Hybrid Pillow

Abstract

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

Description

[Technical Field]

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

[0002] The present invention relates to a hybrid pillow. In particular, the present invention relates to a molded hybrid pillow comprising a coil panel and a gel layer embedded within a foam comfort layer. [Background technology]

[0003] The effectiveness and desirability of a support cushion depend, to some extent, on how comfortable the user can be with it over extended periods. In this regard, many users prefer support cushions made of flexible foam, especially mattresses. However, over the lifespan of body support cushions such as mattresses and pillows, flexible foam can lose both height and firmness. This decrease in the durability of the support cushion can result in a reduction in its comfort.

[0004] Of course, it is desirable that the resilience and comfort of body support cushions be maintained for as long as possible, and there is a constant need to improve the durability, comfort, and resilience of these products. Therefore, body support cushions that enable such improvements in durability, comfort, and resilience, and that allow such characteristics to be maintained over a long period of time, are highly desirable and beneficial. [Overview of the project]

[0005] The present invention includes hybrid body support cushions such as hybrid pillows. In some embodiments, the hybrid pillow comprises various layers, including one or more coil panels formed integrally with a foam cushion structure together with a gel layer enclosing the coil panels between the gel and the foam.

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

[0007] In some embodiments, the recesses defined on the upper surface of the cushioning material are generally rectangular, but it is conceivable that the recesses may be formed with various outer periphery shapes and have various depths, depending on the shape and size of the coil panel and gel layer (i.e., gel-molded spring array).

[0008] In some embodiments, the coil panel is formed of a plurality of coil springs arranged in rows and / or columns in an array or matrix. An upper first fabric layer is positioned to cover the upper end of each coil spring, and a lower second fabric layer is positioned below the lower end of each coil spring. The first and second fabric layers are joined, for example, welded, between the coil springs, thereby forming coil pockets. The ends of the coil springs may be in direct contact with the fabric layers, or alternatively, pieces of material such as cushions or scrims may be placed between the coil springs and the fabric layers. Such intermediate materials can prevent the coil springs from protruding through the fabric layers or tearing the fabric layers in other ways.

[0009] In some embodiments, the fabric layer allows for minimizing or completely preventing the gel layer from penetrating, submerging, or otherwise coming into contact with the coil spring. For this reason, in some embodiments, the first and second fabric layers are hydrophobic fabrics, waterproof fabrics, etc.

[0010] In some embodiments, the gel layer is a substantially uniform layer of elastomer gel-like material that can provide a cooling effect by acting as a heat sink or heat dissipation device from the user's body or any part thereof located on the pillow.

[0011] In some embodiments, the gel layer may have a substantially smooth outer surface, but the surface shape and feel of the gel may be determined in accordance with the surface of the mold into which the gel is poured. Furthermore, the gel may also vary in density along the surface of the pillow. The outer edge or periphery of the gel may have a regular or irregular shape, and the gel layer may vary in thickness and / or density. For example, the thickness of the gel may be greater in the center compared to the region toward the periphery of the gel.

[0012] In some embodiments, the pillow includes two or more coil panels and / or two or more gel-molded spring arrays. For example, there may be multiple gel-molded spring arrays arranged across the upper surface of the cushioning material, or the pillow may include a first gel-molded spring array on the upper surface and a second gel-molded spring array on the lower surface.

[0013] According to some exemplary embodiments of the present invention, a mold is provided and a liquid gel is dispensed into the mold. After the liquid gel is dispensed into the mold, a coil panel is placed on top of the gel in the mold. After the coil panel and gel are placed in the mold, a liquid foam precursor is dispensed into the mold and the liquid precursor foams to form a cushioning material.

[0014] According to some other embodiments, instead of forming the gel layer in the same mold as the cushioning material, the gel layer may be applied to the cushioning material after the gel layer has been formed individually. The coil panel may still be provided to the mold before the foam precursor is provided so that the coil panel becomes integrated with the cushioning material. Alternatively, both the coil panel and the gel layer may be applied to the cushioning material after it has been formed.

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

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

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

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

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

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

[0021] [Figure 4] It is an exploded perspective view of another exemplary hybrid pillow made according to the present invention.

[0022] [Figure 5] It is a flowchart depicting an exemplary method of forming a molded hybrid pillow.

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

[0024] [Figure 7] It is a top view of one exemplary cloth layer used in a coil panel defining a plurality of openings of a first pattern.

[0025] [Figure 8] It is a top view of another exemplary cloth layer used in a coil panel defining an opening within a plurality of central welds.

Mode for Carrying Out the Invention

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

[0027] Referring first to Figure 1, an exemplary perspective view of a body support cushion 10 is provided, and for the purpose of immediate teaching and ease of reference, the body support cushion 10 is also called a pillow or hybrid pillow. However, a body support cushion made according to the present invention can be embodied in various structures that support one or more parts of the end user's body. The term "body support cushion" can include, in non-limiting examples, various types of supports such as bedding and / or cushions for chairs and furniture, pillows, pads for medical devices and instruments (e.g., wheelchair seat pads, wheelchair pads, medical pads, hospital stretcher pads, operating table pads, positioning pads), pads for furniture (e.g., upholstery pads, furniture cushions, furniture pads), pads for exercise equipment and devices (e.g., exercise cushions, sports and exercise pads, gymnastics mats), pads for recreational equipment and devices (e.g., camping and sleeping mats), pads for clothing (e.g., bra straps, shoulder pads, shoe linings, boot linings), pads for household goods (e.g., anti-fatigue mats, mattress pads, mattress covers, mattress tops, pillow tops, etc.), pad accessories (e.g., briefcase shoulder straps, computer carry cases, wallets, gloves, etc.), pet beds, etc. Therefore, any of these types of structures and other items may fall within the scope of the term "pillow" or "body support cushion" and be used interchangeably.

[0028] Still referring to Figure 1, the exemplary hybrid pillow 10 has a generally rectangular outer shape, having an arched upper surface 14 and a needle-shaped lower surface 16 joined by an arched curvature at or around the outer edge 18 of the pillow 10. In the exemplary pillow, the height or distance between the upper surface 14 and the lower surface 16 of the pillow 10 is about 2 to 10 inches. In some other embodiments, the height is about 3 to 5 inches. However, it should be understood that this range is not exhaustive and other sizes may be available.

[0029] An exemplary pillow may be arched in one or both of its length (long side) and width (short side) dimensions. Similarly, an exemplary pillow may have a generally flat upper and / or lower surface joined by a straight or arched curve at or around the outer edge of the pillow, or alternatively, the upper and / or lower surface may be arched overall. As used herein, “outer edge” can be one or more edges that define the shape of the pillow. An exemplary pillow may also have a variety of shapes other than the rectangular shape shown, and therefore the shape should not be considered limiting.

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

[0031] With respect to the cushioning material 30, in the exemplary pillow 10, the cushioning material 30 is made of viscoelastic foam (sometimes called “memory foam” or “low-rebound foam”). However, in other embodiments, the cushioning material may be made of a variety of materials without departing from the intent and scope of the present invention, and latex foam or mesh-like non-viscoelastic foam may be used, but are not limited to these.

[0032] The cushioning material may be formed from various forms through various embodiments, and the following outline is not exhaustive. For example, open-cell or non-mesh viscoelastic foam may be used. In some embodiments, temperature-responsive foam may be used. Temperature responsiveness within the user's body temperature range (or the temperature range to which the pillow 10 is exposed by contact with or proximity to the user's body while resting thereon) can offer significant advantages. As used herein and in the appended claims, a material is considered "responsive" to temperature changes if it exhibits a hardness change of at least 10% as measured by International Organization for Standardization (ISO) standard 3386 over a temperature range of 10°C to 30°C. In other embodiments, it may be desirable for the foam to be substantially insensitive to temperature. As used herein, a material is considered "substantially insensitive" to temperature changes if it exhibits a hardness change of less than 10% as measured by International Organization for Standardization (ISO) standard 3386 over a temperature range of 10°C to 30°C. In some embodiments, flexible polyurethane foam may be used, and in some embodiments, mesh foam may be utilized.

[0033] The cushioning material of the pillow 10 may consist of any of the various soft foams mentioned that can distribute pressure from the user's body or any part thereof across the pillow 10 or, more generally, the body support cushion 10. In some exemplary embodiments, the density of the soft foam used is generally sufficient to support the user's neck and shoulders. Such soft foams may include, but are not limited to, latex foam, mesh-like or non-mesh-like viscoelastic foam (sometimes called memory foam or low-rebound foam), mesh-like or non-mesh-like non-viscoelastic foam (sometimes called “conventional” foam), polyurethane high-rebound foam, expanded polymer foam (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), or any combination thereof.

[0034] The exemplary cushioning material 30 is a viscoelastic foam having sufficient density and hardness as well as low rebound, allowing pressure to be uniformly absorbed and evenly distributed across the cushioning material 30 of the pillow 10. Generally, such viscoelastic foams have a hardness of at least 10N and not exceeding 80N, measured by applying a compressive pressure of at least 40% of the initial thickness of the material to a sample of the material from a plate at about room temperature (e.g., 21°C to 23°C), where the 40% compression is held for a set time established by the International Organization for Standardization (ISO) 2439 hardness measurement standard. In some embodiments, the body support cushion or pillow 10 has a hardness of about 70 kg / m 3 ~Approx. 110kg / m 3 A foam can be utilized that is composed of a viscoelastic foam having a density and a hardness of about 25N to about 50N. In some embodiments, the viscoelastic foam may have a hardness of about 10N, about 20N, about 30N, about 40N, about 50N, about 60N, about 70N, or about 80N to provide the desired degree of comfort and body conformity.

[0035] The viscoelastic foam used in the exemplary cushioning material 30 of the pillow 10 may also have a density that assists in providing a desired level of comfort, a quality of conforming to the body, and an increased degree of durability of the material. In some embodiments, the viscoelastic foam has a density of about 30 kg / m 3 or more and about 150 kg / m 3 or less. In some embodiments, the density of the viscoelastic foam used in the pillow 10 is about 30 kg / m 3 , about 40 kg / m 3 , about 50 kg / m 3 , about 60 kg / m 3 , about 70 kg / m 3 , about 80 kg / m 3 , about 90 kg / m 3 , about 100 kg / m 3 , about 110 kg / m 3 , about 120 kg / m 3 , about 130 kg / m 3 , about 140 kg / m 3 , or about 150 kg / m 3 It will be appreciated that the selection of a viscoelastic foam having a particular density affects other properties including the firmness of the foam, the behavior of the foam in reacting to pressure, and the overall feel of the foam, but that a viscoelastic foam having the desired density and firmness can be readily selected for a particular desired application.

[0036] The exemplary recesses 36 defined on the upper surface 35 of the cushioning material 30 are generally rectangular, but it is conceivable that the recesses 36 may be formed with various peripheral edge shapes and have various depths determined according to the shape and size of, for example, the coil panel 40 and the gel layer 50 (i.e., the gel-molded spring array 52). The recesses 36 can be formed in various ways depending on the method of forming the body support cushion 10. For example, in an exemplary embodiment described later with reference to Figure 5, the cushioning material 30 is made of foam, and the liquid gel and coil panel are placed in a mold (e.g., in the form of a sheet that is individually molded containing the coil and gel), and the foam precursor is applied so that foaming occurs around the coil panel 40 and the gel. Thus, in such an embodiment, once the liquid gel is set in the gel layer 50 and the foaming precursor is set, the resulting cushioning material 30 is displaced around the coil panel 40 and the gel layer 50 during the foaming process to define the recesses 36. Alternatively, in some embodiments, the coil / gel sheet may be formed together in separate molds, and once cured, the liquid precursor of the cushioning material may be placed around it in the other mold to form an exemplary pillow. In further embodiments and other alternatives, if the cushioning material is formed independently, the recesses may also be formed therein or cut after the cushioning material has been formed.

[0037] Next, with reference to Figure 3-3A, toward the coil panel 40 which is positioned within the recess 36 of the cushioning material 30 and forms part of the gel-molded spring array 52, the exemplary coil panel 40 is formed of a plurality of coil springs 44 arranged in rows and / or columns in an array or matrix. An upper first fabric layer 46 is positioned to cover the upper end of each coil spring 44, and a lower second fabric layer 47 is positioned below the lower end of each coil spring 44. The first and second fabric layers 46, 47 are joined, for example, welded between the coil springs 44, thereby forming a coil pocket. The ends of the coil springs 44 may be in direct contact with the fabric layers 46, 47, or alternatively, a piece of material such as a cushion or scrim may be placed between the coil springs 44 and the fabric layers 46, 47. Such an intermediate material can prevent the coil springs 44 from protruding through the fabric layers 46, 47 or tearing the fabric layers 46, 47 in other ways. The first and second fabric layers 46, 47 are additionally joined, e.g., welded, along the outer edges 49 of the first and second fabric layers 46, 47 to define the coil panel 40. Furthermore, the two fabric layers 46, 47 may be two separate pieces of fabric, or in other embodiments, a single piece of fabric that covers the spring, is folded, and joined at the open end. The space between the coil springs 44 shown in Figure 3A is an example of the weld between the first and second fabric layers 46, 47 and is not intended to be limiting. For example, in some embodiments, the welded joint of the first and second fabric layers 46, 47 may have a width of about 3 mm to about 5 mm. Similarly, the size of the coil pocket formed by the first and second fabric layers 46, 47 may vary based on the size of the coil spring housed therein.

[0038] The first and second fabric layers 46, 47 may be made of various materials. Non-limiting examples of materials include nonwoven fabrics, warp knits, nylon, rayon, polyester, spacer fabrics, etc. However, this list is not exhaustive. In one embodiment, when a nonwoven fabric is used, it may be desirable that the nonwoven fabric be free from various defects, including but not limited to shavings, scabs, holes, and / or scraps. Additionally, in some such embodiments in which a nonwoven fabric may be used, the weight of the nonwoven fabric is approximately 40 g / m². 2 ~about 80g / m 2 It may be between these. In other embodiments, the first and second fabric layers 46, 47 may be made of different materials. For example, the first fabric layer 46 may be spunlace mesh cloth (e.g., about 70 g / m²). 2 The second fabric layer 47 may be a nonwoven fabric as described above, and may have a weight of .

[0039] As previously mentioned and shown in Figure 2, the gel layer 50 is positioned adjacent to the coil panel 40. Thus, in some embodiments, it is desirable that the fabric of at least the first fabric layer 46 minimizes or completely prevents the gel layer 50 from penetrating, burrowing into, or otherwise coming into contact with the coil spring 44. More specifically, such fabric can minimize or prevent the gel, which could bind the springs and / or degrade their functionality, from penetrating, burrowing into, or otherwise coming into contact with the springs during their rotation. For this reason, the first and second fabric layers 46, 47 are, in some embodiments, hydrophobic fabrics, waterproof fabrics, etc.

[0040] In some embodiments, the materials of the first and second fabric layers may limit air permeability so that air does not easily escape when the coil panel 40 is compressed. Similarly, when the compressive force of the pillow is released, the expansion of the coil panel 40 may occur slowly because the air is drawn slowly through the first and second fabric layers 46, 47. In some embodiments, the materials of the first and second fabric layers may be air-impermeable with air-permeable portions located at specific positions. By controlling the size, number, and / or location of the air-permeable portions, the airflow into and out of the fabric layers 46, 47 and the coil panel 40 can also be controlled.

[0041] For example, referring to Figure 7-8, according to some exemplary embodiments, a coil panel may define a plurality of airflow openings that vary the amount of airflow through the coil and the panel. More specifically, in some embodiments, the first and / or second fabric layers may have openings of varying densities to improve the airflow through each panel. In Figure 7, an exemplary first fabric layer 446, arranged to cover a plurality of coil springs 444, defines a number of openings 448 per square inch. Modifying the size and density of the openings in the first and / or second fabric layers would, of course, regulate the airflow through the coil panel.

[0042] Figure 8 shows another exemplary first fabric layer 546 having an alternative pattern opening. In this shown embodiment, in addition to welding the first fabric layer 546 to a second fabric layer (not shown) between the coil springs 544, the first fabric layer 546 is additionally welded to the second fabric layer in the central portion of the coil springs 544 to form a central weld 547 within each coil spring 544. As shown in Figure 8, an opening 548 is defined within these central welds 547 to allow airflow. In non-limiting embodiments, the diameter of the central welds 547 is about 21 mm to about 25 mm, and the diameter of the openings 548 is about 9 mm to about 10 mm. Although the above description of Figures 7-8 is directed toward the first fabric layer, it should be understood that the second fabric layer may similarly include an opening in one or more of the first and second coil panels of the present invention, either instead of or in addition to the first fabric layer.

[0043] Returning to Figures 3 and 3A, and now focusing on the multiple coil springs 44 of the coil panel 40, the number of coils per square foot of an exemplary coil panel 40 may range from approximately 14 to approximately 250. The coil springs 44 may vary in size and number within the coil panel 40. In some non-limiting embodiments, for example, a coil spring may have a maximum diameter of approximately 3 inches and a maximum height of approximately 3 inches in its compressed height. The spring may have an unloaded height and a loaded height shorter than the unloaded height, which is the fully relaxed height. In a non-limiting embodiment, a coil mini-spring may be used having an unloaded or coil-free height of approximately 20 mm to approximately 26 mm and a loaded or compressed height of approximately 18 mm to approximately 20 mm. Alternatively, in a second non-limiting embodiment, a larger coil may be used having an unloaded or coil-free height of approximately 90 mm to approximately 110 mm and a loaded or compressed height of approximately 27.5 mm to approximately 32.5 mm. Coil springs may, in some embodiments, be constructed of 17.5 wire gauge (e.g., wire with a diameter of approximately 1.25 mm) or 19.5 wire gauge. Coil springs may have a consistent wire size (diameter), or the wire size may vary across the coil spring. In some embodiments, coil springs may be made approximately 3 and 3 / 4 turns (± 1 / 4 turn) to form a coil. When constructed, each end of the wire forming the coil may be within the coil spring structure. Coil springs may have various shapes, for example, barrel, cylindrical, or hourglass shapes. The pitch and diameter may be symmetrical or asymmetrical, allowing the coil spring to have a linear or nonlinear response when compressed. However, other sizes, shapes, and variations may be available. For example, a coil spring may be a coil-in-coil design in which the diameter of one or both coils can vary, for example, a conical design. Furthermore, combinations of coil types may be available.

[0044] The coil spring 44 can be loaded by the engagement and joining of the first and second fabric layers 46, 47. Specifically, the coil spring 44 can be preloaded to about 0.1 lbs-weight to about 0.8 lbs-weight. The spring constant of the coil spring 44 may also vary. That is, the spring constant of the coil spring 44 may be about 0.2 lbs / in to about 3.0 lbs / in. The spring constant may also be the same or within the same range across the surface of the pillow 10, or alternatively, the range may vary or change depending on the location.

[0045] The spring constant of the coil spring 44 may also vary. That is, the spring constant of the coil spring 44 may be approximately 0.2 lbs / in to approximately 3.0 lbs / in. The spring constant may also be the same or within the same range across the coil panel 40, or alternatively, the range may vary or change depending on the location.

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

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

[0048] The exemplary pillow 10 shown in Figure 2 includes only a single coil panel as part of a gel-molded spring array 52, but it should be understood that the gel-molded spring array 52 may have two or more coil panels. Similarly, there may be multiple gel-molded spring arrays arranged across the upper surface of the cushioning material. The number and location of the gel-molded spring arrays and / or coil panels may depend on the size of the body support cushion, or other design characteristics and considerations.

[0049] Returning to Figure 2, as described above, the gel layer 50 is positioned above the coil panel 40. More specifically, the exemplary gel layer 50 extends outward beyond the outermost coil 44 of the coil panel 40, while the first and second fabric layers 46, 47 of the coil panel 40 extend outward beyond the gel layer 50 when the coil panel 40 and the gel layer 50 are adjacent to each other. However, in other embodiments, the gel layer 50 may extend outward beyond the first and second fabric layers 46, 47 when the coil panel 40 and the gel layer 50 are adjacent to each other. Furthermore, although only one gel layer 50 is shown, in other embodiments, a second gel layer may also be positioned on the lower surface of the cushioning material.

[0050] The gel layer 50 contained in the pillow 10 can generally consist of a substantially uniform layer of elastomer gel-like material that can provide a cooling effect by acting as a heat sink or heat dissipation device that can dissipate heat from the user's body or any part thereof located on the pillow 10. For example, in some embodiments, the gel layer 50 can consist of a polyurethane-based gel made by combining Hyperlast® LU1046 polyol, Hyperlast® LP5613 isocyanate, and a thermoplastic polyurethane film or talc powder, respectively manufactured and sold by Dow Chemical Company Corp. (Midland, Mich.), with a thermal conductivity of 0.1776 W / m*K and 0.1184 mm² as established by the International Organization for Standardization (ISO) 22007-2 volumetric specific heat measurement standard. 2Thermal diffusivity of / s, and 1.503 MJ / (m 3 It may be combined to manufacture a gel insert having a volumetric specific heat of K). However, it is also conceivable that a number of other types of gels capable of absorbing a quantity of heat and providing a cooling effect may be used according to this embodiment and manufactured to have a desired thermal conductivity, thermal diffusivity, and volumetric specific heat without departing from the intent and scope of the subject matter described herein.

[0051] In some embodiments, the gel layer 50 may have a substantially smooth outer surface, but the surface shape and feel of the gel may be determined in accordance with the surface of the mold into which the gel is poured. Furthermore, the gel may also vary in density along the surface of the pillow. As will be understood in the following description of exemplary methods for forming the body support cushion of the present invention, the outer edge or periphery of the gel may be regular or irregular in shape. Furthermore, the gel may also vary in thickness and / or density. For example, the thickness of the gel may be greater in the center compared to the region toward the periphery of the gel.

[0052] In the exemplary pillow 10, the outer surface of the gel layer 50 is substantially identical to the upper surface 35 of the cushioning material 30, such that the outer surface of the gel layer 50 and the upper surface 35 of the cushioning material 30 collectively form the upper surface 14 of the body support cushion 10. The outer surface of the gel layer 50 may form a shape that is generally symmetrical to the opposite side of the pillow 10 (i.e., the lower surface 16), even if the materials defining the surface are different. However, as described above, other shapes may be used.

[0053] However, according to some other embodiments, the gel layer may be surrounded by cushioning material in such a way that the materials are not in the same plane. For example, the gel layer may be embedded or recessed within the surrounding cushioning material, or the gel layer may extend outward in part or in whole beyond the upper surface of the cushioning material. For example, the outer surface of the gel may define one or more features, such as ribs or bumps, that extend beyond the upper surface of another generally planar pillow. Similarly, instead of simply placing additional gel in recesses adjacent to the coil panel, additional gel may be placed in divots of foam.

[0054] Furthermore, regarding the density and hardness of the pillow 10, as shown above, the density of the gel layer 50 is generally different from that of the cushioning material 30. In the exemplary pillow 10 shown in Figure 2, the density of the cushioning material 30, for example, viscoelastic foam, is sufficient to support the user's neck and shoulders, while the gel layer 50 has a higher density sufficient to support the user's head. More specifically, the exemplary cushioning material has a density of approximately 40 kg / m³. 3 ~about 80kg / m 3 It is composed of a viscoelastic foam having a density of approximately 25N to approximately 50N, while the exemplary gel layer 50 has a density of approximately 800 kg / m³ 3 ~Approx. 1200kg / m 3 It is made of very soft polyurethane with a density of approximately 25-50 Shore OOO hardness. Of course, the specific density and other support properties of both the cushioning material and the gel may vary depending on the design characteristics of the support cushion.

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

[0056] Referring still to Figure 2, the cover 60 is also positioned around the cushioning material 30 and the gel-molded spring array 52. ​​In the exemplary pillow 10, the cover 60 is made of cloth, but in other embodiments, a variety of materials may be used, including but not limited to breathable cloths such as cotton, cotton blends, 100% polyester cloth, rayon, nylon, or spandex blends for enhanced performance and elasticity, or any blend of the foregoing. This list is not exhaustive, and other materials may be used. The cloth of the cover 20 may be quilted and / or may include a variety of designs, including but not limited to "hard" side or "soft" side labels. The cover 60 also defines the outer perimeter of the pillow 10, and therefore the shapes of the various layers located within the cover 20, together with the outer edge of the cover 20, define the shape of the pillow 10. The cover 60 may also, in some embodiments, include phase-change materials to enhance the cooling sensation to the user. Where desired, a pillow case, generally formed of a thin cloth, may be positioned over the cover 20. The exemplary cover 20 is closed around its outer edge 18 and includes a closure 62 for accessing the interior of the pillow 10 or, alternatively, for removing the contents inside for cleaning the cover 60 when desired. The closure 62 may extend along one or more sides of the pillow 10 to facilitate the arrangement of layers therein. The closure 62 may be of various types, including but not limited to zippers, buttons, snaps, hook-and-loop fasteners, etc.

[0057] Referring next to Figure 4, a second exemplary body support cushion 110 made according to the present invention similarly includes a gel-molded spring array 152 on the upper surface 135 of the cushioning material 130a, 130b, but also includes a second gel-molded spring array 152 on the lower surface 134 of the cushioning material 130a, 130b.

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

[0059] Each gel layer 150 contained within the pillow 110 is composed of a substantially uniform layer of elastomer gel material that can provide a cooling effect by acting as a heat sink or heat dissipation device that dissipates heat from the user's body or a part thereof located on the pillow 110.

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

[0061] Referring next to Figure 5, an exemplary method for manufacturing a hybrid pillow made according to the present invention begins with a mold, which in some embodiments has an outer periphery shape generally similar to the body support cushion 10 shown in Figure 2, although the shape and size may vary. For example, the mold may be a rectangle having a curved upper half and a lower half that define the crown shape of the exemplary pillows 10, 110 shown in Figures 1 and 4. However, any shape and design of the support cushion described above can be formed with a single mold or tool. The mold may be formed with a first half and a second half, as described below.

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

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

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

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

[0066] According to embodiments in which the gel is initially provided as a liquid, the concentration of the resulting gel layer may vary across the resulting support cushion. As the gel liquid is poured into the mold and settles toward the bottom of the mold, the liquid gel, in some embodiments, has a greater depth in the center and a greater depth near the outer edge. Thus, an exemplary pillow made of liquid gel may have less of the final gel layer toward the edges of the pillow and more of the final gel layer within the crown region of the pillow. Similarly, as the liquid gel settles, the resulting gel layer may have an irregular shape in some embodiments.

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

[0068] Each of the exemplary pillows described above may additionally contain additives such as copper to improve moisture content and inhibit mold growth. Other additives, such as carbon or charcoal for filtration, may be provided to improve flame retardancy or to improve the foam's odor. Other additives, such as graphite, aluminum, silver, charcoal, and gel, may also be included for various benefits known in the art. Further additions to the exemplary pillows may provide far-infrared radiation for rejuvenation properties. Moreover, one or more layers of the pillow may be coated with nanobiomaterials or phase change materials (PCMs) to enhance the cooling sensation for the user. These phase change materials (PCMs) may be coatings including, but not limited to, commercially available organic materials, inorganic materials, solid materials, and biomaterials. Additionally, one or more layers may further contain biocides, preservatives, odor blockers, fragrances, pigments, dyes, stain repellents, antistatic agents, antifouling agents, waterproofing agents, moisture permeable agents, etc., as known in the art.

[0069] Those skilled in the art will recognize that additional embodiments are possible without departing from the teachings of the present invention or the following claims. This detailed description, in particular the specific details of the exemplary embodiments disclosed herein, is given primarily for clarity of understanding and should not be understood as an unnecessary limitation, and modifications may be made without departing from the intent or scope of the claimed invention, and will be obvious to those skilled in the art in reading this disclosure.

Claims

1. A cushioning material that defines the recessed area, A coil panel is disposed within the recess of the cushioning material, wherein the coil panel is formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, and the upper fabric layer and the lower fabric layer are joined between the plurality of coil springs and along the outer edge of the coil panel. A gel layer is disposed within the recess of the cushioning material, covering the coil panel. Equipped with, The gel layer is formed on one side of the coil panel to form a gel-molded spring array. The cushioning material includes a molded foam placed in the gel-molded spring array opposite to the gel layer, A hybrid pillow in which the molded foam and the gel layer are fixed to each other around the outer circumference of the coil panel.

2. The molded foam of the cushioning material surrounds the gel-molded spring array at least partially. The hybrid pillow according to claim 1.

3. The gel layer extends from the recess of the cushioning material. The hybrid pillow according to claim 1.

4. The coil panel is completely encased between the gel layer and the molded foam of the cushioning material. The hybrid pillow according to claim 1.

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

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

7. The upper fabric layer and the lower fabric layer are formed of a nonwoven fabric material or a hydrophobic material. The hybrid pillow according to claim 1.

8. The aforementioned hybrid pillow A second coil panel is disposed in the second recess of the cushioning material opposite to the coil panel, wherein the second coil panel is formed of a plurality of second coil springs, a second upper fabric layer, and a second lower fabric layer, and the second upper fabric layer and the second lower fabric layer are joined between the plurality of second coil springs and along the outer edge of the second coil panel. A second gel layer is disposed within the second recess of the cushioning material, covering the second coil panel. The hybrid pillow according to claim 1, further comprising the features described above.

9. A method for manufacturing a hybrid pillow, wherein the method is Dispensing liquid gel into a mold, In the above type, a coil panel is placed on top of the liquid gel, where the coil panel is formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, and the upper fabric layer and the lower fabric layer are joined between the plurality of coil springs and along the outer edge of the coil panel. Dispense the foam precursor into the mold, The foam precursor is foamed to form a cushioning material that is fixed to the coil panel. It has the following steps: A method for solidifying the liquid gel so that a gel layer is placed on the coil panel.

10. The cushioning material and the gel layer are fixed to each other around the outer circumference of the coil panel. The method according to claim 9.

11. The coil panel is completely encased between the gel layer and the cushioning material. The method according to claim 9.

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

13. The liquid gel solidifies before the step of foaming the foam precursor so that a gel-forming spring array is formed before the foam precursor is dispensed into the mold. The method according to claim 9.

14. It is a molded hybrid pillow, A cushioning material that defines the recessed area, A coil panel is disposed within the recess of the cushioning material, wherein the coil panel is formed of a plurality of coil springs, an upper fabric layer, and a lower fabric layer, and the upper fabric layer and the lower fabric layer are joined between the plurality of coil springs and along the outer edge of the coil panel. A gel layer is disposed within the recess of the cushioning material, covering the coil panel. It is equipped with, The gel layer is formed on one side of the coil panel to form a gel-molded spring array. The cushioning material includes a molded foam placed in the gel-molded spring array opposite to the gel layer, The molded foam and the gel layer are fixed to each other around the outer circumference of the coil panel. A molded hybrid pillow in which at least one of the upper fabric layer and the lower fabric layer prevents contact between the gel layer and the rotation of the plurality of coil springs.

15. Each of the aforementioned springs has an enclosed height of less than 3 inches and a diameter of less than 2 inches. The molded hybrid pillow according to claim 14.

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

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

18. The upper fabric layer and the lower fabric layer are formed of a nonwoven fabric material or a hydrophobic material. The molded hybrid pillow according to claim 14.

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