`
`<19>Worw I|||||||||||||||||||||l||||||||||||l||||||ll|||||||||||||||||||||||||||||||||||||||||||||||||||
`International Bureau
`IN
`(10) International Publication Number
`
`(43) International Publication Date
`1 July 2010 (01.07.2010)
`
`(51)
`
`(21)
`
`(22)
`
`International Patent Classification:
`
`A47G 9/00 (2006.01)
`
`International Application Number:
`PCT/US2009/069018
`
`International Filing Date:
`21 December 2009 (21.12.2009)
`
`(25)
`
`Filing Language:
`
`English
`
`English
`
`US
`
`Publication Language:
`
`Priority Data:
`61/140,622
`24 December 2008 (24.12.2008)
`
`Applicant 0’or all designated States except US): TEM-
`PUR-PEDIC MANAGEMENT, INC.
`[US/US]; 1713
`Jaggie Fox Way, Lexington, KY 40511 (US).
`
`Inventor; and
`flor US only): RASMUSSEN,
`Inventor/Applicant
`Kristina [DIQDK]; Skolevej 7, DK—5800 Nyborg
`
`Agent: MORAN, Kevin; Michael Best & Friedrich LLP,
`100 East Wisconsin Avenue, Suite 3300, Milwaukee, WI
`53202 (US).
`
`(26)
`
`(30)
`
`(71)
`
`WO 2010/075294 A1
`
`(81) Designated States (unless otherwise indicated, for every
`kind of national protection available): AE, AG, AL, AM,
`AO, AT, AU, AZ, BA, BB, BG, BH, BR, BW, BY, BZ,
`CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, DO,
`DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT,
`HN, HR, HU, ID, IL, IN, IS, JP, KE, KG, KM, KN, KP,
`KR, KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD,
`ME, MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI,
`NO, NZ, OM, PE, PG, PH, PL, PT, RO, RS, RU, SC, SD,
`SE, SG, SK, SL, SM, ST, SV, SY, TJ, TM, TN, TR, TT,
`TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW.
`
`Designated States (unless otherwise indicated, for every
`kind ofregional protection available): ARIPO (BW, GH,
`GM, KE, LS, MW, MZ, NA, SD, SL, SZ, TZ, UG, ZM,
`ZW), Eurasian (AM, AZ, BY, KG, KZ, MD, RU, TJ,
`TM), European (AT, BE, BG, CH, CY, CZ, DE, DK, EE,
`ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU, LV,
`MC, MK, MT, NL, NO, PL, PT, RO, SE, SI, SK, SM,
`TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW,
`ML, MR, NE, SN, TD, TG).
`Published:
`
`with international search report (Art. 21(3))
`
`\«-’1«v..'11rr n 7"‘
`5
`($4
`
`ll
`
`(54) Title: PILLOW
`
`V-1
`
`<u'..-a=ges..-<2...-u%5a§u:..*n:'
`
`'V"g“-‘{"§"’x'7‘»'
`-\¢ #470’!
`’
`‘/75§’3"\""§\:
`.3 ‘Y?3‘é"l*‘31
`--
`A914
`v.x.>.r2-filh‘
`«;;s~..-§%s:¢:§;§)2/
`s.
`§§H§..T.§‘§'_§§,‘§3.T\L;fi
`tar/if/rrrrrr/r/zir./1'/rrg_4/(4/1/‘fr//_z4'1t;g'44
`
`(57) Abstract: A pillow assembly including a visco-elastic foa111 core and a cover having a top portion and a side portion that is
`more permeable than the top portion. The core comprises a top layer of foam, a bottom layer of foam, and a filler of granulated
`foam filler positioned between the top layer and the bottom layer. The core further includes a side layer coupled to the top layer
`and bottom layer to define a cavity containing the filler, such that the side layer is more permeable than the top layer. At least one
`of the side layer and the side portion comprises a 3D textile. The assembly is shaped to include a plurality of lobes. The cover fur-
`ther includes a bottom portion having a material that is less permeable than the side portion, such that the bottom portion compris-
`es a material that is the same as the top portion.
`
`|PR2017-00351
`
`<fl
`<1-
`ax
`
`NI
`
`n
`l\
`cE
`
`aV
`
`-1
`
`cN g
`
`IPR2017-00351
`Fredman EX1006 Page 1
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`CROSS-REFERENCE TO RELATED APPLICATIONS
`
`PILLOW
`
`[0001]
`
`Priority is hereby claimed to U.S. Provisional Patent App. No. 61/140,622, filed
`
`December 24, 2008, the entire contents of which are herein incorporated by reference.
`
`BACKGROUND
`
`[0002]
`
`Conventional pillows can be found in a wide variety of shapes and sizes, and are
`
`often adapted for supporting one or more body parts of a user.
`
`[0003]
`
`Many pillows are constructed entirely or partially out of foam material. For
`
`example, polyurethane foam is commonly used in pillows of all types, and can be used alone
`
`or in combination with other types of cushion materials. In many cases, pillows are
`
`constructed entirely or partially of visco-elastic material, thereby providing the pillow with an
`
`increased ability to conform to a user and to thereby distribute the weight or other load of the
`
`user. Some Visco-elastic materials are also temperature sensitive, thereby also enabling the
`
`pillow to change shape based at least in part upon the temperature of the supported body part.
`
`[0004]
`
`Although the number and types of pillows constructed with Visco-elastic materials
`
`continue to increase, the capabilities of such materials are often underutilized. In many cases,
`
`this underutilization is due to poor pillow design and/or the choice of material(s) used in the
`
`pillow.
`
`[0005]
`
`Based at least in part upon the limitations of existing pillows containing visco-
`
`elastic material and the high consumer demand for improved pillows in a wide variety of
`
`applications, new pillows are welcome additions to the art.
`
`SUMMARY
`
`[0006]
`
`Some embodiments of the present invention provide a pillow comprising a core
`
`and a plurality of lobes extending from the core, wherein the core includes a top layer and a
`
`bottom layer between which is located granulated filler material, wherein the top layer,
`
`bottom layer, and/or granulated foam comprises Visco-elastic foam. The sides of the core can
`
`be defined by highly porous material (such as a 3D textile material) in some embodiments.
`
`Also, the core can be enclosed within a cover having highly porous sides (e.g., made of a 3D
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 2
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`textile material or a velour or stretch velour material) corresponding to and covering the sides
`
`ofthe core and/or a highly porous bottom (e.g., again, made ofa 3D textile material or a
`
`velour or stretch velour material) corresponding to and covering the bottom layer of the core.
`
`In some embodiments, the top of the cover can be less porous than the sides or bottom of the
`
`cover, whereas in other embodiments, the top and bottom of the cover are less porous than
`
`the sides of the cover. Examples of material that can be used for the top of the cover include
`
`a double jersey fabric, velour, or stretch velour. In some alternative embodiments, these
`
`same materials can be used for the bottom of the cover, such as in embodiments in which the
`
`top and bottom of the cover are both less porous than the sides of the cover.
`
`[0007]
`
`A pillow assembly including a visco-elastic foam core and a cover having a top
`
`portion and a side portion that is more permeable than the top portion. The core comprises a
`
`top layer of foam, a bottom layer of foam, and a filler of granulated foam filler positioned
`
`between the top layer and the bottom layer. The core further includes a side layer coupled to
`
`the top layer and bottom layer to define a cavity containing the filler, such that the side layer
`
`is more permeable than the top layer. At least one of the side layer and the side portion
`
`comprises a 3D textile. The assembly is shaped to include a plurality of lobes. The cover
`
`further includes a bottom portion having a material that is less permeable than the side
`
`portion, such that the bottom portion comprises a material that is the same as the top portion.
`
`[0008]
`
`A pillow assembly including a core having a top layer of foam, a side layer and a
`
`bottom layer, and a cover surrounding the core. The core further includes a granulated foam
`
`filler positioned between the top layer and the bottom layer. The side layer is coupled to the
`
`top layer and the bottom layer to define a cavity containing the filler. The side layer is more
`
`permeable than the top layer and the bottom layer. The assembly is shaped to include a
`
`plurality of lobes.
`
`[0009]
`
`Further aspects of the present invention, together with the organization and
`
`operation thereof, will become apparent from the following detailed description of the
`
`invention when taken in conjunction with the accompanying drawings, wherein like elements
`
`have like numerals throughout the drawings.
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 3
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0010]
`
`FIG. 1 is a perspective view of a pillow according to the present invention, shown
`
`with a portion of the cover removed to expose the core of the pillow.
`
`[0011]
`
`FIG. 2 is a detail cross-sectional View of the pillow of FIG. 1.
`
`DETAILED DESCRIPTION
`
`[0012]
`
`Before the various embodiments of the present invention are explained in detail, it
`
`is to be understood that the invention is not limited in its application to the details of
`
`construction and the arrangements of components set forth in the following description or
`
`illustrated in the drawings. The invention is capable of other embodiments and of being
`
`practiced or of being carried out in various ways. Also, terms such as "first", "second", and
`
`"third" are used herein and in the appended claims for purposes of description and are not
`
`intended to indicate or imply relative importance or significance. The term “first” does not
`
`necessarily refer to the top most layer, rather, it refers to the first of a plurality, without
`
`indicating a particular location or position. Similarly, the terms “top” and “bottom” are used
`
`for the purpose of description and are not intended to indicate or imply relative importance,
`
`significance, unless otherwise specified. The term “top” does not necessarily refer to the top
`
`most layer, and “bottom” does not necessarily refer to the bottom most layer.
`
`[0013]
`
`The use of "including," "comprising," or "having" and variations thereof herein is
`
`meant to encompass the items listed thereafter and equivalents thereof as well as additional
`
`items. Unless limited otherwise, the terms "connected," "coupled," and variations thereof
`
`herein are used broadly and encompass direct and indirect connections and couplings. In
`
`addition, the terms "collected" and "coupled" and variations thereof are not restricted to
`
`physical or mechanical connections or couplings.
`
`[0014]
`
`A pillow 100 according to an embodiment of the present invention is illustrated in
`
`FIGS. 1-2. The pillow 100 comprises a core 110 having a plurality of lobes I20, I30
`
`extending from a central portion of the core l 10. In some embodiments, the lobes I20, 130
`
`all have substantially the same size. However, in other embodiments (including that shown
`
`in FIG. I), the lobes I20, 130 can have different sizes. In particular, two of the lobes 120 in
`
`the illustrated embodiment are smaller than the other two lobes 130. Any combination of
`
`lobes having the same size or different sizes is possible, and falls within the spirit and scope
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 4
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`of the present invention. Also, in other embodiments, the core 110 can have three lobes, five
`
`lobes, or more lobes ofthe same or different size. In any case, the lobes I20, 130 can be
`
`equally or unequally spaced about the periphery of the pillow 100. The lobed shape of the
`
`pillow 100 provides a number of support surfaces for a user. For example, the lobed shapes
`
`can enhance breathing of a user resting his or her head against the pillow 100 (e. g., when
`
`sleeping on the user’s side or stomach), and can also provide support for the shoulder and/or
`
`neck of the user when the user is sleeping on his or her side or back.
`
`[0015]
`
`With continued reference to FIGS. 1 and 2, the core 110 of the illustrated pillow
`
`100 includes a top layer 140, a bottom layer 150 opposite the top layer 140, and sidewalls
`
`160 connecting the top layer 140 and the bottom layer 150. The top layer 140, bottom layer
`
`150 and sidewalls 160 define a cavity 170 shaped to receive filler material 180. The pillow
`
`100 can include a rib where the top layer 140 and sidewalls 160 meet and are joined, and/or a
`
`rib where the bottom layer 150 and the sidewalls 160 meet and are joined. The top layer 140,
`
`bottom layer 150 and sidewalls 160 can be secured to one another in any suitable manner,
`
`such as by adhesive or cohesive bonding material, by being bonded together during formation
`
`of the top layer 140, bottom layer 150, and sidewalls 160, by tapc, hook and loop fastcncr
`
`material, or conventional fasteners, by stitches extending at least partially through the top
`
`layer 140, bottom layer 150, and/or sidewalls 160, or in any other suitable manner.
`
`[0016]
`
`The top layer 140, bottom layer 150 and sidewalls 160 can have any thickness
`
`desired. By way of example only, in some embodiments the top layer 140, bottom layer 150,
`
`and sidewalls 160 are each approximately 1cm in thickness. In other embodiments, the top
`
`layer 140, bottom layer 150 and sidewalls 160 can be less than lcm thick or greater than lcm
`
`thick.
`
`[0017]
`
`By virtue of the generally box-shaped core structure defined by the top layer 140,
`
`bottom layer 150, and sidewalls 160 in some embodiments, the pillow 100 can provides
`
`enhanced support to a user, as well as providing space for the filler material 180.
`
`[0018]
`
`In some embodiments, the top layer 140, bottom layer 150 and sidewalls 160 can
`
`include one or more rclcasablc fastcncrs (c.g., zippcrs, buttons, clasps, laccs, hook and loop
`
`fastener material pieces, hook and eye sets, tied ribbons, strings, cords, or other fastener
`
`elements). Such fasteners can be located between the top layer 140 and sidewall 160,
`
`between a sidewall 160 and the bottom layer 150, or within an opening in the top layer 140,
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 5
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`sidewall 160, and/or bottom layer 150, and can be positioned to allow access to the cavity
`
`170, such as to remove or add filler material 180 within the cavity 170. By way of example
`
`only, the top layer 140 can have a zippered slot through which filler material 180 can be
`
`inserted and removed.
`
`[0019]
`
`In some embodiments, the top layer 140 and/or bottom layer 150 comprises visco-
`
`elastic foam (sometimes referred to as "memory foam" or "low resilience foam"). In such
`
`embodiments, the top layer 140 and bottom layer 150 can have a hardness of at least about 30
`
`N and no greater than about 175 N for desirable softness and body-conforrning qualities. In
`
`other embodiments, visco-elastic foam top and bottom layers 140, 150 having a hardness of
`
`at least about 40 N and no greater than about 110 N are used for this purpose. In still other
`
`embodiments, visco-elastic foam top and bottom layers 140, 150 having a hardness of at least
`
`about 40 N and no greater than about 75 N are utilized. Unless otherwise specified, the
`
`hardness of a material referred to herein is measured by exerting pressure from a plate against
`
`a sample of the material having length and width dimensions of 40 cm each (defining a
`
`surface area of the sample of material), and a thickness of 5 cm to a compression of 40% of
`
`an original thickness of the material at approximately room temperature (c.g., 21-23 degrees
`
`Celsius), wherein the 40% compression is held for a set period of time, following the
`
`International Organization of Standardization (ISO) 2439 hardness measuring standard.
`
`[0020]
`
`In those embodiments having visco-elastic top and/or bottom layers 140, 150, the
`
`visco-elastic foam of such layers 140, 150 can also have a density providing a relatively high
`
`degree of material durability. The density of the visco-elastic foam in such embodiments can
`
`also impact other characteristics of the foam, such as the manner in which the top layer 140
`
`and bottom layer 150 respond to pressure, and the feel of the foam. In some embodiments,
`
`the visco-elastic foam of the top layer 140 and/or bottom layer 150 has a density of no less
`
`than about 30 kg/m3 and no greater than about 150 kg/m3 . In other embodiments, a visco-
`
`elastic foam top layer 140 and/or bottom layer 150 having a density of at least about 70 kg/m3
`
`and no greater than about 130 kg/m3 is utilized. In still other embodiments, a visco-elastic
`
`foam top layer 140 and/or bottom layer 150 having a density of at least about 80 kg/m3 and
`
`no greater than about 120 kg/mg is utilized.
`
`[0021]
`
`The visco-elastic foam of the top layer 140 and/or bottom layer 150 can be
`
`selected for responsiveness to any range of temperatures. However, in some embodiments, a
`
`temperature responsiveness in a range of a user's body temperatures (or in a range of
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 6
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`temperatures to which the pillow 100 is exposed by contact or proximity to a user's body
`
`resting thereon) can provide significant advantages. For example, a visco-elastic foam
`
`selected for the top layer 140 and/or bottom layer 150 can be responsive to temperature
`
`changes above at least about 0°C. In some embodiments, a visco-elastic foam selected for
`
`the top layer 140 and/or bottom layer 150 can be responsive to temperature changes within a
`
`range of at least about 10°C. In other embodiments, a visco-elastic foam selected for the top
`
`layer 140 and/or bottom layer 150 can be responsive to temperature changes within a range of
`
`at least about 15°C. As used herein, a material is considered "responsive" to temperature
`
`changes if the material exhibits a change in hardness of at least 10% measured by ISO
`
`Standard 3386 through the range of temperatures between 10 and 30 degrees Celsius.
`
`[0022]
`
`In some embodiments, significant advantages are achieved by utilizing reticulated
`
`visco-elastic foam for the top layer 140 and/or bottom layer 150 of the pillow 100. As will be
`
`described in greater detail below, reticulated foam can provide significantly increased
`
`ventilation for the top and/or bottom layer 140, 150 of the pillow 100, thereby enhancing the
`
`ability of the pillow 100 to transport heat away from the user’s body thereon. Such use of
`
`rcticulatcd foam can also enhance the ability of the pillow 100 to wick moisture away from
`
`the user’s body thereon.
`
`[0023]
`
`Reticulated foam (visco-elastic or otherwise) is a cellular foam structure in which
`
`the cells of the foam are essentially skeletal. In other words, the cells of the reticulated foam
`
`are each defined by a plurality of apertured windows surrounded by cell struts. The cell
`
`windows of reticulated foam can be entirely gone (leaving only the cell struts) or
`
`substantially gone. In some embodiments, the foam is considered "reticulated" if at least
`
`50% of the windows of the cells are missing (i.e., windows having apertures therethrough, or
`
`windows that are completely missing and therefore leaving only the cell struts). Such
`
`structures can be created by destruction or other removal of cell window material, or
`
`preventing the complete formation of cell windows during the manufacturing process of the
`
`foam.
`
`[0024]
`
`By virtue of the skeletal cellular structure of reticulated visco-elastic foam used
`
`for the top layer 140 and/or the bottom layer 150, heat and moisture can be transferred away
`
`from the source of heat (e.g., a user's body), thereby helping to prevent one or more areas of
`
`the top layer 140 and bottom layer 150 from reaching an undesirably high temperature. Also,
`
`the reticulated structure of visco-elastic foam in the top layer 140 and/or bottom layer 150
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 7
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`enables significantly higher airflow into, out of, and through the top layer 140 and bottom
`
`layer 150 - a characteristic of the top layer 140 and bottom layer 150 that can reduce heat in
`
`the respective layer. At the same time, the visco-elastic nature of foam in the top layer 140
`
`and/or bottom layer 150 provides desirable tactile contact and pressure responsiveness for
`
`user comfort. In this regard, the reticulated visco-elastic foam of some embodiments has a
`
`reduced hardness level, thereby providing a relatively soft and comfortable surface for a
`
`user's body. In conjunction with the slow recovery characteristic of reticulated visco-elastic
`
`foam, the top layer 140 and/or bottom layer 150 can also at least partially conform to the
`
`user's body, thereby distributing the force applied by the user's body upon the top layer 140
`
`and/or bottom layer 150.
`
`[0025]
`
`In some embodiments, reticulated visco-elastic foam used for the top layer 140
`
`and/or bottom layer 150 can have a hardness of at least about 20 N and no greater than about
`
`150 N for desirable softness and pressure-responsive qualities. In other embodiments, a top
`
`layer 140 and/or bottom layer 150 of reticulated visco-elastic foam having a hardness of at
`
`least about 30 N and no greater than about 100 N is utilized. In still other embodiments, a top
`
`layer 140 and/or bottom layer 150 of rcticulatcd visco-elastic foam having a hardness of at
`
`least about 40 N and no greater than about 85 N is utilized.
`
`[0026]
`
`Reticulated visco-elastic foam used for the top layer 140 and/or bottom layer 150
`
`can also have a density providing a relatively high degree of material durability. As noted
`
`above with regard to non-reticulated visco-elastic foam, the density of reticulated visco-
`
`elastic foam of top layer 140 and/or bottom layer 150 can also impact other characteristics of
`
`the foam, such as the manner in which the respective surface responds to pressure, and the
`
`feel of the foam. In some embodiments, the top layer 140 and/or bottom layer 150 is
`
`constructed of reticulated visco-elastic foam having a density of no less than about 30 kg/m3
`
`and no greater than about 175 kg/m3. In other embodiments, a top layer 140 and/or bottom
`
`layer 150 of reticulated visco-elastic foam having a density of at least about 50 kg/m3 and no
`
`greater than about 120 kg/m3 is utilized. In still other embodiments, a top layer 140 and/or
`
`bottom layer 150 of reticulated visco-elastic foam having a density of at least about 70 kg/ms
`
`and no greater than about 95 kg/m3 is utilized.
`
`[0027]
`
`Reticulated visco-elastic foam of the top layer 140 and/or bottom layer 150 can be
`
`selected for responsiveness to any range of temperatures. However, in some embodiments, a
`
`temperature responsiveness in a range of a user’s body temperatures (or in a range of
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 8
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`temperatures to which the pillow 100 is exposed by contact or proximity to a user’s body
`
`resting thereon) can provide significant advantages. For example, a reticulated visco-elastic
`
`foam selected for the top layer 140 and/or bottom layer 150 can be responsive to
`
`temperatures changes (as defined above) above at least 0°C. In some embodiments, the
`
`reticulated visco-elastic foam selected for the top layer 140 and/or bottom layer 150 can be
`
`responsive to temperature changes within a range of at least about 10°C. In other
`
`embodiments, the reticulated visco-elastic foam selected for the top layer 140 and/or bottom
`
`layer 150 can be responsive to temperature changes within a range of at least about 15°C.
`
`[0028]
`
`Although reticulated or non-reticulated visco-elastic foam used for the top layer
`
`140 and/or bottom layer 150 presents significant and unique advantages in many
`
`embodiments of the present invention, it should be appreciated that other types of foam can
`
`be used to construct either or both layers 140, 150, including without limitation polyurethane
`
`foam, latex foam, any expanded polymer (e. g., expanded ethylene vinyl acetate,
`
`polypropylene, polystyrene, or polyethylene), and the like.
`
`[0029]
`
`In some embodiments of the present invention, the pillow 100 is provided with
`
`sidewalls 160 that are highly porous, and therefore provide a significant degree of ventilation
`
`for the pillow, allowing air to enter and exit the pillow 100 readily through the sides of the
`
`pillow 100. The inventors have discovered that this capability is achieved through use of a
`
`3D textile core sidewall 160, which has the added benefit of providing structural strength to
`
`the pillow 100 to retain the box-shaped core structure described above. As alternatives to the
`
`3D textile material, other breathable fabrics can instead be used as desired.
`
`[0030]
`
`The filler material 180 of the pillow 100 can include, but is not limited to,
`
`granulated visco-elastic foam (e. g., visco-elastic foam that has been shredded, chopped, and
`
`the like, visco-elastic foam balls, discs, plates, or other pieces, and the like). The granulated
`
`visco-elastic foam can be reticulated or non-reticulated visco-elastic foam, or a combination
`
`of such foams. By virtue of its porosity, reticulated visco-elastic foam can be highly
`
`attractive for use as granulated filler material 180, enabling a greater degree of pillow
`
`ventilation, heat transport away from the user’s body, and moisture wicking away from the
`
`user’s body. The granulated visco-elastic foam filler material 180 can comprise a number of
`
`loose pieces of visco-elastic foam having the same or different sizes and shapes at least
`
`partially filling the cavity 170 of the core 110.
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 9
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`[0031]
`
`The filler material 180 is a supportive layer providing a relatively stiff but flexible
`
`and resilient substrate. The resiliently deformable nature of the filler l80 can therefore
`
`provide a degree of user comfort to the extent that the user's weight affects the shape of the
`
`pillow 100. In some embodiments, the filler material 180 has a hardness of at least about 50
`
`N and no greater than about 300 N for a desirable degree of support and comfort. In other
`
`embodiments, the filler material 180 has a hardness of at least about 80 N and no greater than
`
`about 250 N. In still other embodiments, the filler material 180 has a hardness of at least
`
`about 90 N and no greater than about 180 N.
`
`[0032]
`
`Like visco-elastic foam used for the top layer 140 and/or bottom layer 150 of the
`
`pillow 100, visco-elastic foam filler material 180 can have a density providing a relatively
`
`high degree of material durability. Also, the density of such filler material 180 can impact
`
`other characteristics of the visco-elastic foam, such as the manner in which the filler material
`
`180 responds to pressure, and the feel of the foam. In some embodiments, the filler material
`
`180 has a density of about 85 kg/m3 . However, a suitable density for visco-elastic foam filler
`
`material 180 for an average weight pillow 100, for example, can be between about 30 and
`
`about 140 kg/m3. Further, a suitable density for visco-elastic foam filler material 180 for a
`
`light-weight pillow 100, for example, can be less than about 40 kg/m3 . Likewise, a suitable
`
`density for visco-elastic foam filler material 180 for a heavy-weight pillow 100, for example,
`
`can be greater than about 130 kg/m3. Alternatively, the granulated visco-elastic foam utilized
`
`as the filler material 180 can have any density in accordance with the desired characteristics
`
`of the pillow 100.
`
`[0033]
`
`In some embodiments, non-reticulated visco-elastic foam filler material 180
`
`having a density of no less than about 30 kg/m3 and no greater than about 150 kg/m3 is used.
`
`In other embodiments, a non-reticulated visco-elastic foam filler 180 having a density of at
`
`least about 70 kg/m3 and no greater than about 130 kg/m3 is utilized. In still other
`
`embodiments, a reticulated visco-elastic foam filler 180 having a density of at least about 80
`
`kg/m3 and no greater than about 120 kg/m3 is utilized.
`
`[0034]
`
`Alternatively, reticulated visco-elastic foam filler material 180 having a density
`
`of no less than about 30 kg/m3 and no greater than about 175 kg/m3 is used. In other
`
`embodiments, a non-reticulated visco-elastic foam filler 180 having a density of at least about
`
`50 kg/m3 and no greater than about 120 kg/m3 is utilized. In still other embodiments, a
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 10
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`reticulated visco-elastic foam filler 180 having a density of at least about 70 kg/m3 and no
`
`greater than about 95 kg/m3 is utilized.
`
`[0035]
`
`In addition, a suitable visco-elastic foam filler material 180 possesses an
`
`indentation load deflection, or “ILD,” of 65% between 100-500 N loading, and a maximum
`
`10% rebound according to the test procedure governed by the ASTM-D-1564 standard.
`
`[0036]
`
`The granulated filler material 180 can be made up of recycled, virgin, or scrap
`
`reticulated and/or non-reticulated visco-elastic foam material. The granulated filler material
`
`180 may consist of pieces of a nominal length, or the granulated filler material 180 may
`
`consist of pieces of varying lengths. For example, granulated filler material 180 may have a
`
`nominal length of about 1.3 cm. Also, granulated filler material 180 may consist of varying
`
`lengths between about 0.6 cm and about 2 cm. The granulated filler material 180 can be as
`
`short as 0.3 cm and as long as 4 cm., or the filler material 180 can be any length in
`
`accordance with the desired characteristics of the pillow 100. In some embodiments of the
`
`present invention, the granulated filler material 180 is comprised of 16-20% having a length
`
`longer than 2 cm, 38-42% having a length between 1 and 2 cm, and 38-42% of the pieces
`
`shorter than 1 cm. Significant cost savings and waste reduction can be realized by using
`
`scrap or recycled filler material 180 rather than virgin filler material 180. The visco-elastic
`
`foam used as the filler material 180 is made from a polyurethane foam material; however, the
`
`filler material 180 can be made from any other visco-elastic polymer material that exhibits
`
`similar properties.
`
`[0037]
`
`The composition of the filler material 180 can be varied to alter the
`
`characteristics of the pillow 100 and the cost of the pillow 100. In some embodiments of the
`
`present invention, the filler material 180 is a combination of granulated visco-elastic foam
`
`and a fiber material. The fiber material can be made from any kind of textile, such as an
`
`organic textile (cotton) or a synthetic textile, which is often less expensive than visco-elastic
`
`foam. In some embodiments of the present invention, the fiber material has a density of
`
`about 1 g/cm3. However, a suitable density for the fiber material for an average weight
`
`pillow 100, for example, is 0.1 — 2 g/cmg. Further, a suitable density for the fiber material for
`
`a light-weight pillow 100, for example, can be less than about 0.3 g/cm3 . Likewise, a suitable
`
`density for the fiber material for a heavy-weight pillow 100, for example, can be greater than
`
`about 1.8 g/cm3. Alternatively, the fiber material utilized in combination with the granulated
`
`IPR2017-00351
`
`IPR2017-00351
`Fredman EX1006 Page 11
`
`
`
`WO 2010/075294
`
`PCT/US2009/069018
`
`visco-elastic foam as the filler material 180 can have any density in accordance with the
`
`desired characteristics of the pillow l00.
`
`[0038]
`
`In some embodiments of the present invention, the filler material 180 is
`
`comprised of about 50% fiber material, while the remaining composition includes granulated
`
`visco-elastic foam as described above. However, a suitable range of fiber material in the
`
`filler material 180 for an average-cost pillow 100, for example, can be between about 20%
`
`and about 80%. Further, a suitable range of fiber material in the filler material 180 for a more
`
`expensive pillow 100, for example, can be more than about 30% of the filler material 180.
`
`Likewise, a suitable range of fiber material in the filler material 180 for a less expensive
`
`pillow 100, for example, can be greater than about 70% of the filler material 180.
`
`[0039]
`
`In still other embodiments of the present invention, the filler material 180 is a
`
`combination of granulated visco-elastic foam and polystyrene balls, which are often less
`
`expensive than visco-elastic foam. The filler material 180 of such embodiments can also
`
`include an organic or synthetic fiber material, depending on the desired characteristics of the
`
`pillow 100. The polystyrene balls may consist of balls of a nominal diameter, or the
`
`polystyrene balls may consist of balls of varying diameters. For example, the polystyrene
`
`balls may have a nominal diameter of about 5mm. Also, the polystyrene balls may consist of
`
`varying diameters between about 1 mm and about 10 mm. The polystyrene balls can also be
`
`as small as 0.5 mm and as long as 20mm, or the polystyrene balls can be any length in
`
`accordance with the desired characteristics of the pillow 100.
`
`[0040]
`
`In some embodiments of the present invention, the filler material 180 is
`
`comprised of about 50% polystyrene balls, while the remaining composition includes
`
`granulated visco-elastic foam as described above. However, a suitable range of polystyrene
`
`balls in the filler material 180 for an av