Pillow with Chemically Treated Nonwoven Layer

Abstract

A pillow is designed to provide various benefits and protections through the use of a nonwoven layer delivery vehicle that is insertable into one or more sleeves positioned outside the core of the pillow and within outer shell of the pillow. The benefits may be refreshable in some applications by having the nonwoven layer being accessible by the user threw a zippered opening such that the user may periodically retrieve a used nonwoven layer and reinsert a new nonwoven layer which is treated with same or a different chemical formulation.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to USSN 63 / 763,607 filed on Feb. 26, 2025, and the complete contents thereof is herein incorporated by reference.BACKGROUND

[0002] Pillows are typically used by humans for comfort or aesthetic design. Pillows come in many varieties including bed pillows, throw pillows, decorative pillows, cushions and other varieties. Pillows that aid with sleeping are a form of bed pillow that support the head and neck, whereas other pillow types are designed to support the body while sitting. Pillows are made with many different materials and come in many different shapes; however, pillows are not typically used to deliver a therapeutic benefit beyond comfort and support.SUMMARY

[0003] People spend on average 6-8 hours asleep while in bed. This sleeping time provides an opportunity to deliver therapies that enhance comfort via hygiene, temperature regulation, quality and quantity of sleep, among other advantages, utilizing the intimate interface that exists between one's head, neck and face, and with the pillow encasement. There is a need for a pillow that delivers added therapeutic benefits and / or functionality without sacrificing the pillows primary functions of comfort and support is needed.

[0004] An embodiment of the invention is a pillow design that features a pillow encasement which includes at least one low density chemically treated, resilient nonwoven layer designed to enhance comfort and support, while delivering added benefits and / or functionality such as hygiene, temperature regulation, aromatherapy, and other technologies that improve or enhance sleep quality. The pillow's design allows for insertion of chemically treated nonwoven layers after the pillow encasement production process or alternatively may be integrated into the production process. The proximity of the treated nonwoven surfaces relative to the user best ensures efficacy of the chemical treatment and provides greater opportunity for tailored technology solutions.

[0005] Another embodiment of the invention is to use the pillow to provide a therapy to the subject during their sleeping hours. The chemically treated nonwoven layer can be periodically changed, e.g., daily, weekly, monthly, or on ad hoc basis to provide a refreshed functionality to the pillow. For example, a chemically treated nonwoven layer may include anti-oderant agents and or scents or aromas that provide aroma therapy, and the subject can use his or her pillow to provide a refreshed treatment when the chemical in the previous layer is dissipated or otherwise loses its desired strength. Furthermore, the pillow can provide different treatments during different periods by, for example, the subject using a nonwoven layer as an aroma therapy one week, and then using another nonwoven layer treated with an anti-oderant in following week.DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is an exemplary isometric view of a fibrous nonwoven material.

[0007] FIG. 2 is an exemplary side view of a vertically lapped fibrous nonwoven material.

[0008] FIG. 3 is a sketch showing a sleeve on the inner side of the pillow outer cover.

[0009] FIGS. 4a, 4b, and 4c show different examples of pillow inserts where FIG. 4a shows a fiber fill insert, FIG. 4b shows a latex foam insert, and FIG. 4c shows a memory foam insert.

[0010] FIG. 5 shows side views of different pillow configurations.DESCRIPTION

[0011] In the practice of the invention, one or a plurality of layers of low density, chemically treated, resilient nonwoven are incorporated into the outer shell of a pillow's encasement. FIG. 1 shows an example of a layer 10 of nonwoven. FIG. 2 shows that the nonwoven may be vertically lapped. However, other nonwovens such as cross lapped, or air laid nonwovens may also be used in the practice of the invention.

[0012] FIG. 1 shows an example of a nonwoven 10 material. In particular, embodiments of this invention pertain to the use of what are often termed thermobonded nonwoven materials, where a fibrous mass (i.e., one that is not “knitted” or “woven”) has adjacent fibers joined together at varying locations by binder material. The nonwoven 10 has height, width, and length dimensions (i.e., it is three-dimensional in character).

[0013] A “nonwoven” is a manufactured sheet, web, or batt of natural and / or man-made fibers or filaments that are bonded to each other by any of several means. Manufacturing of nonwoven products is well described in “Nonwoven Textile Fabrics” in Kirk-Othmer Encyclopedia of Chemical Technology, 3rd Ed., Vol. 16, July 1984, John Wiley & Sons, p. 72-124 and in “Nonwoven Textiles”, November 1988, Carolina Academic Press. Nonwovens are commercially available from a number of manufacturers.

[0014] FIG. 2 shows an example of a vertically lapped nonwoven 12 material. Vertical lapping may be performed using methods known in the art, e.g., as set forth in US 2008 / 0155787 and U.S. 7,591,049, each of which is incorporated herein by reference. Vertically lapped nonwovens are commercially available from a number of sources. Because of the configuration of the lapping, such as is shown in FIG. 2, the nonwoven 12 has more stiffness and resilience in the vertical direction.

[0015] Fibers which may be used in nonwovens according to the claimed invention are wide ranging and include any fibrous network which, when heated in an unmolded environment, will expand at least 5% in any direction (i.e., expansion in at least one of the vertical, horizontal, or lateral directions, and possibly all of these directions). The nonwoven can be obtained from a number of commercial sources, and may be in a vertically lapped configuration or random configuration. Vertically lapped (V-Lap) configurations may provide some advantages in terms of support or comfort when boards / blanks made of V-Lap are expanded in a mold and they are oriented in a direction which opposes, for example, the weight of a person's back or buttocks. In the practice of this invention, V-lap nonwoven is preferably used, and is preferably compressed to form boards, as will be described below. The V-lap nonwoven will be generally compressed 50%, 60%, 70%, 80%, 90%, etc. from its original height dimension, and, on subsequent heating will be able to expand towards, up to, or beyond its original height dimension.

[0016] Nonwovens in the practice of this invention are typically fabricated from a mass of fibers which include binder fibers and one or more other fibers. The binder fibers have a melting temperature that is below the melting or decomposition temperature of the one or more other fibers, e.g., binder fibers typically have a melting temperature of 80-150° C. (polyesters are typical examples of binder fibers used in the production of nonwovens (examples of elastic polyester binder fibers include ELK®, E-PLEX®, and EMF type high elastic LMF are commercially available from Teijin Limited, Toray Chemical Korea Inc., and Huvis Corporation, respectively)). Once the binder fibers are melted, they will generally tack along the outsides of the one or more other fibers, and, on cooling, will harden to produce the nonwoven which is essentially a mass of the one or more other fibers with adjacent fibers held together at various locations throughout the nonwoven by binder material which results from melting and re-hardening of the binder fibers. These nonwovens are often referred to as thermobonded nonwovens. The thermobonded nonwovens in the practice of this invention will have at least 5% by weight binder material, with up to 95% by weight of the one or more other fibers. Depending on the needs of the article manufacturer the binder material may constitute 5-50% by weight of the nonwoven with the remainder being the one or more other fibers, or the one more other fibers plus additional materials. For example, the other materials can include but are not limited to fire retardant compounds scented compounds, antimicrobial compounds or materials (e.g., silver particles or fibers), polymeric coatings, metal or ceramic particles; etc. Examples of FR chemicals / compounds include, but are not limited to, phosphoric acid and its derivatives, phosphonic acid and its derivatives, sulfuric acid and its derivatives, sulfamic acid and its derivatives, boric acid, ammonium phosphates, ammonium polyphosphates, ammonium sulfate, ammonium sulfamate, ammonium chloride, ammonium bromide.),

[0017] The ratio of binder material to the one or more other fibers in the nonwovens used in the practice of the invention can vary widely from 5% by weight binder material: up to 95% by weight one or more other fibers; 10% by weight binder material: up to 90% by weight one or more other fibers; 15% by weight binder material: up to 85% by weight one or more other fibers; 20% by weight binder material: up to 80% by weight one or more other fibers; 25% by weight binder material: up to 75% by weight one or more other fibers; 30% by weight binder material: up to 70% by weight one or more other fibers; 35% by weight binder material: up to 65% by weight one or more other fibers; 40% by weight binder material: up to 60% by weight one or more other fibers; 45% by weight binder material: up to 55% by weight one or more other fibers; 50% by weight binder material: up to 50% by weight one or more other fibers; 55% by weight binder material: up to 45% by weight one or more other fibers; 60% by weight binder material: up to 40% by weight one or more other fibers; 65% by weight binder material: up to 35% by weight one or more other fibers; 70% by weight binder material: up to 30% by weight one or more other fibers; 75% by weight binder material: up to 25% by weight one or more other fibers; etc. Depending on the application, the ratio may range from 5:95 to 95:5.

[0018] Examples of thermobonded nonwovens which may be used in the practice of this invention include but are not limited to:

[0019] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, polyester fiber (Exemplary types of polyesters which may be used in the practice of the invention include, but are not limited to PET (polyethylene terephthalate), PTT (polytrimethylene terephthalate), and PBT (polybuthylene terephthalate);

[0020] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, polyacrylonitrile fiber;

[0021] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, polyvinyl alcohol fiber (PVA);

[0022] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, polytetrafluoroethylene fiber (PTFE), like TEFLON for example;

[0023] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, polyamide fiber, like nylon or perlon for example;

[0024] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, wool fiber;

[0025] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, coconut fiber;

[0026] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, hemp fiber;

[0027] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, flax fiber;

[0028] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, jute fiber;

[0029] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, cotton fiber;

[0030] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, viscose fiber, like rayon for example;

[0031] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, polyethylene fiber;

[0032] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, polypropylene fiber;

[0033] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, Kevlar fiber;

[0034] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, Basofil fiber;

[0035] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, Belcotex fiber;

[0036] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, Nomex fiber;

[0037] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, O-PAN fiber;

[0038] any thermobonded nonwoven made with up to 95% of any denier, any fiber length, Tencel fiber; and

[0039] any thermobonded nonwoven made with up to 95% of a mixture of any of the fibers set forth above or any mixture of fibers with other fibers of interest (e.g. silver fibers for providing antimicrobial resistance, basalt fibers, natural fibers (e.g., cotton, ramie, coir, hemp, abaca, sisal, kapok, jute, flax, linen, kenaf, coconut fiber, pineapple fiber, wool, cashmere, and silk), man-made fibers (e.g., polyester, nylon, acrylics, acetate, polyolefins, melamine fibers, elastomeric fibers, polybenzimidazole, aramid fibers, polyimide fibers, modacrylics, polyphenylene sulfide fibers, oxidized PAN fiber, carbon fibers, novoloid fibers, manufactured cellulosic fibers (e.g., rayon, lyocell, bamboo fiber, Tencel, and Modal), and manufactured fire-retardant (FR) cellulosic fibers (e.g., Visil.®, Anti-Fcell, Daiwabo's Corona. fibers, Anti-Frayon, Sniace's FR rayon, and Lenzing FR)).

[0040] It is also noted that hollow core fibers, e.g., hollow core polyethylene terephthalate (PET) may be used in nonwovens for use in the practice of the invention. In addition, nonwovens useful in the practice of the invention can be formed using composite fibers, sometimes referred to as sheath-core fibers. Binder fibers used to produce nonwovens useful in the practice of this invention include sheath-core fibers, where the sheath is polyester or some other low melting temperature material.

[0041] The invention will employ one or more nonwoven layers such as shown in FIG. 1, as essentially a delivery vehicle to provide a consumer with benefits and / or functionality such as hygiene, temperature regulation, aromatherapy, and other technologies that improve or enhance sleep quality. It will do this by positioning at least one low density chemically treated, resilient nonwoven layer designed to enhance comfort and support for the pillow user into the outer shell of the pillow's encasement. The layer(s) inserted inside the outer shell of the pillow's encasement may be 0.25 to 1.5 inches thick, and most preferably 0.5 to 1 inch thick. They can have any length and width dimension to match and / or approximate the person contacting surfaces of the pillow. For example, in a standard bedding pillow the length may be 2 to 3.5 feet, and the width may be 1 to 2 feet. Whereas for an ornamental pillow used on a sofa for example, the width and length might be closed to a 1 foot by 1 foot square.

[0042] The chemical(s) providing the benefit and / or functionality can be impregnated in the nonwoven layer by, for example, dipping the nonwoven layer in a liquid containing the chemicals of interest, spraying or misting a chemical formulation with the chemical of interest onto the nonwoven layer, 3D printing a chemical formulation of interest onto selected areas of the nonwoven layer, etc. In a particularly preferred method of chemical application to the nonwoven layer(s) used in the pillow's encasement, a physical method (e.g., application of pressure by a squeegees, etc.) is used to drive the chemical formulation into the nonwoven layer(s), as is taught in U.S. Pat. No. 11,718,952, Method of Chemical Treatment on Nonwovens, that issued on Aug. 8, 2023 to Tintoria Piana, US Inc., which is hereby incorporated by reference.

[0043] In a particular embodiment, the nonwoven layer is used to deliver “aromatherapy” to the user of the pillow. In this embodiment, the nonwoven layer is treated with a scented chemical formulation. For example, the chemical formulation can be an essential oil of grapefruit to provide a sweet citrus aroma, an essential oil of ginger to give a spicy warm aroma, an essential oil of geranium to give a more subtly sweet floral aroma, an essential of frankinscense to give a camphor and citrus aroma, an essential oil of eucalyptus radiata to give a camphorous and slightly minty aroma, a cyprus essential oil to sweet balsamic and pine / juniper aroma, a clove oil to provide a warm and pungent aroma, a clary sage essential oil to provide a herbaceous lavender like aroma, a citronella essential oil to provide pungent citrus aroma, a cinnamon cassia or cinnamon bark essential oil to provide a warm and spicy aroma, a cedarwood essential oil to provide a warm woodsy aroma, a camphor oil to provide a medicinal aroma, and an essential oil of chamomile for a sweet smell, etc. Different aromas are believed by many to provide benefits for anxiety, depression, muscle soreness, etc.

[0044] Generally speaking, the chemical formulations may include water / oil repellents, antimicrobials, flame retardants, microencapsulated scents, microencapsulated cosmetics, microencapsulated essential oils, microencapsulated PCM (Phase Change Material), probiotics, odor control agents, photocatalytic agents, UV absorbers, anti-allergens, hydrophilic agents, hand modifying agents, antistatic agents, insect repellants, and ceramics that emit far infrared and / or negative ions. That is, beside aroma therapy, the formulations can help for provide cooling (e.g., PCMs), hygiene (odor absorption and probiotics), safety (fire retardant and antistatic agents), as well as many other benefits, for persons using the pillows.

[0045] FIG. 3 shows that the treated nonwoven layer is preferably slid into an inner sleeve of the pillow outer shell on either or preferably both sleeping surfaces. The sleeve may be a mesh material or light weight fabric. The pillow outer shell is preferably a fabric, and, in the case of aroma therapy, one in which scents readily pass through, and, in the case of cooling, a fabric which readily permits heat to be transmitted from the persons head to the PCM on the nonwoven layer, and, in the case protection (such as by inset repellants, anti allergens, antimicrobials) a fabric which readily allows these agents to pass from the nonwoven layer(s) through the pillow outer shell. Generally, cotton, cotton blends, hemp, or synthetics such as rayon and lycra might be used in the pillow outer shell.

[0046] The nonwoven layer may be sewn in-place (i.e., fully contained), or added as an insert in FIG. 3. There are numerous advantages to use of the inner sleeve and inserting the nonwoven layer including without limitation:

[0047] 1. Provides the ability to utilize one outer sleeve design for many different chemically treated nonwoven inserts.

[0048] 2. Enables late-stage customization which leads to lower manufacturing cost and SKU reduction.

[0049] 3. Allows for domestic production of the treated nonwoven and low-cost country manufacture of the outer sleeve.

[0050] The pillow may be filled with a variety of different filling materials to satisfy differences in comfort preference, support characteristics, environmental impacts and price. A list of possible pillow filling materials includes at least the following: polyester fiber, wool fiber, cotton fiber, Kapok fiber, buckwheat, feather, down, down alternative, microbead, polyurethane foam, memory foam, latex foam, shredded foam, gel, gel beads, gel coatings and others.

[0051] More than one filling material may be used in the practice of the invention to achieve a desired level of comfort and support, and the pillow filling materials may be encased or loose. For example, FIG. 4a shows a fiber fill, FIG. 4b shows a latex foam, and FIG. 4c shows a memory foam.

[0052] As discussed above, pillow encasements usable in the practice of the invention may be made from a variety of fabrics including at least the following: cotton, polyester, silk, satin, nylon, linen, bamboo, rayon, microfiber, fleece, blends of the aforementioned and others.

[0053] Bed pillows come in a variety of sizes and vary with geographic location. Pillows come in a variety of styles including, as shown in FIG. 5, gusset style, knife edge style and contour cut ergonomic style pillows designed to support and maintain spinal alignment of the head and neck.

[0054] Other advantages and configurations will be readily recognized from the above description and the claims below.

Claims

1. A pillow, comprisinga core;an outer shell which encases the core, wherein the outer shell has an interior surface and an exterior surface;at least one sleeve affixed to the interior surface of the outer shell; andat least one chemically treated nonwoven layer inserted or insertable within the at least one sleeve, wherein when the at least one chemically treated nonwoven layer is inserted within the at least one sleeve the at least one chemically treated nonwoven layer is positioned between the core and the outer shell.

2. The pillow of claim 1 further comprising an access opening for accessing the at least one sleeve.

3. The pillow of claim 2 wherein the access opening comprises a zipper and the access is opening is opened and closed by the zipper.

4. The pillow of claim 1 wherein the at least one chemically treated nonwoven layer is treated with a chemical which provides a functionality which extends from the nonwoven layer through the outer shell selected from the group consisting of delivering an aroma or scent, delivering an odor control agent, delivering a water or oil repellant, and delivering an antimicrobial agent or insect repellant.

5. The pillow of claim 1 wherein the at least one chemically treated nonwoven layer is treated with a chemical which provides a physical functionality which extends from the nonwoven layer through the outer shell selected from the group consisting of ultraviolet (UV) absorption, antistatic activity, cooling activity, emission of infrared and / or negative ions.

6. The pillow of claim 1 wherein the pillow has a top side and a bottom side, wherein the at least one sleeve comprises both a first sleeve affixed to the inner surface of the outer shell at the top side of the pillow, and a second sleeve affixed to the inner surface of the outer shell at the bottom side of the pillow.

7. The pillow of claim 1 wherein the at least on chemically treated nonwoven layer is treated with phase change materials (PCMs).

8. The pillow of claim 1 wherein the at least one chemically treated nonwoven material is treated with a chemical that provides an aroma or scent.

9. The pillow of claim 1 wherein the at least one chemically treated nonwoven material is treated with a chemical that provides an antimicrobial functionality.

10. A method of using a pillow to provide a therapy or protectant to a subject, comprising providing a pillow, comprisinga core;an outer shell which encases the core, wherein the outer shell has an interior surface and an exterior surface; andat least one sleeve affixed to the interior surface of the outer shell; inserting at least one chemically treated nonwoven layer within the at least one sleeve, wherein when the at least one chemically treated nonwoven layer is inserted within the at least one sleeve the at least one chemically treated nonwoven layer is positioned between the core and the outer shell, wherein the at least one chemically treated nonwoven layer is treated with a chemical which provides a functionality which extends from the nonwoven layer through the outer shell selected from the group consisting of delivering an aroma or scent, providing a cooling function, delivering an odor control agent, delivering a water or oil repellant, and delivering an antimicrobial agent or insect repellant.

11. The method of claim 10 wherein the chemical delivers an aroma or scent through the outer shell.

12. The method of claim 10 wherein the chemical delivers an odor control agent through the outer shell.

13. The method of claim 10 wherein the chemical delivers an antimicrobial agent or insect repellant through the outer shell.

14. The method of claim 7 further comprising retrieving the at least chemically treated nonwoven layer from the at least one sleeve, and then inserting another at least one chemically treated nonwoven layer into the at least one sleeve.

15. The method of claim 14 wherein the retrieving the at least chemically treated nonwoven layer from the at least one sleeve, and then inserting another at least one chemically treated nonwoven layer into the at least one sleeve is performed by accessing the at least one sleeve using a zipper affixed to the at least one sleeve.

16. The method of claim 14 wherein the retrieving the at least chemically treated nonwoven layer from the at least one sleeve, and then inserting another at least one chemically treated nonwoven layer into the at least one sleeve are performed multiple times on a repeating basis over time.

17. The method of claim 14 wherein the at least one chemically treated nonwoven layer that is retrieved includes a same chemical as the chemical on the another at least one chemically treated nonwoven layer that is inserted into the at least one sleeve.

18. The method of claim 14 wherein the at least one chemically treated nonwoven layer that is retrieved includes a different chemical from the chemical on the another at least one chemically treated nonwoven layer that is inserted into the at least one sleeve.

Images