Adjustable shape-retaining cushion assembly

Abstract

An adjustable flexible and / or shape-retaining cushion assembly includes an internal structure that may be formed into a desired shape (e.g., into a desired curvature to provide optimized comfort) and that may retain the shape until it is intentionally changed. The internal structure may be surrounded by padding and enclosed in a soft outer encasement to provide the overall cushion. The disclosed cushion assembly provides a unique flexible and shapeable construction while providing a look and feel that resembles a conventional pillow enabling the pillow to fit standard sized pillow cases and accessories that may match the desired decor of any room.

Description

ADJUSTABLE SHAPE-RETAINING CUSHION ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 667,782 filed July 4, 2024, the entire contents of which are hereby fully incorporated herein by reference for all purposes.FIELD OF THE INVENTION

[0002] The present invention relates to support cushions such as pillows, including an adjustable shape-retaining cushion assembly.BACKGROUND OF THE INVENTION

[0003] Traditional pillows do not typically include an inner shaped or molded structure and instead depend on the filler material within the pillow as a means of adjusting the pillow into a supportive shape. However, because the filler material may not be structurally supported within the pillow, the filler material has a tendency to become displaced and / or deformed to the point that it may be ineffective for this purpose. One remedy to this is to use additional pillows to bolster oneself in an attempt to properly support the appendage or area of the body requiring support. Unfortunately, however, because such additional pillows also suffer from the same problem, and because the additional pillows may shift with respect to one another, this remedy is mostly ineffective.

[0004] Currently there are many specialized pillows on the market which are specifically shaped in an effort to support the user’s preferred optimal sleeping position. Forexample, some of the pillows may be designed to address discomforts such as back or neck pain and are thereby formed in a particular shape to hold and support the head in an intentional single position. However, such pillows are permanently shaped and are thereby not reconfigurable.

[0005] In addition, some patents, such as US10806282B2, describe pillows suitable for use in a variety of positions but only if the individual only uses particular portions of the pillow. Other patents, such as US10085575B2, describe pillows that can be used for different positions but require being disassembled and then re-assembled to provide different structural shapes depending on the needs of the user. This type of product makes it particularly difficult if a user is in a relaxed state and wishes to change positions, thereby requiring that the user become fully alert to disassemble and re-assemble the pillow to prepare it for the new position.

[0006] Another example includes a tube-hke travel pillow containing a single flexible element within its core surrounded by outer cushioning. In use, the tube structure may be formed into a horseshoe shape and placed around the users’ neck area to support the user’s head while sitting upright (e.g., on an airplane). However, having a tube shape with only a single flexible rod element does not enable planar twisting of the pillow into suitable shapes for sleeping. Indeed, such planar twisting of a pillow and the subsequent retention of the resulting twisted shape requires the shape-retaining inner frame within the pillow of the invention described herein. Furthermore, such a tube-shaped pillow is not designed for every night use given that it fails to fully support the user’s head and shoulders as required for all night sleeping.

[0007] None of the disclosed art addresses the need for a pillow assembly that can be shaped and reshaped by the user without disassembly and reassembly and that is able to retainits user-adjusted shape reliably even when bent or formed in a corner-to-corner or twisting form.

[0008] Furthermore, research has shown that a significant percentage of the population does not sleep in just one position throughout the night, let alone an optimal position. As such, given the currently available pillows, a user would need to purchase a wide variety of different pillows, each to accommodate a particular sleeping position. This would not only be costly but highly inconvenient.

[0009] Accordingly, there is a need for an adjustable shape-retaining cushion assembly.SUMMARY OF THE INVENTION

[0010] According to one aspect, one or more embodiments are provided below for cushion assembly including an outer shell including a shell left edge and a shell right edge and a shell inner volume; an adjustable flexible frame within the shell inner volume and including a frame left edge and a frame right edge and a frame first channel extending from the frame left edge to the frame right edge and a first flexible member within the frame first channel and extending from the frame left edge to the frame right edge, the adjustable flexible frame extending from the shell left edge to the shell right edge; and an amount of filler material within the shell inner volume.

[0011] In another embodiment, the first flexible member comprises a material that is manually formable with sufficient memory to retain a first shape when manually formed into the first shape.

[0012] In another embodiment, the cushion assembly further comprises a frame second channel extending from the frame left edge to the frame right edge; and a second flexiblemember within the frame second channel and extending from the frame left edge to the frame right edge.

[0013] In another embodiment, the first flexible member and the second flexible member form elements of a grid-shaped flexible member.

[0014] In another embodiment, the frame second channel is parallel to the frame first channel.

[0015] In another embodiment, the adjustable flexible frame includes a first section of material including a first line of stitching and a second line of stitching forming a first gap therebetween, and the frame first pocket comprises the first gap.

[0016] In another embodiment, the adjustable flexible frame includes a second section of material in an opposing arrangement with the first section of material and wherein the first line of stitching and the second line of stitching connect the first section of material to the second section of material.

[0017] In another embodiment, the first gap is formed between first section of material and the second section of material.

[0018] In another embodiment, the first section of material includes a flexible material including fabric or film.

[0019] In another embodiment, a width of the first gap matches a width of the first flexible member.

[0020] In another embodiment, the amount of filler material includes a first amount of filler material above the adjustable flexible frame and / or a second amount of filler material below the adjustable flexible frame.

[0021] In another embodiment, the first amount of filler material is contained in a first filler pouch and / or the second amount of filler material is contained in a second filler pouch.

[0022] In another embodiment, the frame left edge is attached to the shell left edge and / or the frame right edge is attached to the shell right edge.

[0023] In another embodiment, the first flexible member includes a rod.

[0024] In another embodiment, the rod extends linearly from the frame left edge to the frame right edge.

[0025] In another embodiment, the rod extends non-linearly from the frame left edge to the frame right edge.

[0026] In another embodiment, the outer shell includes an opening and the first flexible member and / or the amount of filler material are removeable from the shell inner volume through the opening.

[0027] In another embodiment, the opening is sealable.

[0028] The disclosed features can be combined as to utilized to create a multitude of various embodiments of which only some of the possible variations have been disclosed. Other aspects, features, and advantages of the invention will become apparent from the disclosed detailed descriptions along with the accompanying drawings. The embodiments described and illustrated herein are exemplary and are not meant to limit the scope of the invention in any way.BRIEF DESCRIPTION OF DRAWINGS

[0030] Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:

[0031] FIG. 1 shows a sectional side view of a flexible and / or shape-retaining cushion assembly according to exemplary embodiments hereof;

[0032] FIG. 2 shows an exploded view of a flexible and / or shape-retaining cushion assembly according to exemplary embodiments hereof;

[0033] FIG.3A shows a sectional top view of a flexible and / or shape-retaining cushion assembly according to exemplary embodiments hereof;

[0034] FIG.3B shows a sectional side view of a flexible and / or shape-retaining cushion assembly according to exemplary embodiments hereof;

[0035] FIG. 4 shows flexible and / or shape-retaining members being inserted into of a flexible and / or shape-retaining cushion assembly according to exemplary embodiments hereof;

[0036] FIG. 5 shows flexible and / or shape-retaining members being inserted into of a flexible and / or shape-retaining cushion assembly according to exemplary embodiments hereof;

[0037] FIG. 6 shows flexible and / or shape-retaining members being inserted into of a flexible and / or shape-retaining cushion assembly according to exemplary embodiments hereof;

[0038] FIG. 7 shows top views of filler material assembly according to exemplary embodiments hereof;

[0039] FIG. 8 shows example pillows implemented with a flexible and / or shaperetaining cushion assembly according to exemplary embodiments hereof; and

[0040] FIG. 9 shows additional types of cushions that may be implemented with a flexible and / or shape-retaining cushion assembly according to exemplary embodiments hereof;DETAILED DESCRIPTION OF THE INVENTION

[0041] In general, an adjustable flexible shape-retaining cushion assembly is disclosed herein. The flexible shape-retaining cushion assembly may include an internal structure that may be formed into a desired shape (e.g., into a desired curvature to provide optimized comfort) and that may retain the shape until intentionally changed. The internal structure may be surrounded by padding and enclosed in a soft outer encasement to provide the overall cushion.

[0042] For the purpose of this specification, the adjustable flexible shape-retaining cushion assembly will be described primarily as a generally rectangular pillow for use with every night sleeping. However, it is understood that this is for demonstration and that the adjustable flexible shape-retaining cushion assembly may be implemented as any type(s) and / or shape(s) of cushions for any applications. For example, the adjustable shape-retaining cushion assembly may be implemented as a circular or oval-shaped pillow, and / or as any other shape. In addition, the adjustable shape-retaining cushion assembly may be implemented into cushions used for orthopedic support for medical purposes, as cushions implemented into furniture, etc. It also is understood that the scope of the adjustable shape-retaining cushion assembly is not limited in any way by the types of cushions that it may be used to form and / or provide.

[0043] The disclosed invention provides a unique flexible and shapeable construction while allowing the pillow to look and feel like a conventional pillow and for the pillow to fit standard sized pillow cases and accessories that may match the desired decor of any room.

[0044] FIG. 1 shows a generalized side sectional view of an adjustable shape-retaining cushion assembly 100.

[0045] In some embodiments, as shown in FIG. 1, the adjustable shape-retaining cushion assembly 100 (also referred to herein as simply the pillow 100) includes an outer encasement 200, an adjustable shape-retaining assembly 300, and a filler assembly 500. The adjustable shape-retaining cushion 100 also may include an alternative shape-retaining assembly 400 as described in other sections. The adjustable shape-retaining cushion assembly 100, the outer encasement 200, the adjustable shape-retaining assembly 300, and the filler assembly 500 are shown in FIG. 1 as blocks for demonstration and ease of understanding, and it is understood that these elements 100, 200, 300, 500 may be formed as any form and / or as any shape, and that the elements 100, 200, 300, 500 may be combined in any way as necessary for to perform their respective functionalities.

[0046] In general, the flexible shape-retaining assembly 300 is surrounded by the filler assembly 500 and the combination is held within the outer encasement 200. In this way, the user may form the pillow 100 into a desired shape using the shape-retaining assembly 300 while the filler assembly 500 provides soft and comfortable padding to the pillow 100 regardless of the pillow’s shape. While FIG. 1 shows the shape-retaining assembly 300 generally sandwiched between an upper and lower filler assembly 500 in a generally stacked arrangement, it is understood that the filler assembly 500 also may extend into and / or through the shape-retaining assembly 300 (e.g, through gaps in the shape-retaining assembly 300). The formable pillow assembly 100 also may include other elements as necessary to fulfill its functionalities.

[0047] FIG. 2 shows a top view and an exploded view of a formable pillow assembly 100. FIG. 3A shows a top sectional view of the formable pillow assembly 100 and FIG. 3B shows a side sectional view of the formable pillow assembly 100, with FIG. 3A taken fromthe perspective of the cut-lines a-a in FIG. 3B and FIG. 3B taken from the perspective of the cut-lines b-b in FIG. 3A.

[0048] In some embodiments, as shown in FIGS. 2-3, the outer encasement 200 may include a top side 210 of material and a back side 220 of material arranged face-to-face and secured together using a peripheral seam, e.g., using a seam piping accent 230 or other type of seam. This may form an inner volume 240 within the outer encasement 200 designed to receive and securing the shape-retaining assembly 300 and the filler assembly 500. The peripheral seam also may include an opening 250 that may be configured with zipper(s), buttons, snaps, hook and loop material, etc. to secure the opening 250 closed and to allow access to the inner volume 240 as needed.

[0049] In some embodiments, as shown in FIG. 2, the shape-retaining assembly 300 includes a shape-retaining encasement 308 comprising a top side 310 of material and a bottom side 320 of material arranged face-to-face to form an inner volume 322 therebetween. The top and bottom sides 310, 320 of the shape-retaining assembly 300 also may be secured together using a peripheral seam. This may form the encasement 308 with a left edge, a right edge, a top edge, and a bottom edge. The inner volume 322 may be segmented into one or more retaining pockets 330, e.g. , using stitching, adhesive, heat sealing (by the use of a heat activated adhesive layer), etc., with each pocket 330 sized and designed to receive one or more shaperetaining members 335. The shape-retaining members 335 also are flexible, and as such, may be referred to herein as flexible members 335 and / or as flexible shape-retaining members 335 and / or as flexible and / or shape-retaining members 335.

[0050] For example, in some embodiments, a pocket 330 may be formed by implementing two parallel lengths of stitching between the top and bottom sides 310, 320thereby forming a gap between the stitching that provides the retaining pocket 330 that may receive a shape-retaining member 335. The pocket 330 also may be referred to as a channel. The gap may generally match the diameter of the shape-retaining member 335 so that the member 335 may fit snug within the corresponding pocket 330. The stitching may preferably extend from the encasement’s 308’s left edge to the encasement’s 308’s right edge such that the pocket 330 and the member 335 therein also may extend accordingly.

[0051] In some embodiments, a pocket 330 may be formed using a single piece of material, e.g., one of the top side of material 310 and / or the bottom side 320 of material and folding a portion of the material over onto itself, e.g., along a longitudinal axis from the left side to the right side. The overlapping portions of the piece of material may then be stitched together along the longitudinal axis to form a channel extending from the left side to the right side. This may be repeated to form a plurality of pockets 330 to receive and secure shaperetaining members 335 as described herein.

[0052] In some embodiments, as shown in FIG. 2, the shape-retaining member 335 may include a rod and the corresponding retaining pocket 330 may be formed horizontally across the shape-retaining assembly 300 within the inner volume 322 to receive and secure the rod. Other shaped shape-retaining members 335 and corresponding retaining pockets 330 also may be formed and utilized as described in other sections.

[0053] In some embodiments, a plurality of pockets 330 may be formed with a predetermined spacing between the pockets 330 (e.g., l”-2”). Also, the spacings between the different pockets 330 need not match. While FIG. 2 shows six horizontal parallel retaining pockets 330 and six corresponding shape-retaining members 335 (e.g., rods), it is understood that the shape-retaining assembly 300 may include any number of shape-retaining members335 and corresponding retaining pockets 330. It also is understood that the different pockets330 and corresponding members 335 may be arranged at any orientation(s) with respect to one another and with respect to the shape-retaining assembly 300 (e.g., horizontal, vertical, diagonal, and / or at any combinations thereof). In addition, while the shape-retaining members 335 are shown in FIG. 2 as generally linear, the shape-retaining members 335 may comprise any shape(s) including one or more curvatures and / or other non-linear elements. Furthermore, while the retaining pockets 330 and corresponding shape-retaining members 335 are shown as being parallel with one another, the different retaining pockets 330 and corresponding shaperetaining members 335 may be placed at offset angles with respect to one another.

[0054] In some embodiments, the shape-retaining members 335 may each be inserted into a corresponding retaining pocket 330. The left and right ends of the members 335 may be capped using end caps 340. With the shape-retaining members 335 inserted, the retaining pockets 330 (and the overall shape-retaining assembly 300) may then be sealed at an edge of the shape-retaining assembly 330 e.g., using a zipper 350 (or buttons, snaps, hook and loop material, and / or a fold-over flap, etc.) to secure the shape-retaining members 335 therein. In this way, the shape-retaining members 335 may be removed and / or replaced and / or other shape-retaining members 335 may be added by unzipping the zipper 350 to open the retaining pockets 330 as needed. It may be preferable that the shape-retaining members 335 and their corresponding retaining pockets 330 each include a sufficient length to extend substantially (e.g., at least 90%) across the entire width of the overall pillow 100 (as shown in FIG. 3A). It also may be preferable that the shape-retaining assembly 300 include a sufficient number of retaining pockets 330 and corresponding shape-retaining members 335 arranged between the top edge of the assembly 300 and the bottom edge of the assembly 300 such that the entirety(or at least the majority) of the pillow 100 may be shaped using the shape-retaining assembly 300

[0055] In addition, because each pocket 330 may surround an entirety of its corresponding shape-retaining member 335 from the first end of the member 335 to the second end of the member 335, the pocket 330, being snug about the member 335, may not provide room within the pocket 330 for the member 335 to shift and / or move within the pocket 330, and instead, as the shape-retaining member 335 may be bent or otherwise formed into a particular shape, the member 335 may cause the pocket 330 to also be formed into the particular shape. With a plurality of retaining pockets 330 holding a plurality of corresponding shape-retaining members 335, this forming of the members 335 may cause the top and bottom sides 210, 220 of material comprising the shape-retaining assembly 300 to be formed into the particular shape, which in turn may cause the entire pillow 100 to be formed into the particular shape.

[0056] In some embodiments, the shape-retaining assembly 300 comprising the top and bottoms sides 310, 320 of material, the retaining pockets 330 formed between the sides 310, 320, and the shape-retaining members 335 received and secured therein, may form and be referred to as a shape-retaining frame 300 that extends within and across the entirety (or at least across the majority) of the pillow 100 from the pillow’s 100’s left edge to its right edge and from its top edge to its bottoms edge as depicted in FIG. 3A. In this way, the overall shape and / or curvature of the entire (or the majority) of the pillow 100 may be adjusted and held by the shape-retaining assembly 300 (the shape-retaining frame 300). In addition, because the entirety (or at least the majority) of the pillow’s 100’s footprint includes the shape-retainingassembly 300 or frame, the pillow 100 may be formed into complex shapes such as a helix(formed by applying a planar twist to the pillow 100).

[0057] In some embodiments, as shown in FIG. 2-3, the filling assembly 500 may include a first portion 500a (e.g., a top portion) and a second portion 500b (e.g., a bottom portion). The first portion 500a may be positioned above the shape-retaining assembly 300 and the second portion 500b may be positioned below the shape-retaining assembly 300. Other portions of the filling assembly 500 also may be included in other areas, e.g., at the left and / or right ends of the shape-retaining assembly 300.

[0058] In some embodiments, the first and second portions 500a, 500b may each include filler material 530 within a corresponding filler pouch 532. The filler pouches 532 may each include a top side 510 of material and a bottom side 520 of material arranged face- to-face and secured together using a peripheral seam. This may form an inner volume 534 within each pouch 532 designed to receive and securing the filler material 530. The peripheral seam also may include an opening 550 that may be configured with zipper(s), buttons, snaps, hook and loop material, and / or a fold-over flap, etc. to secure the opening 550 closed and to allow access to the inner volume 534 as needed (e.g., to add and / or remove filler material 530).

[0059] In some embodiments, it may be preferable that the first and second portions 500a, 500b of the filler assembly 500 generally include a matching or similar footprint as the overall formable pillow assembly 100 so that the entire footprint of the pillow 100 encompasses the filler material 530. In other embodiments, the first and second portions 500a, 500b may simply comprise the filler material 530 placed within the inner volume 240 of the outer encasement 200, e.g., above and below the shape-retaining assembly 300 without the use of the filler pouches 532.

[0060] In some embodiments, the filler material 530 of the first portion 500a may match the filler material 530 of the second portion 500b so that the overall pillow 100 may be uniform in this regard. In other embodiments, the first and second portions 500a, 500b may include different filler materials 530 and / or different amounts of the filler materials 530. In this way, different sides of the pillow 100 may provide different levels of cushion that the user may utilize by simply flipping the pillow 100 over. In addition, different pouches 532 containing different filler materials 530 and / or different amounts of filler materials 530 may be interchanged by opening the outer encasement 200 (e.g., by opening the zippered opening 250 to access the pouches 532 therein).

[0061] In some embodiments as shown in FIG. 3B, the shape-retaining assembly 300 may be positioned generally at the vertical midhne of the pillow 100. In some embodiments, the shape-retaining assembly 300 may be connected to the outer encasement 200 while in this position such that the relative position of the shape-retaining assembly 300 with respect to the overall pillow 100 may be generally fixed. For example, the shape-retaining assembly 300 may be attached to at least a portion of the peripheral seam between the encasement’s 200’ s top side 210 of material and back side 220 of material. For example, the left edge of the shaperetaining encasement 308 may be attached to the left edge of the outer encasement 200, the right edge of the shape-retaining encasement 308 may be attached to the right edge of the outer encasement 200, the top edge of the shape-retaining encasement 308 may be attached to the top edge of the outer encasement 200, and the bottom edge of the shape-retaining encasement 308 may be attached to the bottom edge of the outer encasement 200. This may form a contained upper space above the shape-retaining assembly 300 within the outer encasement’s inner volume 240 to receive and secure the upper portion 500a of the filler material 530 (e.g.,the upper pouch 532 of filler material 530) and a contained lower space within the outer encasement’s inner volume 240 below the shape-retaining assembly 300 to receive and secure the lower portion 500b of the filler material 530 (e.g., the lower pouch 532 of filler material 530). This may ensure that the shape-retaining assembly 300 is held in the middle interior of the pillow 100 such that it may not be by a user’s face or head when it is resting upon the pillow 100.

[0062] In other embodiments, the lower portion 500b of filler material 530 may be omitted, e.g, if only the top side of the pillow 100 is intended for use. This may reduce the pillow’s size and the amount of materials used to make the pillow 100 and may be beneficial for when a smaller and more compact pillow 100 may be desired, e.g, during travel.

[0063] FIG. 4 shows a top view of the shape-retaining members 335 being inserted into corresponding retaining pockets 330 formed within the inner volume 322 of the shaperetaining assembly 300. The upper image of FIG. 4 shows the shape-retaining assembly 300 without shape-retaining members 335, the middle image shows the shape retaining members 335 being inserted into corresponding retaining pockets 330, and the lower image shows the resulting assembly 300. In some embodiments, the top side 310 of material and the bottom side 320 of material of the shape-retaining assembly 300 may include fabric, textiles, films and / or other suitable types of materials and may include cotton, nylon, polyester, polyethylene terephthalate (PET), bamboo, any other suitable materials and / or any combinations thereof. In this way, the outer encasing of the shape-retaining assembly 300 may be soft and flexible to accommodate the forming of the shape-retaining members 335 into the desired shape(s).

[0064] In some embodiments, the shape-retaining members 335 may comprise flexible and / or bendable materials (e.g., hyperflexible materials) with sufficient memory such asaluminum, copper, steel, muscle wire or Nitinol wire and / or other types, alloys, and / or any combinations of types of metals. In some embodiments, the members 335 may comprise other materials such as carbon fiber, plastic and / or rubber, and / or combinations of plastic, rubber and / or metal (e.g., rubber coated metal wire or rods). The members 335 may be solid, hollow, coaxial, extruded, coextruded, co-combined, co-formed, spun and / or woven, and / or constructed using any suitable materials and / or techniques and / or any combinations thereof.

[0065] In some embodiments, the shape-retaining members 335 may include generally circular cross-sectional shapes with diameters of about 0.0625” to about 0.5”, and preferably about 0.125” to about 0.25”. In some embodiments, the shape-retaining members 335 may include planar (e.g., flat or rectangular) cross-sectional shapes similar to fettuccine or pappardelle noodles with widths of about 0.125” to about 1.0” (but bendable and shaperetaining as described herein). Other cross-sectional shaped members 335 also may be used.

[0066] Also, different types of shape-retaining members 335, e.g., comprising different materials and / or different diameters or widths of materials, may be implemented together into different and / or the same retaining pockets 330. For example, the members 335 may be implemented as flexible “goosenecks” (including ball and socket joints throughout).

[0067] In some embodiments, e.g., when using shape-retaining members 335 with planar or flat shaped cross-sections (although circular cross-section shaped members 335 also may be used), the shape-retaining assembly 300 also may distribute the weight of the user’s head more evenly across the shape-retaining assembly 300 and the overall pillow 100. That is, the shape retaining assembly 300 may prevent the user’s head from sinking too deep into the pillow 100 (which may not provide adequate support to the user’s head and neck areas) and instead may provide balanced support to the user’s head, similar to how a snow shoedistributes the weight of its wearer across the soft snow upon which he / she may be walking. In these embodiments, the flexibility (e.g., spring coefficient) of the shape-retaining members 335 may be chosen to allow the shape-retaining assembly 300 to flex downward an appropriate distance due to the weight of the user’s head when the user places his / her head onto the pillow 100 to provide comfort to the user but may not flex too far downward to a point where the support is no longer sufficient. That is, the members 335 may preferably flex under the forces of the user’s head but not necessarily be reformed into the flexed shape and therefore not retain the flexed shape). Instead, the members 335 may simply flex downward while applying upward forces to the user’s head. In this way, the members 335 may provide support to the user’s head without being reshaped thereby.

[0068] If using muscle wire or Nitinol wire, which may be caused to return to a predetermined shape when heated using electrical current without having to manually re-form the member 335, a power source (such as a rechargeable battery and a controller chip) may be provided along with a user interface on a mobile or desktop application.

[0069] It may be preferable that each shape-retaining member 335 be manually deformable with sufficient memory to retain its formed shape until intentionally changed. It also may be preferable that the shape-retaining members 335 generally retain their shape under the forces applied to the member 335 during use of the pillow 100. That is, it may be preferable that the shape-retaining assembly 300 comprising the shape-retaining members 335 retain its desired form (as shaped by the user) as forces are applied to the pillow 100 by the weight of the user’s head and shoulders when the user’s head is placed onto the pillow 100 while sleeping with the pillow 100.

[0070] In some embodiments, the shape-retaining members 335 are designed to be bent, straightened, and bent again at least hundreds of times and preferably up to at least 5000 times (and more preferably up to at least 10,000 times) without the mechanical integrity of the members 335 being compromised. In addition, if a shape-retaining member 335 were to malfunction (e.g., kink or break), the member 335 may be easily replaced by a new member335 by opening the shape-retaining assembly 300, removing the compromised member 335, and inserting the replacement member 335 in its place.

[0071] In addition, it is understood that not all retaining pockets 330 need to be occupied by a shape-retaining member 335 (some may remain empty), and that more than one shape-retaining member 335 may be inserted into any single retaining pocket 330. In this way, the flexibility of the shape-retaining assembly 300 may be adjusted depending on how many and which types of shape-retaining members 335 are used, in what positions (e. , which pockets 330 are used), etc.

[0072] FIG. 5 shows a top view of another embodiment of the shape-retaining members336 being inserted into corresponding retaining pockets 323 formed within the inner volume 322 of the shape-retaining assembly 300. The upper image of FIG. 5 shows the shaperetaining assembly 300 without shape-retaining members 336, the middle image shows the shape retaining members 336 being inserted into corresponding retaining pockets 323, and the lower image shows the resulting assembly 300. In some embodiments, the shape-retaining members 336 may include non-linear elements, e.g., undulating steps or curvatures. That is, the members 336 may be bent to include different shapes between the left and right far ends of the members 336. The left and right ends of the members 336 may be capped with end caps345. While the non-linear elements shown in FIG. 5 include upward and downward right-angle bends that form steps within the members 336, it is understood that the non-linear elements may include other types of shapes such as smooth upward and downward curvatures (e.g, waves), diagonal shaped curvatures (e.g, saw-tooth), interlaced wires, helical forms, other types of shapes, and / or any combinations thereof. In general, the non-linear elements may be provided in order to widen the overall footprint of the members 336. Such wider formatted members 336 may be less likely to rotate or otherwise shift during use. In addition, such wider formatted members 336 also may enable the overall footprint of the pillow 100 to be not only bent but also planarly twisted (e.g., from opposing diagonally located points) and / or formed into complex shapes.

[0073] In some embodiments, because the shape-retaining members 336 may include wider footprints, the retaining pockets 323 designed to receive the members 336 also may be widened to match. In some embodiments, the spacing between the aforementioned retaining pockets 330 of FIGS. 2 and 4 may be dimensioned to correspond to the width of the shape retaining members 336 such that these gaps between stitched pockets 330 may form the retaining pockets 323 to receive and secure the wider members 336. In this way, retaining pockets 330 holding shape-retaining members 335 and retaining pockets 323 holding shaperetaining members 336 may be implemented within the same shape-retaining assembly 300 simultaneously. Other details described in other sections regarding the shape-retaining members 335 and their corresponding retaining pockets 330 also pertain to the shape-retaining members 336 and their corresponding retaining pockets 323 of FIG. 5, and as such, these details will not be repeated here to avoid duplicity.

[0074] In some embodiments, other elements may be inserted and secured within the retaining pockets 330, 323, such as, but not limited to, cooling jell pack(s), heat retaininginserts, weighted inserts, active powered health providing infrared LED light strips, speakers, active cooling (e.g., Peltier), heating, white noise generators, air purifiers and / or ventilation tubes, manifold air movement assemblies, vibrational elements, and / or other types of elements.

[0075] FIG. 6 shows a top view of an embodiment of a shape-retaining assembly 400 including a top side 410 of material and a bottom side 420 of material arranged face-to-face to form an inner volume 422 therebetween. The upper image of FIG. 6 shows the shape-retaining assembly 400 without shape-retaining members 435, the middle image shows the shape retaining member(s) 435 being inserted between the top and bottom sides 410, 420, and the lower image shows the resulting assembly 400.

[0076] In some embodiments, the shape-retaining member 435 may be inserted between the top and bottom sides 410, 420 and the top and bottom sides 410, 420 may be sealed together thereby entrapping the shape-retaining member 435 therebetween. In some embodiments, the top and bottom sides 410, 420 may be interlocked together using stitching, adhesive, snap members, notches and detents, zippers, insertable tabs, using other interlocking techniques, and / or any combinations thereof. In some embodiments, it may be preferable that the top and bottom sides 410, 420 be releasably connected to one another so that the sides 410, 420 may be separated to release the shape-retaining member 435 so that the member 435 may be removed and / or replaced and then interlocked again for use. Alternatively, the top and bottom sides 410, 420 may be co-molded about the shape-retaining member 435 while comprising flexible thermoplastic elastomers (TPE), thermoplastic polyurethane (TPU), skinned urethane foam, other suitable materials, and / or any combinations thereof.

[0077] In some embodiments, as shown in FIG. 6, the shape-retaining member 435 may include a grid comprising the same or similar materials as the shape-retaining members335, 336 of FIGS. 2, 4 and 5. In some embodiments, the top and bottom sides 410, 420 of the shape-retaining assembly 400 may include cutouts 440 that correspond to the openings within the grid-shaped shape-retaining member 435. This may reduce the amount of material used and may improve the flexibility of the assembly 400. In other embodiments, the shaperetaining assembly 400 may include interlocking members 450 on the opposing sides of the top and bottom sides 410, 420 in the areas of the grid openings of the shape-retaining member 435 that may interlock with one another through the grid openings when the shape-retaining member 435 is sandwiched between the top and bottom sides 410, 420. In this way, the shaperetaining assembly 400 may be held together. The cutouts 440 and / or the interlocking members 450 also may form pockets or channels 460 between adjacent rows and / or columns of the cutouts 440 and / or the interlocking members 450 that may receive and secure the horizontal and / or vertical elements comprising the grid-shaped shape-retaining member 435. While the shape-retaining member 435 is shown in FIG. 6 as grid-shaped with generally linear elements, it is understood that this is for demonstration and that the shape-retaining member 435 may include other shapes and / or forms (e.g., an alternating jogging pattern, a sawtooth pattern, a crisscrossing pattern, etc.).

[0078] In any of the embodiments described herein, the shape-retaining assembly 300 may enable the pillow 100 to be rolled up for stowage (e.g, to fit into a carry on bag), vacuum sealed, and / or otherwise formed into a compact space-saving configuration.

[0079] FIG. 7 shows a top view of a filler pouch 532 filled with filler material 530 and a top view of the filler material 530 by itself. The filler pouch 532 in the upper image has been made transparent for clarity. In some embodiments, the filler pouch(es) 532 may comprise a fabric, textile, film and / or other suitable type(s) of material comprising nylon, rayon, polyester,polypropylene, cotton, bamboo fabric, any other suitable material, and / or any combinations thereof. In some embodiments, the fill material 530 may comprise shredded memory foam, natural and / or regular latex, down, shredded fabric, other suitable types of filler materials, and / or any combinations thereof.

[0080] FIG. 8 shows images of the shape-retaining cushion assembly 100 formed into various exemplary shapes for demonstration. The top image shows the pillow 100 formed into an arched shape that may allow the user to place his / her arm under the pillow 100 while resting his / her head comfortably on top of the pillow 100. The middle image shows the pillow 100 bent to flex around the user’s head to support the head in the center while extending upwards on both sides to cover the user’s ears to dampen sound. The bottom image shows the pillow 100 formed with a curved portion on the outer circumference that may support the user’s the lower neck.

[0081] It is understood that while the shape-retaining cushion assembly 100 has been described herein primarily as being generally rectangular in shape, the shape-retaining cushion assembly 100 may be formed as any desired shape. For example, FIG. 9 shows images of additional types of pillows and / or cushions that may be implemented using the shape-retaining cushion assembly 100, including (a) a pillow devised to allow the user’s arm to fit under the arched section of the pillow, (b) a pillow including a section for the user’s head to rest utilizing various foam core types and shapes, and (c) a pillow including a cutout portion at the neck area.

[0082] With respect to any of the embodiments described herein, additional aspects of the adjustable shape-retaining cushion assembly 100 may include the following:

[0083] The pillow 100 may include embroidered and or embossed elements on the outer encasement 200 (and / or on a protective pillow case acting as the outer surface of the encasement 200) may include a raised pattern allowing air to flow more easily across the pillow 100 regardless of the formed shape of the pillow 100. In addition, the encasement 200 can be water resistant is such a manner as to allow the air flow even as the fabric repels moister.

[0084] The material used for the encasement 200 may preferably include cotton, preferably long-staple cotton (and / or organic cotton), e.g., with a thread count of 500. Other materials, such as synthetic materials including polyester fabric can be used with or without a polyurethane film for protection against allergies. Blends can be utilized as well such as a nylon blend with cooling features and additionally, the fabrics may be treated with antimicrobial agents.

[0085] The materials also may include metallic copper and / or silver threading interweaved within the fabric structure and / or used for the embordered or quilted details for added anti-microbial protection. Other anti-microbial agents also may be used.

[0086] It is understood that any aspect and / or element of any embodiment of the shaperetaining cushion assembly 100 described herein may be combined with any aspect and / or element of any other embodiment of the shape-retaining cushion assembly 100 in any way to form additional embodiments of the shape-retaining cushion assembly 100 all of which are within the scope of the shape-retaining cushion assembly 100.

[0087] Where a process is described herein, those of ordinary skill in the art will appreciate that the process may operate without any user intervention. In another embodiment, the process includes some human intervention (e.g., a step is performed by or with the assistance of a human).

[0088] As used herein, including in the claims, the phrase “at least some” means “one or more,” and includes the case of only one. Thus, e.g., the phrase “at least some ABCs” means “one or more ABCs”, and includes the case of only one ABC.

[0089] As used herein, including in the claims, term “at least one” should be understood as meaning “one or more”, and therefore includes both embodiments that include one or multiple components. Furthermore, dependent claims that refer to independent claims that describe features with “at least one” have the same meaning, both when the feature is referred to as “the” and “the at least one”.

[0090] As used in this description, the term “portion” means some or all. So, for example, “A portion of X” may include some of “X” or all of “X”. In the context of a conversation, the term “portion” means some or all of the conversation.

[0091] As used herein, including in the claims, the phrase “using” means “using at least,” and is not exclusive. Thus, e.g., the phrase “using X” means “using at least X.” Unless specifically stated by use of the word “only”, the phrase “using X” does not mean “using only X.”

[0092] As used herein, including in the claims, the phrase “based on” means “based in part on” or “based, at least in part, on,” and is not exclusive. Thus, e.g., the phrase “based on factor X” means “based in part on factor X” or “based, at least in part, on factor X.” Unless specifically stated by use of the word “only”, the phrase “based on X” does not mean “based only on X.”

[0093] In general, as used herein, including in the claims, unless the word “only” is specifically used in a phrase, it should not be read into that phrase.

[0094] As used herein, including in the claims, the phrase “distinct” means “at least partially distinct.” Unless specifically stated, distinct does not mean fully distinct. Thus, e.g., the phrase, “X is distinct from Y” means that “X is at least partially distinct from Y,” and does not mean that “X is fully distinct from Y.” Thus, as used herein, including in the claims, the phrase “X is distinct from Y” means that X differs from Y in at least some way.

[0095] It should be appreciated that the words “first,” “second,” and so on, in the description and claims, are used to distinguish or identify, and not to show a serial or numerical limitation. Similarly, letter labels (e.g., “(A)”, “(B)”, “(C)”, and so on, or “(a)”, “(b)”, and so on) and / or numbers (e.g, “(i)”, “(ii)”, and so on) are used to assist in readability and to help distinguish and / or identify, and are not intended to be otherwise limiting or to impose or imply any serial or numerical limitations or orderings. Similarly, words such as “particular,” “specific,” “certain,” and “given,” in the description and claims, if used, are to distinguish or identify, and are not intended to be otherwise limiting.

[0096] As used herein, including in the claims, the terms “multiple” and “plurality” mean “two or more,” and include the case of “two.” Thus, e.g, the phrase “multiple ABCs,” means “two or more ABCs,” and includes “two ABCs.” Similarly, e.g, the phrase “multiple PQRs,” means “two or more PQRs,” and includes “two PQRs.”

[0097] The present invention also covers the exact terms, features, values and ranges, etc. in case these terms, features, values and ranges etc. are used in conjunction with terms such as about, around, generally, substantially, essentially, at least etc. (i.e., "about 3" or “approximately 3” shall also cover exactly 3 or "substantially constant" shall also cover exactly constant).

[0098] As used herein, including in the claims, singular forms of terms are to be construed as also including the plural form and vice versa, unless the context indicates otherwise. Thus, it should be noted that as used herein, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

[0099] Throughout the description and claims, the terms “comprise”, “including”, “having”, and “contain” and their variations should be understood as meaning “including but not limited to”, and are not intended to exclude other components unless specifically so stated.

[0100] It will be appreciated that variations to the embodiments of the invention can be made while still falling within the scope of the invention. Alternative features serving the same, equivalent or similar purpose can replace features disclosed in the specification, unless stated otherwise. Thus, unless stated otherwise, each feature disclosed represents one example of a generic series of equivalent or similar features.

[0101] The present invention also covers the exact terms, features, values and ranges, etc. in case these terms, features, values and ranges etc. are used in conjunction with terms such as about, around, generally, substantially, essentially, at least etc. (i.e., "about 3" shall also cover exactly 3 or "substantially constant" shall also cover exactly constant).

[0102] Use of exemplary language, such as “for instance”, “such as”, “for example” (“e.g.,”) and the like, is merely intended to better illustrate the invention and does not indicate a limitation on the scope of the invention unless specifically so claimed.

[0103] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended toT1cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

CLAIMS1. A cushion assembly comprising: an outer shell including a shell left edge and a shell right edge and a shell inner volume; an adjustable flexible frame within the shell inner volume and including a frame left edge and a frame right edge and a frame first channel extending from the frame left edge to the frame right edge and a first flexible member within the frame first channel and extending from the frame left edge to the frame right edge, the adjustable flexible frame extending from the shell left edge to the shell right edge; and an amount of filler material within the shell inner volume.

2. The cushion assembly of claim 1 wherein the first flexible member comprises a material that is manually formable with sufficient memory to retain a first shape when manually formed into the first shape.

3. The cushion assembly of claim 1 further comprising: a frame second channel extending from the frame left edge to the frame right edge; and a second flexible member within the frame second channel and extending from the frame left edge to the frame right edge.

4. The cushion assembly of claim 3 wherein the first flexible member and the second flexible member form elements of a grid-shaped flexible member.

5. The cushion assembly of claim 3 wherein the frame second channel is parallel to the frame first channel.

6. The cushion assembly of claim 1 wherein the adjustable flexible frame includes a first section of material including a first line of stitching and a second line of stitching forming a first gap therebetween, and the frame first pocket comprises the first gap.

7. The cushion assembly of claim 6 wherein the adjustable flexible frame includes a second section of material in an opposing arrangement with the first section of material and wherein the first line of stitching and the second line of stitching connect the first section of material to the second section of material.

8. The cushion assembly of claim 7 wherein the first gap is formed between first section of material and the second section of material.

9. The cushion assembly of claim 6 wherein the first section of material includes a flexible material including fabric or film.

10. The cushion assembly of claim 6 wherein a width of the first gap matches a width of the first flexible member.

11. The cushion assembly of claim 1 wherein the amount of filler material includes a first amount of filler material above the adjustable shape-retaining frame and / or a second amount of filler material below the adjustable shape-retaining frame.

12. The cushion assembly of claim 11 wherein the first amount of filler material is contained in a first filler pouch and / or the second amount of filler material is contained in a second filler pouch.

13. The cushion assembly of claim 1 wherein the frame left edge is attached to the shell left edge and / or the frame right edge is attached to the shell right edge.

14. The cushion assembly of claim 1 wherein the first flexible member includes a rod.

15. The cushion assembly of claim 14 wherein the rod extends linearly from the frame left edge to the frame right edge.

16. The cushion assembly of claim 14 wherein the rod extends non-hnearly from the frame left edge to the frame right edge.

17. The cushion assembly of claim 1 wherein the outer shell includes an opening and the first flexible member and / or the amount of filler material are removeable from the shell inner volume through the opening.

18. The cushion assembly of claim 17 wherein the opening is sealable.

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