and triangular elongated members 110t. As shown in these figures, the sides of elongated members 110r, 110p can be aligned along successive planes PH, PV, PD when stacked. Thus, to cut elongated members 110r, 110t, a cutting tool can pass through the virgin block material along a planar, flat, planar orientation. The same applies to elongated members with other cross-sectional shapes (not shown), such as diamond, square and parallelogram.

[0091] FIG. 14 is a schematic diagram of a system for a cutter 400 to cut a block 300 of virgin foam into elongated members. As shown in FIG. 14, cuts 310h, 310l, 310v can be made to produce one or more elongated members 110r, for example in some embodiments in a batch 320. The batch 320 can be sized to include a sufficient number of elongated members 110 to produce one or less than one (1 / 2, 1 / 4, etc.) individual comfort devices 100. In some embodiments, the batch 320 comprises a single vertical cut 310V in the block 300. In some embodiments, horizontal 310h and longitudinal 310l cuts are made before the vertical cut 310v. Thus, at the end of the vertical cut 310v, the batch 320 comprises a fully formed elongated member 110r. Depending on the size of the elongated member 110, the size of the batch 320 can vary. Larger elongate members 110 may require larger batches 320. Meanwhile, smaller elongate members 110 may require smaller batches 320. The use of batches 320 during the manufacturing process of the elongate members 110 can reduce manufacturing time, increase efficiency, and improve control for manufacturing the comfort device 100. The manufacturing process of the elongate members 110 is described further below.

[0092] 14 is a schematic perspective view of one type of commercially available foam block cutting machine 400 that may be used to cut foam to create the elongated members 110 disclosed herein. The machine 400 may include a conveyor belt system having an inlet conveyor 420 and an outlet conveyor 422. The machine 400 also includes a horizontal cutter 410h and a vertical cutter 410v. The cutters 410h, 410v may be equipped with different types of cutting devices, including but not limited to saws, hacksaws, bandsaws, oscillating saws, heated wires, or lasers. The machine includes a programmable digital controller (not shown) that controls the vertical height and longitudinal position of the cutter 410h, the lateral position of the vertical cutter 410v, and the movement of the input conveyor 420 and the outlet conveyor 422, all of which are independently controllable. This type of cutting device is commercially available, so details of its construction and operation are not provided herein.

[0093] In use, the block 300 is placed on the input conveyor belt 420 of the machine 400. In some embodiments, the vertical position of the cutter 410h is provided in a first position above the surface of the conveyors 420, 422, the cutter 410h is activated, and the conveyors 420, 422 move the block 300 into the cutter 410h to make a first horizontal cut through the block 300 to make a first sheet 301 at the bottom of the block 300. The height of the cutter 410h can then be changed to a second position, and the process can be repeated to cut additional sheets 302, 303, 304 until the block 300 is cut into the desired number of sheets. Each sheet 301, 302, 303, 304 can have a thickness corresponding to a dimension of the desired elongated member 110r, such as width 123b or depth 126b (FIG. 6).

[0094] The machine 400 can also be used to divide the block 300 into longitudinal logs. For example, the machine 400 can adjust the position of the vertical cutter 410v to make the longitudinal incision 310l, and then drive the conveyors 420, 422 to move the block 300 (or the stack of sheets 301, 302, 303, 304) relative to the vertical cutter 410v to cut the sheets into left and right logs 306, 305.

[0095] After dividing the stacked sheets 301, 302, 303, 304 into left and right logs 306, 305, the machine can move a vertical cutter 410v across the logs to simultaneously make the final cuts 310v needed to completely form the elongated members 110r and separate batches 320 of elongated members 110r from the logs 306, 305. As each batch 320 is separated from the logs 306, 305, the batch is dropped into a pile of elongated members 110r.

[0096] In some embodiments, the discharge conveyor 422 can be driven to first move the batch 320 away from the logs 306, 305 and then move the conveyor back towards the logs 306, 305, thereby inducing a tipping of the batch 320 into a pile of separate elongate members 110r away from the logs 306, 305. Additionally, the conveyor 422 can be driven to move the batch 320 of elongate members 110r away from the logs 306, 305 before the next batch 320 of elongate members 110r is cut from the logs 306, 305.

[0097] Optionally, the conveyor 422 can be driven to move the batches 320 far enough away from the logs 306, 305 that when a subsequent batch 320 is cut from the logs 306, 305, it falls in such a way that it remains separated from the previous batch 320 by, for example, a predetermined minimum spacing 424. The spacing 424 can be of any desired size. In some embodiments, the size of the spacing 424 can be at least about ½ inch, the width of a human hand, a length that provides clearance for a pusher device (described below), or any other size. Thus, the batches 320 are cut from the logs 306, 305 and maintained in a spaced apart relationship to one another. This can provide a further optional advantage in that it is easier to pick up or sweep another separate batch 320 from the conveyor 422 into the cover 160 for manufacturing the comfort device 100 with improved efficiency.

[0098] The machine 400 may also include one or more pusher devices 430. The pusher 430 may be configured to push the batches 320 of the elongate members 110 off the conveyor 422. For example, in some embodiments, the pusher 430 may be configured to push the batches 320 towards a staging / packaging area of ​​the comfort device 100 where the batches 320 are inserted into the covers 160 of the comfort device 100 by a human or another machine (not shown).

[0099] As mentioned above, in some embodiments, each batch 320 can include a sufficient number of elongate members 110 to fill a single comfort device 100. Optionally, the batches are sized such that an integer number (e.g., 1, 2, 3, 4...) of batches 320 are sufficient to completely fill a single comfort device 100. For example, each batch 320 can include a sufficient number of elongate members 110 such that a single batch 320 or an integer number of batches 320 are sufficient to fill a single bean bag. In another example, each batch 320 can include a sufficient number of elongate members 110 to fill a single pillowcase. In some embodiments, the batches 320 are made first and the elongate inserts 110 are cut from the batch. In another embodiment, the block is first scored and then each batch is separated from the other batches.

[0100] Optionally, the block of cushioning material 300 can include two or more materials. For example, the layers 301, 302, 303, 304 can be made of different material compositions or of the same or similar material compositions but with different dimensions and / or specifications, such as different sizes, densities, weights, textures, load deflection rates or other properties or specifications. Such different material compositions can include, for example, but without limitation, polyurethane foam, memory foam, gel foam, latex rubber foam, convoluted phone, evelon foam, reflex foam, high density foam, high resilience phone, Supreme™ foam, rebonded foam, closed cell foam, or dry fast foam, or other foams or cushioning materials. As used herein, the phrase "different materials" is intended to mean either a) different compositions, such as memory foam being different from latex, and b) different material properties, such as different dimensions (thickness, depth), different densities, different weights, etc. [Are there other different properties of cushioning materials? Perhaps a measure of resiliency (stretchiness)?]. Layers 301, 302, 303, 304 are described below as being horizontally oriented and stacked one on top of the other. However, the following description applies equally to layers 301, 302, 303, 304 that are vertically oriented next to each other, such as logs 305, 306.

[0101] In some embodiments, the desired different materials can be obtained in sheet or block form and cut into sheets using a machine such as machine 400 (FIG. 14). Such sheets can then be stacked, such as in the stacked sheet configuration of layers 301, 302, 303, 304 of FIG. 14. Alternatively, block 300 can comprise side-by-side layers, such as logs 305, 306 made from different materials.

[0102] 15-18, block 300 can comprise different materials in a variety of different orientations and arrangements. FIG. 15 shows block 300 comprising layer groups 301G, 302G. First layer group 301G includes layers 301a, 301b, 301c, 301d. Second layer group 302G includes layers 302a, 302b, 302c, 302d. In the configuration shown in FIG. 15, groups 301G, 302G are stacked vertically, although in optional embodiments, layers can be arranged side-by-side.

[0103] In the variation shown in Fig. 16, the layers 301a, 301b, 301c, 301d of the first material are interleaved with the layers 302a, 302b, 302c, 302d of the second material. They are therefore stacked starting from the bottom in the order 301a, 302a, 301b, 302b, 301c, 302c, 301d, 302d. In this configuration, when the block 300 is cut along the vertical cut 310V, the individual elongated members 301 formed thereby are groups of mixed material. Moreover, when stacked in the configuration of Fig. 16, the elongated members 301 are at least partially premixed, e.g., the elongated members 301 are more randomly mixed than the groups of elongated members 301 cut from the block shown in Fig. 15.

[0104] Figure 17 shows a block 300 having four different materials forming a plurality of respective layers 301, 302, 303 and 304. More specifically, in the configuration of Figure 17, the layers are stacked in four groups 301G, 302G, 303G, 304G of different materials. Group 301G comprises two layers 301a, 301b of a first material. Group 302G comprises two adjacent layers 302a, 302b of a second material. Group 303G comprises two adjacent layers 303a, 303b of a third material. Group 304G comprises two adjacent layers 304a, 304b of a fourth material.

[0105] FIG. 18 shows a configuration in which layers 301ab, 302ab, 303ab, 304ab are alternated, thereby providing a method of premixing the elongate member 301.

[0106] In the schematic diagram of the embodiment of Figure 19, which is a variation of the embodiment of Figure 14, a block of material 300 includes a first group of layers of material 301G having five layers 301a-301e, and a second group of layers 302G includes five layers 302a-302e.

[0107] In operation, as the batch 320m with elongated members 110r made of different materials is cut from the block 300, it falls into the rolled batch 320m on the conveyor 422, similar to that described with reference to Figure 14. By including different materials in multiple layers of the block 300, the rolled batch 320m is partially premixed. Optionally, in some embodiments, the batch 320m can move from the conveyor 422 into a mixer 500, which can be in the form of any of a variety of commonly available drum mixers.

[0108] The drum mixer 500 can be configured to rotate and tumble one or more batches 320m. In some embodiments, the mixer 500 is sized to receive, mix, and discharge one or more batches 320m sufficient to fill a single cushion cover 160.

[0109] After mixing one or more batches 320m, the batches 320m may be discharged into the cushion cover 160. In some embodiments, the mixer 500 is mounted to discharge into a funnel 502 that leads to the cushion cover 160. Additionally, in some embodiments, the mixer 500 may have a door at its bottom to allow gravity to discharge the mixed batches 320m into the cushion cover 160 below.

[0110] In some embodiments, additional filler material may be inserted into the cover 160 and / or mixer 500 for later insertion into the cover 160. For example, but not limited to, materials such as down feathers, loose fiber, ball fiber, wool, chopped foam, chopped latex, or any mixture of the above (shown generally and identified in FIG. 19 by reference numeral 111). In some embodiments, the total weight of the additional filler material 111 may be about 5% or more of the total weight of all of the elongated inserts and filler materials 111 loaded into the cover 160.

[0111] 20 is a flow chart illustrating a process 500 that may be used to manufacture elongate members 110, 110a, 110b, 110c, 110d, 110e, or any of the other elongate members disclosed above. In block operation 502, a block of foam 300 is placed on a machine 400. As previously mentioned, for purposes of this disclosure, various types of foam may be used.

[0112] In operation block 504, the block 300 is cut. Various types of cuts 310 can be made in the block 300. In some embodiments, cuts 310h are made with cut surfaces parallel to the xy axes. In some embodiments, cuts 310v are made with cut surfaces parallel to the xz axes. In some embodiments, cuts 310l are made with cut surfaces parallel to the yz axes. In some embodiments, the cuts 310 have linear cut surfaces. In other embodiments, one or more cuts 310 have non-linear cut surfaces. The cuts 310 can be made to produce elongate members 110 with different sizes. The cuts 310 can also be made to produce elongate members 110 with different cross-sectional areas. The cuts 310 can be configured to generate a stack of inserts with a sufficient number of inserts to fill a single comfort device. In some embodiments, each stack of inserts is an individual batch 320 for a single comfort device.

[0113] The cuts 310 can be horizontal cuts. In some embodiments, the cuts 310v are vertical cuts. The cuts 310 can be made perpendicular to the surface of the block 300 such that the cuts 310 are transverse to the surface. In some embodiments, the cuts 310 are made at an angle to the surface of the block 300. The machine 400 can make a series of horizontal cuts 310h and one or more longitudinal cuts 310l to generate one or more rows from the block 300. For example, the horizontal cuts 310h can be made to define the height of the elongated member 110, and the longitudinal cuts 310l can be made to define the length of the elongated member 110. Another set of vertical cuts 310v can be made to define the depth of the elongated member 110.

[0114] At block 506, after the incision 310 is made, the elongate members 110 may be collected. The process of collecting the elongate members 110 may be manual or automated. In some embodiments, a sufficient number of the elongate members 110 may be collected to fill an individual comfort device 100.

[0115] At block 508, the cut inserts 110 from the block 300 may be organized into separate piles or batches 320. For example, the machine 400 may be configured to discharge batches 320 of elongate members 110 comprising a sufficient number of elongate members 110 such that one or an integer number of batches is sufficient to completely fill one comfort device 100. In some embodiments, organization of the elongate members 110 is achieved by controlling a conveyor 422 to accumulate and space the batches.

[0116] In some embodiments, a pusher 430, shown in FIG. 14, is controlled to move the elongate members 110 to form batches 320. In some embodiments, the pusher 430 can be controlled to push one or more stacks of the elongate members 110 to another location on the discharge conveyor 422 or to a different downstream conveyor belt (not shown). The machine 400 can be configured to use the pusher 430 to push a particular stack or batch 320 of inserts 110 in one direction and move another stack or batch 320 of inserts 110 in a different direction. Optionally, the stacks can be separated by a predetermined distance 424 to allow the pusher 430 to easily transfer the stacks to a different discharge conveyor belt. Separating the stacks (or batches 320) from the block 300 by a predetermined distance 424 also allows for the next batch 320 to be cut without interference and / or mixing. In some embodiments, the predetermined distance 424 is about 1 inch or more. This predetermined distance 424 between the peaks is adjustable.

[0117] At block 510, the elongate members 110 can be placed within compartments 168 in the cover 160 of the comfort device 100. In some embodiments, the elongate members 110 are inserted into compartments 168 defined by the cover 160 of the comfort device 100. In some embodiments, different types of elongate members 110 (e.g., sizes, densities, shapes and / or materials) are placed within the different compartments 168 to provide unique stretch and / or compression responses.

[0118] 21 illustrates a method 530 of producing one or more elongate members 110 from a block 300 of foam material. In operation block 532, the block 300 is placed on a conveyor belt of a cutting machine. The block 300 may be made of foam. A variety of different types of foam may be used for purposes of this disclosure, including, but not limited to, polyurethane foam, memory foam, gel foam, latex rubber foam, convolute foam, evelon foam, reflex foam, high density foam, high resilience foam, supreem foam, rebond foam, closed cell foam, or dry fast foam.

[0119] At block 534, horizontal incisions 310h are made along cutting planes parallel to the xy axes. For example, a horizontal cutter 410h can be used to cut the block into sheets of foam by driving conveyors 420, 422 to pass the block 300 relative to the cutter 410h in a motion parallel to the xy plane.

[0120] At block 536, one or more longitudinal incisions 310l are made with a cutting plane parallel to the zy axis. For example, a vertical cutter 410v can be used to cut a block 300, already cut into sheets, into foam logs by driving conveyors 420, 422 to pass the block 300 relative to the cutter 410v in a motion parallel to the zy plane.

[0121] At block 538, a vertical cut 310v is made with a cutting surface parallel to the xz axis. For example, the vertical cutter 410v may be used to cut a block 300 that has already been cut into a number of foam sheets and logs by driving the cutter 410v laterally through the block 300 with a motion parallel to the xz plane. In some embodiments, only one cut 310v with a cutting surface parallel to the xz axis is made to form a single batch 320 of elongate members 110. In another embodiment, multiple vertical cuts 310v with cutting surfaces parallel to the xz axis are made for each batch 320 of elongate members.

[0122] In some embodiments, the longitudinal cuts 310l having cut surfaces parallel to the yz-axis can be equidistant from one another. For example, a first cut is made 8 inches away from a first side of the block 300, a second cut is made 8 inches away from the first cut, and the second cut is further away from the first side of the block 300 and the first cut. In this example, the first cut and the second cut can define an 8 inch length of the elongate member 110. In another example, a fourth cut and a fifth cut are made 1 inch and 2 inches away from the second side of the block 300. In this example, the third cut and the fourth cut can define a 1 inch width or 1 inch height of the elongate member 110. In another embodiment, the cuts 310 are not equidistant from one another.

[0123] At block 540 , the elongate members 110 produced by the above-mentioned cuts 310 are collected for being placed into individual comfort devices 100 .

[0124] In some embodiments, the method 530 is used to manufacture a batch of long elongated members 110 from a block 300 of foam material. The method 530 may include placing the block 300 of foam material on an input conveyor belt of a cutter, the input conveyor belt of the cutter defining an input axis. The method 530 may further include transporting the block 300 of foam material along the input conveyor belt to a cutting area of ​​the cutter. The method 530 may further include cutting the block 300 into a plurality of horizontal layers and at least two rows, and producing a first batch from the large block of foam material by making at least a first cut in the horizontal layer. The first cut may be transverse to the horizontal layer of the block 300. The method 530 may further include the steps of separating the first batch from the first remainder of the large block of foam material and producing a second batch from the first remainder of the large block of foam material by making at least a second cut in the horizontal layer, the second cut being transverse to the horizontal layer. The second batch may be separated from the second remainder of the block of foam material 300 in a manner similar to the first batch.

[0125] The method 530 of manufacturing a batch of elongated elongated members 110 from a block of foam material 300 can include placing the block of foam material 300 on an input conveyor belt of a cutter. The input conveyor belt can define an input axis, and the block of foam material 300 can have a width, a height, and a depth. The method 530 can further include moving the block of foam material 300 along the input conveyor belt in a first direction, the first direction being parallel to the input axis. The method 530 can also include making one or more first cuts, making one or more second cuts, and making a first of one or more third cuts, the first of the one or more third cuts producing a first batch of elongated inserts. The first batch of elongated inserts can be separated from a first remainder of the large block of foam material. The method 530 may further include performing a second of the one or more third cuts to produce a second batch of elongated inserts, which may be separated from a second remainder of the larger block of foam material.

[0126] In another embodiment, the one or more first cuts are parallel to a first plane defined by the depth and width of the large block of foam material. In some embodiments, the one or more second cuts are parallel to a second plane defined by the depth and height of the large block of foam material, and the one or more third cuts are parallel to a third plane defined by the width and height of the large block of foam material. The one or more second cuts and the one or more third cuts can be orthogonal to the one or more first cuts.

[0127] In some embodiments, an efficient batch manufacturing method for pillows filled with multiple elongated inserts can be performed by a cutting machine cutting a large block of foam material, cut in batches as described above. The method can include a combination of the following steps: (1) placing the block of foam material on an input conveyor belt of the cutting machine, the input conveyor belt defining an input axis; (2) transporting the large block of foam material along the input conveyor belt to a cutting area of ​​the cutting machine; (3) cutting the large block of foam material into a plurality of horizontal layers; (4) generating a first batch from the large block of foam material by making at least a first cut in the horizontal layers, the first vertical cut being transverse to the horizontal layers; and (5) transporting the first batch to a first discharge conveyor belt. (6) collecting a first plurality of long inserts from the first batch; (7) inserting the first plurality of long inserts into a first pillow; (8) producing a second batch from the large block of foam material by making at least a second vertical cut in the horizontal layer, the second vertical cut being transverse to the horizontal layer; (9) transferring the second batch to a second discharge conveyor belt; (10) collecting a second plurality of long inserts from the second batch; and (11) inserting the second plurality of long inserts into a second pillow.

[0128] In some embodiments, the method for efficient batch manufacturing of pillows may further include one or more of the following features in any combination: (i) the plurality of horizontal layers have the same height, (ii) the first and second discharge conveyor belts define a first and second discharge axis, respectively, (iii) the first and second discharge axes are different from the input axis and different from each other, (iv) the first and second batches comprise a number of elongate inserts sufficient to fill at least a predetermined portion of the first and second pillows, respectively, (v) the predetermined portion is at least 75% of the first and second pillows, (vi) the location and number of the first cuts are related to the size and / or volume of the first pillow, (vii) the location and number of the second cuts are related to the size and / or volume of the second pillow, (viii) the first batch volume and the second batch volume are the same, and (ix) the first batch volume and the second batch volume are different.

[0129] In another embodiment, the method for efficient batch manufacturing of pillows may further include the steps of: (i) moving the first batch and the remainder of the large block of foam material along an input conveyor belt; (ii) transferring the first batch to a first discharge conveyor belt while the remainder of the large block of foam material remains on the input conveyor belt; and (iii) moving the first batch in a first direction along the first discharge conveyor belt.

[0130] In another embodiment, the method for efficient batch manufacturing of pillows may further include the steps of: (i) moving the first batch and the remainder of the large block of foam material along an input conveyor belt; (ii) transferring the first batch to a second discharge conveyor belt while the remainder of the large block of foam material remains on the input conveyor belt; and (iii) transferring the second batch to a second discharge conveyor belt, further including the steps of moving the first batch in a second direction along the second discharge conveyor belt.

[0131] In some embodiments, a method for producing a batch of elongated inserts from a large block of foam material may include a combination of the following steps. (1) placing the large block of foam material on an input conveyor belt of a cutter, the input conveyor belt defining an input axis; (2) transporting the large block of foam material along the input conveyor belt to a cutting area of ​​the cutter; (3) cutting the large block of foam material into a plurality of horizontal layers and at least two rows; (4) generating a first batch from the large block of foam material by making at least a first cut in the horizontal layer, the first cut being transverse to the horizontal layer; (5) separating the first batch from a first remainder of the large block of foam material; (6) generating a second batch from the first remainder of the large block of foam material by making at least a second cut in the horizontal layer, the second cut being transverse to the horizontal layer; and (7) separating the second batch from a second remainder of the large block of foam material.

[0132] In some embodiments, a method for producing a batch of elongated inserts from a large block of foam material can include a combination of the following steps: (1) placing the large block of foam material on an input conveyor belt of a cutter, the input conveyor belt defining an input axis, the large block of foam material having a width, a height and a depth, (2) moving the large block of foam material along the input conveyor belt in a first direction, the first direction being parallel to the input axis, (3) making one or more first cuts, (4) making one or more second cuts, and (5) making one of the one or more third cuts. (5) performing a first of the one or more third cuts to produce a first batch of elongated inserts; (6) separating the first batch of elongated inserts from the first remainder of the large block of foam; (7) performing a second of the one or more third cuts to produce a second batch of elongated inserts; and (8) separating the second batch of elongated inserts from the second remainder of the large block of foam.

[0133] In another embodiment, the method above may further include one or more of the following features in any combination: (i) the one or more first cuts are parallel to a first plane defined by a depth and a width of the large block of foam material, (ii) the one or more second cuts are parallel to a second plane defined by a depth and a height of the large block of foam material, (iii) the one or more third cuts are parallel to a third plane defined by a width and a height of the large block of foam material, and (iv) the one or more second cuts and the one or more third cuts are orthogonal to the one or more first cuts.

[0134] During normal use of the comfort device 100, the elongate member 110 can move in a variety of ways. The elongate member 110 can move vertically or horizontally during normal use (e.g., when the comfort device is supporting the user's head). In addition, the elongate member 110 can also twist and bend. In order for the elongate member 110 to withstand repeated and prolonged use of the comfort device 100, the elongate member 110, in some embodiments, has specific material properties, compressive responses, and / or elasticity. Such properties allow the elongate member 110 to withstand shear stresses, bending moments, and / or torques resulting from repeated and prolonged use of the comfort device 100 and to maintain its initial size, volume, and / or shape. In some embodiments, the dimensions (e.g., length, width, height, and / or cross-sectional area) of the elongate member 110 affect the compressive response and / or elasticity. Thus, by changing the dimensions of the elongate member 110, the compressive response and / or elasticity of the elongate member 110 can be changed.

[0135] Naturally, various other modifications, adaptations, and alternative designs are possible in light of the above teachings. Thus, it should be understood at this point that, within the scope of the claims, the invention may be practiced otherwise than as specifically described herein. Various combinations or subcombinations of the specific features and aspects of the above-disclosed embodiments may be made and still be considered to fall within the scope of one or more of the present inventions. Furthermore, any particular feature, aspect, method, property, nature, quality, attribute, element, etc. disclosed herein in relation to one embodiment can be used in all other embodiments set forth herein. Thus, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another to form various forms of the disclosed invention. For this reason, it is intended that the scope of the invention disclosed herein should not be limited by the specific disclosed embodiments described above.

[0136] The present invention may also take various modifications and alternative forms, examples of which are shown in the drawings and described in detail herein. However, it should be understood that the present invention should not be limited to the particular forms or methods disclosed, but rather, the present invention should cover all modifications, equivalents, and alternatives falling within the spirit and scope of the various embodiments described and the appended claims. Any method disclosed herein does not have to be performed in the order recited. The methods disclosed herein include specific actions performed by a practitioner. However, they may also include, explicitly or implicitly, instructions of these actions by any third party. For example, an action such as "place an insert in a compartment" includes "ordering the insert to be placed in the compartment."

[0137] The ranges disclosed herein also encompass any and all overlaps, subranges, and combinations thereof. Language such as "up to," "at least," "greater than," "less than," "between" includes the recited numbers. As used herein, numbers following terms such as "approximately," "about," and "substantially" include the recited numbers (e.g., about 10%=10%) and also represent an amount close to the recited amount that still performs the desired function or achieves the desired result. For example, terms such as "approximately," "about," and "substantially" can refer to an amount that is less than 10%, less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the recited amount.

[0138] Personal support devices such as pillows, or larger devices such as soft furniture in the form of chairs or loveseats, sometimes called "bean bag" furniture, provide support and comfort to users by supporting the structures of different body parts such as the head, neck, shoulders, hips, and spine. They can also help prevent and reduce various types of back and neck pain, as well as shoulder, hip, and other forms of joint pain. For example, pillows can provide support for the head, neck, and shoulders by distributing gravity evenly while sleeping.

[0139] Some personal cushioning devices may take the form of an outer shell filled with a resilient material. The material properties of the insert provide the desired support and comfort. Different types of inserts may provide different levels of support and comfort. Different inserts have different compression responses and / or stretch properties, resulting in different levels of support and comfort for the user. Inserts incorporating firmer materials are not as "springy" as inserts incorporating softer materials.

[0140] Additionally, by varying the characteristics of how and / or how much the cushion is filled, for example by varying the total weight and / or volume of the elongated insert, different levels of support and comfort can be provided. The total weight and total volume of the elongated insert can be used to calculate the "weight ratio" and "volume ratio" of the elongated insert. As used herein, "weight ratio" can refer to the ratio of the weight of the elongated insert to the weight of the pillow having the elongated insert. As used herein, "volume ratio" can refer to the ratio of the volume occupied by the elongated insert in a relaxed state to the volume occupied by the pillow having the elongated insert therein. Meet Sean.

[0141] Different weight and / or volume ratios between the pillow insert and the pillow can result in different amounts of air space between the inserts in the pillow. An increase in the weight and / or volume ratio between the insert and the pillow can be achieved by increasing the number of inserts in the pillow. An increase in the number of inserts can increase the volume occupied by the inserts and therefore decrease the volume occupied by air in the pillow. However, it is possible that a decrease in the weight and / or volume ratio between the insert and the pillow does not necessarily result in a decrease in the number of inserts in the pillow.

[0142] An increase in the volume ratio can provide an increased compression response and therefore more support to the user during use. In some embodiments, an increase in the weight ratio can also provide an increased compression response and therefore more support to the user during use. The compression response and / or stretchability of the pillow insert can also be modified by changing the shape of the pillow insert. For example, a flat rectangular foam insert can have a different compression response and / or stretchability than an elongated cylindrical foam insert.

[0143] List of Exemplary Numbered Embodiments Below is a list of exemplary numbered embodiments. The features listed in the following list of exemplary embodiments can be combined with additional features disclosed herein. Additionally, additional inventive combinations of features are disclosed herein that are not specifically listed in the following list of exemplary embodiments and do not include the same features as the specific embodiments listed below. For the sake of brevity, the following list of exemplary embodiments does not identify all inventive aspects of the present disclosure. The following list of exemplary embodiments is not intended to identify key features or essential features of any subject matter disclosed herein. 1. A bedding pillow, an outer cover having an upper sidewall and a lower sidewall; a first interior compartment disposed within the cover between the upper and lower side walls; an opening in the outer cover that opens to an interior compartment of the outer cover; a fastener assembly disposed in the opening and including at least a first fastening element, the fastening element being movable between an open position and a closed position; a plurality of elongate inserts disposed within the first section of the outer cover; Equipped with The plurality of elongate inserts have an open cell foam material, a first end, a second end, an intermediate portion, and a length between the first end and the second end; the plurality of elongated inserts have cross sections defining cross-sectional areas between about one-sixteenth of an inch square and about one-half of an inch square, the cross sections having at least a plurality of cross-sectional dimensions; A sleeping pillow, characterized in that the length is at least 15 times the maximum cross-sectional dimension among the cross-sectional dimensions. 2. The bedding pillow of embodiment 1, wherein the plurality of elongated inserts have a length of at least 8 inches. 3. A sleeping pillow according to embodiment 1 or 2, wherein the cross-section of the plurality of elongated inserts extends perpendicular to the length of the plurality of elongated inserts. 4. A bedding pillow according to any one of embodiments 1 to 3, wherein a first end of the plurality of elongated inserts has a first cross-section, a second end of the plurality of elongated inserts has a second cross-section, an intermediate portion has a third cross-section, the first cross-section and the second cross-section have the same cross-sectional shape, and the third cross-section has a different cross-sectional shape than the first cross-section and the second cross-section. 5. The sleeping pillow according to any one of embodiments 1 to 4, wherein the plurality of elongated inserts have different lengths. 6. The sleeping pillow according to any one of embodiments 1 to 5, wherein the first end, second end and intermediate portion of the plurality of elongated inserts have a rectangular cross-sectional shape. 7. A sleeping pillow according to any one of the preceding embodiments, wherein the outer cover of the comfort device comprises one or more compartments. 8. The bedding pillow of embodiment 7, wherein one or more compartments have different volumes and shapes. 9. The bedding pillow of embodiment 7, wherein one or more compartments contain elongated inserts having different elasticity. 10. A sleeping pillow as described in any of embodiments 1 to 9, wherein the plurality of elongated inserts have a known elasticity associated with at least one of the following: the material of the plurality of elongated inserts; the length of the plurality of elongated inserts; the cross-sectional area of ​​the plurality of elongated inserts; the magnitude of the force acting on the plurality of elongated inserts; the volume ratio of the total volume of the plurality of elongated inserts to the total volume of the personal comfort device; the weight ratio of the total weight of the plurality of elongated inserts to the total weight of the personal comfort device; the amount of air space between the plurality of elongated inserts; the coefficient of friction of the elongated inserts; and the magnitude of the frictional force acting between the plurality of elongated inserts. 11. A bedding pillow as described in any one of embodiments 1 to 10, further comprising a bulk fill material mixed with the plurality of elongated inserts provided within the first compartment, the bulk fill material being at least 5% of the total weight of all of the bulk fill material and elongated inserts in the first compartment. 12. The bedding pillow of embodiment 11, wherein the loose fill material is at least one of down feathers, loose fiber, ball fiber, wool, chopped foam, and chopped latex. 13. An outer cover having a compartment disposed within the outer cover; an opening provided in the outer cover and opening toward an interior of the compartment of the outer cover; a fastener assembly disposed in the opening, the fastener assembly including a fastener element movable between an open position and a closed position; a plurality of elongate inserts disposed within the first section of the outer cover; A bedding pillow comprising: The plurality of elongate inserts have a first end, a second end, an intermediate portion, and a length between the first end and the second end; The plurality of elongate inserts have cross-sections with at least a plurality of cross-sectional dimensions; A sleeping pillow, the length of which is at least 8 times the maximum cross-sectional dimension of a plurality of cross-sectional dimensions. 14. The bedding pillow of embodiment 13, wherein the outer cover further comprises an upper sidewall and a lower sidewall. 15. The sleeping pillow of embodiment 13 or 14, wherein the upper and lower side walls define at least a portion of the compartment of the outer cover. 16. The sleeping pillow according to any one of embodiments 13 to 15, wherein the plurality of elongated inserts further comprise an open-cell foam material (cell-type foam material). 17. A bedding pillow according to any one of embodiments 13 to 16, wherein the plurality of elongated inserts have a length of at least 8 inches. 18. The sleeping pillow of any one of embodiments 13-17, wherein the cross-section of the plurality of elongated inserts extends perpendicular to the length of the plurality of elongated inserts. 19. A sleeping pillow according to any one of embodiments 13 to 18, wherein the cross-section of the plurality of elongated inserts defines a cross-sectional area of ​​at least one-sixteenth of an inch square. 20. A bedding pillow according to any one of embodiments 13 to 19, wherein a first end of the plurality of elongated inserts has a first cross-section, a second end of the plurality of elongated inserts has a second cross-section, an intermediate portion has a third cross-section, the first cross-section and the second cross-section have the same cross-sectional shape, and the third cross-section has a different cross-sectional shape than the first cross-section and the second cross-section. 21. A bedding pillow as described in any of embodiments 13 to 20, further comprising a bulk filler material mixed with the plurality of elongated inserts provided within the first compartment, the bulk filler material being at least 5% of the total weight of all of the bulk filler material and elongated inserts in the first compartment. 22. The bedding pillow of embodiment 21, wherein the loose fill material is at least one of down feathers, loose fiber, ball fiber, wool, chopped foam, and chopped latex. 23. A bedding pillow, An outer cover; an internal compartment disposed within the cover; a plurality of elongate inserts disposed within an interior section of the outer cover; Equipped with The plurality of elongate inserts have a first end, a second end, and a length between the first end and the second end; The plurality of elongated inserts have a length greater than about 6 inches. 24. The bedding pillow of embodiment 23, wherein the plurality of elongated inserts have a cross-section extending perpendicular to the length of the plurality of elongated inserts, the cross-section defining a cross-sectional area of ​​at least 1 / 16th of an inch squared and less than about 3 / 4 of an inch squared. 25. A bedding pillow as described in embodiment 23 or 24, wherein a first end of the plurality of elongated inserts has a first cross-section, a second end of the plurality of elongated inserts has a second cross-section, and an intermediate portion has a third cross-section, and the first cross-section, second cross-section, and third cross-section have the same shape and size. 26. A bedding pillow as described in any of embodiments 23 to 25, wherein a first end of the plurality of elongated inserts has a first cross-section, a second end of the plurality of elongated inserts has a second cross-section, an intermediate portion has a third cross-section, the first cross-section and the second cross-section have the same cross-sectional shape, and the third cross-section has a different cross-sectional shape than the first cross-section and the second cross-section. 27. A sleeping pillow according to any one of embodiments 23 to 26, wherein the multiple elongated inserts have different lengths. 28. The sleeping pillow of any one of embodiments 23 to 27, wherein the first ends, second ends, and intermediate portions of the plurality of elongated inserts have a rectangular cross-sectional shape. 29. A sleeping pillow according to any one of embodiments 23 to 28, wherein the outer cover of the comfort device comprises one or more compartments. 30. The bedding pillow of embodiment 29, wherein one or more compartments have different volumes and shapes. 31. The bedding pillow of embodiment 29, wherein one or more compartments contain elongated inserts having different elasticity. 32. A sleeping pillow according to any one of embodiments 23 to 31, wherein the fastening mechanism utilizes at least one of the following mechanisms: zippers, hooks, ties, Velcro (registered trademark), clips, buttons, clasps, straps, and pins. 33. A sleeping pillow as described in any of embodiments 23 to 32, wherein the multiple elongated inserts have a known elasticity associated with at least one of the following: the material of the multiple elongated inserts, the length of the multiple elongated inserts, the cross-sectional area of ​​the multiple elongated inserts, the magnitude of the force acting on the multiple elongated inserts, the volumetric ratio of the total volume of the multiple elongated inserts to the total volume of the personal comfort device, the weight ratio of the total weight of the multiple elongated inserts to the total weight of the personal comfort device, the amount of air space between the multiple elongated inserts, the coefficient of friction of the elongated inserts, and the magnitude of the frictional force acting between the multiple elongated inserts. 34. A bedding pillow as described in any one of embodiments 23 to 33, further comprising a bulk filler material mixed with the plurality of elongated inserts provided within the inner compartment, the bulk filler material being at least 5% of the total weight of all of the bulk filler material and elongated inserts in the inner compartment. 35. The bedding pillow of any one of embodiments 23-34, wherein the loose filling material is at least one of down feathers, loose fiber, ball fiber, wool, chopped foam, and chopped latex. 36. A method for efficiently batch manufacturing pillows filled with elongated inserts, the elongated inserts being formed in batches (bundles) by a cutting machine and cut from a block of foam material, the method comprising: placing a block of foam material on an input conveyor belt of a cutter, the input conveyor belt defining an input axis; Transporting a large block of foam material along an input conveyor belt to a cutting area of ​​a cutter; Cutting a large block of foam into a number of horizontal layers; Producing a first batch of elongated inserts from a large block of foam material by making at least a first cut in the horizontal layer, the first cut being transverse to the horizontal layer; transferring the first batch to a first discharge conveyor belt; inserting a first batch of elongate inserts into a first pillowcase, the first batch being large enough to substantially fill the entire first pillowcase; Producing a second batch of elongated inserts from the large block of foam material by making at least a second cut in the horizontal layer, the second cut being transverse to the horizontal layer; inserting a second batch of elongate inserts into a second pillowcase, the second batch of elongate inserts being large enough to substantially fill the entire second pillowcase; The method includes: 37. The method of embodiment 36, wherein the horizontal layers have the same height. 38. The method of embodiment 36 or 37, further comprising, prior to the step of inserting the second batch, transferring the second batch to a second discharge conveyor belt, the first discharge conveyor belt and the second discharge conveyor belt defining a first discharge axis and a second discharge axis, respectively. 39. The method of any of embodiments 36-38, further comprising adding a bulk fill material to the first pillowcase, the bulk fill material being at least 5% of the total weight of all of the bulk fill material and the elongated insert in the first pillowcase, and the bulk fill material being at least one of down feathers, bulk fiber, ball fiber, wool, chopped foam, and chopped latex. 40. The method of any one of embodiments 36-39, wherein the first batch and the second batch comprise a number of elongate inserts sufficient to fill at least a predetermined portion of the first pillow and the second pillow, respectively. 41. The method of embodiment 40, wherein the predetermined portion is at least 75% of the first pillow and the second pillow. 42. The method of any of embodiments 36 to 41, wherein the location and number of the first incisions are associated with the size and / or volume of the first pillow. 43. The method of any of embodiments 36 to 42, wherein the location and number of the second cuts are associated with the size and / or volume of the second pillow. 44. The step of transferring the first batch to a first discharge conveyor belt comprises: moving the first batch along an input conveyor belt; transferring the first batch to a first discharge conveyor belt while the remainder of the large block of foam material remains on the input conveyor belt; moving the first batch in a first direction along a first discharge conveyor belt; 44. The method of any one of embodiments 36 to 43, further comprising: 45. The step of transferring the second batch to a second conveyor belt comprises: moving the first batch and the remainder of the large block of foam material along an input conveyor belt; transferring the first batch to a first discharge conveyor belt while the remainder of the large block of foam material remains on the input conveyor belt; spacing the first batch from the second batch by moving the first batch away from the large block of foam prior to the step of generating the second batch, the spacing being large enough to ensure that the second batch remains spaced from the first batch when the second batch is generated; 45. The method of any one of embodiments 36 to 44, further comprising: 46. ​​The method of any of embodiments 36-45, wherein the volume of the first batch and the volume of the second batch are the same. 47. A method for producing a batch of elongated inserts from a large block of foam material, the method comprising: Cutting a large block of foam into layers; Producing a first batch from the large block of foam material by making at least a first cut in the plurality of layers, the first cut being transverse to the plurality of layers; Separating the first batch from a first remainder of the block of foam material; producing a second batch from the first remainder of the block of foam material by making at least a second incision in the plurality of layers, the second incision being transverse to the plurality of layers; Separating the second batch from the first batch and the second remainder of the large block of foam material; The method includes: 48. A method for producing a batch of elongated inserts from a large block of foam material, the method comprising: placing a large block of foam material onto an input conveyor belt of a cutter, the input conveyor belt defining an input axis, the large block of foam material having a width, a height and a depth; moving the block of foam material in a first direction along an input conveyor belt, the first direction being parallel to an input axis; performing one or more first cuts; performing one or more second cuts; performing a first of one or more third cuts, the first of the one or more third cuts producing a first batch of elongated inserts; Separating a first batch of elongated inserts from a first remainder of the large block of foam; performing a second of the one or more third cuts, the second of the one or more third cuts producing a second batch of elongated inserts; Separating a second batch of elongated inserts from a second remainder of the larger block of foam; The method includes: 49. The method of embodiment 48, wherein the one or more first cuts are parallel to a first plane defined by the depth and width of the large block of foam material, the one or more second cuts are parallel to a second plane defined by the depth and height of the large block of foam material, and the one or more third cuts are parallel to a third plane defined by the width and height of the large block of foam material. 50. The method of embodiment 48 or 49, wherein the one or more second incisions and the one or more third incisions are orthogonal to the one or more first incisions.

Claims

1. A bedding pillow, an outer cover having an upper sidewall and a lower sidewall; a first interior compartment disposed within the outer cover between the upper sidewall and the lower sidewall; an opening in the outer cover that opens to the first interior compartment of the outer cover; a fastener assembly disposed in the opening, the fastener assembly including at least a first fastening element, the fastening element being movable between an open position and a closed position; a plurality of elongate inserts disposed within the first interior section of the outer cover; Equipped with the plurality of elongate inserts having an open cell foam material, a first end, a second end, an intermediate portion, and a length between the first end and the second end; the plurality of elongated inserts have cross sections defining cross-sectional areas between about one-sixteenth of an inch square and about one-half of an inch square, the cross sections having at least a plurality of cross-sectional dimensions; said length being at least 15 times said maximum cross-sectional dimension; wherein the first ends of at least some of the elongated inserts intertwine with a plurality of other elongated inserts in a first portion of the first internal compartment and the second ends of at least some of the elongated inserts intertwine with a plurality of other elongated inserts in a second portion of the first internal compartment, such that when the first portion is compressed, the first ends of at least some of the elongated inserts are pulled downward and the second ends of at least some of the elongated inserts remain relatively stationary, such that the elongated inserts in the first portion are compressed and under load while the elongated inserts in the second portion are uncompressed.

2. 2. The sleep pillow of claim 1, wherein said plurality of elongated inserts have a length of at least 8 inches.

3. 3. The sleeping pillow of claim 1 or 2, wherein the cross-section of the plurality of elongate inserts extends perpendicular to the length of the plurality of elongate inserts.

4. the first ends of the plurality of elongate inserts have a first cross-section; the second ends of the plurality of elongate inserts have a second cross-section; the intermediate portion has a third cross section; the first cross-section and the second cross-section have the same cross-sectional shape; The sleeping pillow according to any one of claims 1 to 3, characterized in that the third cross section has a cross-sectional shape different from the first cross section and the second cross section.

5. The sleeping pillow according to any one of claims 1 to 4, characterized in that the plurality of elongated inserts have different lengths.

6. The sleeping pillow of any one of claims 1 to 5, wherein the first end, the second end and the intermediate portion of the plurality of elongated inserts have a rectangular cross-sectional shape.

7. The sleeping pillow according to any one of claims 1 to 6, characterized in that the outer cover comprises a plurality of internal compartments.

8. 8. The sleeping pillow of claim 7, wherein said internal compartments have different volumes and shapes.

9. 8. The sleep pillow of claim 7, wherein said inner compartments accommodate a plurality of elongated inserts having different elasticity.

10. The sleeping pillow of any one of claims 1 to 9, characterized in that the plurality of elongated inserts have a known elasticity associated with at least one of the following: a material of the plurality of elongated inserts; a length of the plurality of elongated inserts; a cross-sectional area of ​​the plurality of elongated inserts; a magnitude of force acting on the plurality of elongated inserts; a volumetric ratio between a total volume of the plurality of elongated inserts and a total volume of the sleeping pillow; a weight ratio between a total weight of the plurality of elongated inserts and a total weight of the sleeping pillow; an amount of air space between the plurality of elongated inserts; a coefficient of friction of the plurality of elongated inserts; and a magnitude of frictional force acting between the plurality of elongated inserts.

11. a bulk fill material intermixed with the plurality of elongated inserts disposed within the first interior compartment; The sleeping pillow of any one of claims 1 to 10, wherein the bulk fill material is at least 5% of the total weight of the bulk fill material of the first interior section and all of the plurality of elongate inserts.

12. 12. The sleep pillow of claim 11, wherein the loose fill material is at least one of down feathers, loose fiber, ball fiber, wool, chopped foam, and chopped latex.

13. an outer cover having a first interior compartment disposed within the outer cover; an opening in the outer cover that opens into the first interior compartment of the outer cover; a fastener assembly disposed in the opening and including a fastener element movable between an open position and a closed position; a plurality of elongate inserts disposed within the first interior section of the outer cover; A bedding pillow comprising: the plurality of elongate inserts having a first end, a second end, an intermediate portion and a length between the first end and the second end; the plurality of elongate inserts having cross-sections with at least a plurality of cross-sectional dimensions; the length is at least eight times the largest cross-sectional dimension of the plurality of cross-sectional dimensions; wherein the first ends of at least some of the elongated inserts intertwine with a plurality of other elongated inserts in a first portion of the first internal compartment and the second ends of at least some of the elongated inserts intertwine with a plurality of other elongated inserts in a second portion of the first internal compartment, such that when the first portion is compressed, the first ends of at least some of the elongated inserts are pulled downward and the second ends of at least some of the elongated inserts remain relatively stationary, such that the elongated inserts in the first portion are compressed and under load while the elongated inserts in the second portion are uncompressed.

14. The sleeping pillow of claim 13, wherein the outer cover further comprises an upper sidewall and a lower sidewall.

15. 15. The sleeping pillow of claim 13 or 14, wherein an upper sidewall and a lower sidewall define at least a portion of the first interior compartment of the outer cover.

16. The sleeping pillow of any one of claims 13 to 15, wherein the plurality of elongated inserts further comprise an open cell foam material.

17. The sleeping pillow of any one of claims 13 to 16, wherein the plurality of elongated inserts have a length of at least 8 inches.

18. A sleeping pillow according to any one of claims 13 to 17, characterized in that the cross-section of the plurality of elongate inserts extends perpendicular to the length of the plurality of elongate inserts.

19. The sleeping pillow of any one of claims 13 to 18, wherein the cross-sections of the plurality of elongated inserts define a cross-sectional area of ​​at least one-sixteenth of an inch square.

20. the first ends of the plurality of elongate inserts have a first cross-section; the second ends of the plurality of elongate inserts have a second cross-section; the intermediate portion has a third cross-section; the first cross-section and the second cross-section have the same cross-sectional shape; The sleeping pillow according to any one of claims 13 to 19, characterized in that the third cross section has a cross-sectional shape different from the first cross section and the second cross section.

21. a bulk fill material intermixed with the plurality of elongated inserts disposed within the first interior compartment; A sleeping pillow according to any one of claims 13 to 20, characterized in that the bulk fill material is at least 5% of the total weight of all of the bulk fill material and the elongated insert in the first internal section.

22. 22. The sleep pillow of claim 21, wherein the loose fill material is at least one of down feathers, loose fiber, ball fiber, wool, chopped foam, and chopped latex.

23. A bedding pillow, An outer cover; an internal compartment disposed within the outer cover; a plurality of elongate inserts disposed within the interior compartment of the outer cover; Equipped with the plurality of elongate inserts having a first end, a second end, an intermediate portion and a length between the first end and the second end; the plurality of elongated inserts having a length greater than about 6 inches; wherein the first ends of at least some of the elongated inserts intertwine with a plurality of other elongated inserts in a first portion of the interior compartment and the second ends of at least some of the elongated inserts intertwine with a plurality of other elongated inserts in a second portion of the interior compartment, such that when the first portion is compressed, the first ends of at least some of the elongated inserts are pulled downward and the second ends of at least some of the elongated inserts remain relatively stationary, such that the elongated inserts in the first portion are compressed and under load while the elongated inserts in the second portion are uncompressed.

24. 24. The sleeping pillow of claim 23, wherein the plurality of elongate inserts have a cross-section extending perpendicular to the length of the plurality of elongate inserts, the cross-section defining a cross-sectional area of ​​at least 1 / 16th of an inch squared and less than about 3 / 4 of an inch squared.

25. the first ends of the plurality of elongate inserts have a first cross-section; the second ends of the plurality of elongate inserts have a second cross-section; the intermediate portion has a third cross-section; 25. The sleeping pillow of claim 23 or 24, wherein the first cross section, the second cross section and the third cross section have the same shape and size.

26. the first ends of the plurality of elongate inserts have a first cross-section; the second ends of the plurality of elongate inserts have a second cross-section; the intermediate portion has a third cross section; the first cross section and the second cross section have the same cross-sectional shape; The sleeping pillow according to any one of claims 23 to 25, characterized in that the third cross section has a cross-sectional shape different from the first cross section and the second cross section.

27. The sleeping pillow according to any one of claims 23 to 26, characterized in that the plurality of elongated inserts have different lengths.

28. The sleeping pillow of any one of claims 23 to 27, wherein the first ends, the second ends and the intermediate portions of the plurality of elongated inserts have a rectangular cross-sectional shape.

29. A sleeping pillow according to any one of claims 23 to 28, characterized in that the outer cover comprises a plurality of internal compartments.

30. 30. The sleeping pillow of claim 29, wherein said internal compartments have different volumes and shapes.

31. 30. The sleep pillow of claim 29, wherein said interior compartments accommodate a plurality of elongated inserts having different elasticity.

32. the outer cover having a fastening mechanism; The sleeping pillow of any one of claims 23 to 31, wherein the fastening mechanism utilizes at least one of the following mechanisms: zippers, hooks, ties, Velcro, clips, buttons, clasps, straps, and pins.

33. The sleeping pillow of any one of claims 23 to 32, characterized in that the plurality of elongated inserts have a known elasticity associated with at least one of the following: a material of the plurality of elongated inserts; a length of the plurality of elongated inserts; a cross-sectional area of ​​the plurality of elongated inserts; a magnitude of force acting on the plurality of elongated inserts; a volumetric ratio between a total volume of the plurality of elongated inserts and a total volume of the sleeping pillow; a weight ratio between a total weight of the plurality of elongated inserts and a total weight of the sleeping pillow; an amount of air space between the plurality of elongated inserts; a coefficient of friction of the plurality of elongated inserts; and a magnitude of frictional force acting between the plurality of elongated inserts.

34. a bulk fill material intermixed with the plurality of elongated inserts disposed within the interior compartment; A sleeping pillow according to any one of claims 23 to 33, characterized in that the bulk fill material is at least 5% of the total weight of the bulk fill material of the inner compartment and all of the plurality of elongate inserts.

35. Sleeping pillow according to any one of claims 23 to 34, characterized in that the loose filling material is at least one of down feathers, loose fibre, ball fibre, wool, chopped foam and chopped latex.

Images