Seamless pillow or pillow component
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pillow manufacturing processes require precise alignment and extensive stitching of multiple panels, leading to inefficiencies in material usage, flexibility, and comfort, as they are inflexible regarding filler distribution and struggle to vary material characteristics like breathability and cooling without complex panel alignment.
Innovation Solution
A seamless pillow component is created using a single material layer formed by seamless knitting, allowing for varying yarn types, densities, and patterns without seams, with inwardly curved sides to control filler distribution and include apertures for breathability, and ribbed sections for elasticity, reducing material waste and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple panels are joined together by stitching to form a pillow cover, then the pillow can be constructed with varied patterns and materials, but the manufacturing process becomes time-consuming and requires precise alignment
Solution Approach 1:
The patent merges multiple separate panels into a single continuous knitted fabric structure. The pillow cover is formed as one integrated piece of fabric that is then folded and sewn, eliminating the need for multiple separate panels and their associated alignment and stitching requirements. This combining approach maintains material variation capabilities while dramatically improving manufacturing efficiency.
2Reliability
If multiple panels are stitched together to create a pillow cover, then the structure can accommodate filler material, but excess material is needed and material waste increases
Solution Approach 1:
The patent uses a single continuous fabric that is folded to create the pillow cover structure, eliminating the need for multiple separate panels. This segmentation approach reduces material waste by eliminating excess material that would otherwise be required for stitching multiple panels together, while still providing the necessary structural integrity through the folded construction method.
3Reliability
If traditional pillow construction with enclosed space is used, then filler material can be contained, but the filler becomes unevenly distributed and moves toward the periphery
Solution Approach 1:
The patent incorporates inwardly curved sides in the pillow cover construction. These curved surfaces naturally guide and distribute the filler material toward the center of the pillow, preventing the filler from migrating to the periphery. The curvature creates a self-distributing effect that maintains even filler distribution and consistent comfort and support throughout the pillow.
Data Source
AI summary
A pillow component includes a material layer having a top layer, a bottom layer and one or more sides separating the top layer from the bottom layer, and an interior spaced defined between the top layer and the bottom layer, the interior space configured to receive a filler. The material layer is formed by seamless knitting and is seamless about an entirety of a periphery extending in a first direction around the top layer, the bottom layer and the one or more sides. The characteristics of the knit material layer or fabric can be widely varied. A pillow includes the pillow component and a filler in the interior space.