Document made
`
`available under
`
`the
`
`Patent Cooperation Treaty (PCT)
`
`International application number: PCT/US2009/069018
`
`International filing date:
`
`21 December 2009 (21.12.2009)
`
`Document type:
`
`Certified copy of priority document
`
`Document details:
`
`Country/Office: US
`Number:
`61/ 140,622
`
`Filing date:
`
`24 December 2008 (24.12.2008)
`
`Date of receipt at the International Bureau:
`
`11 January 2010 (11.01.2010)
`
`Remark:
`
`Priority document submitted or transmitted to the International Bureau in
`compliance with Rule 17.1(a) or (b)
`
`
`
`World Intellectual Property Organization (WIPO) - Geneva, Switzerland
`Organisation Mondiale de la Propriété Intellectuelle (OMPI) - Geneve, Suisse
`
`|PR2017-00351
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`Fredman EX1007 Page 1
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`IPR2017-00351
`Fredman EX1007 Page 1
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`

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`THE RECORDS OF THE UNITED STATES PATENT AND TRADEMARK
`OFFICE OF THOSE PAPERS OF THE BELOW IDENTIFIED PATENT
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`APPLICATION THAT MET THE REQUIREMENTS TO BE GRANTED A
`FILING DATE.
`
`
`
`APPLICATION NUMBER: 61/140,622
`FILING DATE: December 24, 2008
`RELATED PCT APPLICATION NUMBER: PCT/US09/6901 8
`
`
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` THE COUNTRY CODE AND NUMBER OF YOUR PRIORITY
`APPLICATION, TO BE USED FOR FILING ABROAD UNDER THE PARIS
`CONVENTION, IS US61/140, 622
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`IPR2017-00351
`Fredman EX1007 Page 2
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`

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`Attorney Docket No. 070l63—9474—00
`
`BACKGROUND
`
`PILLOW
`
`[0001]
`
`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.
`
`[0002]
`
`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.
`
`[0003]
`
`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.
`
`[0004]
`
`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
`
`[0005]
`
`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 textile material or a
`
`velour or stretch velour material) corresponding to and covering the sides of the core and/or a
`
`highly porous bottom (e.g., again, made of a 3D textile material or a velour or stretch velour
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`Attorney Docket No. 070l63—9474—00
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`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.
`
`[0006]
`
`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.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0007]
`
`FIG. l 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.
`
`[0008]
`
`FIG. 2 is a detail cross-sectional view of the pillow of FIG. l.
`
`[0009]
`
`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 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.
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`Attorney Docket No. 070l63—9474—00
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`DETAILED DESCRIPTION
`
`[0010]
`
`A pillow 100 according to an embodiment of the present invention is illustrated in
`
`FIGS. 1-2. The pillow 100 comprises a core ll0 having a plurality of lobes 120, 130 extending
`
`from a central portion of the core 110. In some embodiments, the lobes 120, 130 all have
`
`substantially the same size. However, in other embodiments (including that shown in FIG. 1),
`
`the lobes 120, 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 of the present
`
`invention. Also, in other embodiments, the core 110 can have three lobes, five lobes, or more
`
`lobes of the same or different size. In any case, the lobes 120, 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.
`
`[0011]
`
`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 oined, 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 tape, hook and loop fastener material, or conventional
`
`fasteners, by stitches extending at least partially through the top layer 140, bottom layer 150, and
`
`sidewalls 160, or in any other suitable manner.
`
`[0012]
`
`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,
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`and sidewalls 160 are each approximately lcm 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.
`
`[0013]
`
`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.
`
`[0014]
`
`In some embodiments, the top layer 140, bottom layer 150 and sidewalls 160 can
`
`include one or more releasable fasteners (e. g., zippers, buttons, clasps, laces, 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, sidewall 160,
`
`or bottom layer 150, and can be positioned to allow access to the cavity 170, such as to remove
`
`or add filler material l80 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.
`
`[0015]
`
`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-conforming 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 ll0 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 (e. 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.
`
`[0016]
`
`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
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`Attorney Docket No. 070l63—9474—00
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`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/mg. 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/m3
`
`is utilized.
`
`[0017]
`
`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 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.
`
`[0018]
`
`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 reticulated foam
`
`can also enhance the ability of the pillow 100 to wick moisture away from the user’s body
`
`thereon.
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`Attorney Docket No. 070l63—9474—00
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`[0019]
`
`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.
`
`[0020]
`
`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 enables
`
`significantly higher airflow into, out of, and through the top layer l40 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.
`
`[0021]
`
`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 reticulated visco-elastic foam having a hardness of at least about 40 N and
`
`no greater than about 85 N is utilized.
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`Attorney Docket No. 070163—9474—00
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`[0022]
`
`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/m3 and no greater than about 95 kg/m3 is
`
`utilized.
`
`[0023]
`
`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
`
`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.
`
`[0024]
`
`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.
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`Attorney Docket No. 070l63—9474—00
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`[0025]
`
`In some embodiments of the present invention, the pillow 100 is provided with
`
`sidewalls l60 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
`
`l00. 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.
`
`[0026]
`
`The filler material l80 of the pillow l00 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 l80 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 l70 of the core 1 l0.
`
`[0027]
`
`The filler material l80 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 l80 has a hardness of at least about 90 N and no greater than
`
`about 180 N.
`
`[0028]
`
`Like visco-elastic foam used for the top layer 140 and/or bottom layer 150 of the
`
`pillow 100, visco-elastic foam filler material l80 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
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`Attorney Docket No. 070l63—9474—00
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`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 l30 kg/m3. Alternatively, the granulated visco-elastic foam utilized as the filler material
`
`l80 can have any density in accordance with the desired characteristics of the pillow l00.
`
`[0029]
`
`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
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`embodiments, a non-reticulated visco-elastic foam filler 180 having a density of at least about 70
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`kg/m3 and no greater than about l30 kg/m3 is utilized. In still other embodiments, a reticulated
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`visco-elastic foam filler 180 having a density of at least about 80 kg/m3 and no greater than about
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`120 kg/m3 is utilized.
`
`[0030]
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`Alternatively, reticulated visco-elastic foam filler material l80 having a density of
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`no less than about 30 kg/m3 and no greater than about l75 kg/m3 is used. In other embodiments,
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`a non-reticulated visco-elastic foam filler 180 having a density of at least about 50 kg/m3 and no
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`greater than about l20 kg/ms is utilized. In still other embodiments, a reticulated visco-elastic
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`foam filler l80 having a density of at least about 70 kg/m3 and no greater than about 95 kg/m3 is
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`utilized.
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`[0031]
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`In addition, a suitable visco-elastic foam filler material 180 possesses an indentation
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`load deflection, or “ILD,” of 65% between 100-500 N loading, and a maximum 10% rebound
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`according to the test procedure governed by the ASTM-D-1564 standard.
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`[0032]
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`The granulated filler material 180 can be made up of recycled, virgin, or scrap
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`reticulated and/or non-reticulated visco-elastic foam material. The granulated filler material 180
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`may consist of pieces of a nominal length, or the granulated filler material l80 may consist of
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`pieces of varying lengths. For example, granulated filler material l80 may have a nominal
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`length of about 1.3 cm. Also, granulated filler material 180 may consist of varying lengths
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`between about 0.6 cm and about 2 cm. The granulated filler material 180 can be as short as 0.3
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`cm and as long as 4 cm., or the filler material 180 can be any length in accordance with the
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`desired characteristics of the pillow 100. In some embodiments of the present invention, the
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`granulated filler material l80 is comprised of l6-20% having a length longer than 2 cm, 38-42%
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`having a length between 1 and 2 cm, and 38-42% of the pieces shorter than 1 cm. Significant
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`cost savings and waste reduction can be realized by using scrap or recycled filler material 180
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`rather than virgin filler material 180. The visco-elastic foam used as the filler material 180 is
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`made from a polyurethane foam material; however, the filler material 180 can be made from any
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`other visco-elastic polymer material that exhibits similar properties.
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`[0033]
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`The composition of the filler material l80 can be varied to alter the characteristics
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`of the pillow 100 and the cost of the pillow 100. In some embodiments of the present invention,
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`the filler material 180 is a combination of granulated visco-elastic foam and a fiber material.
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`The fiber material can be made from any kind of textile, such as an organic textile (cotton) or a
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`synthetic textile, which is often less expensive than visco-elastic foam. In some embodiments of
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`the present invention, the fiber material has a density of about l g/cm3. However, a suitable
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`density for the fiber material for an average weight pillow l00, for example, is 0.1 — 2 g/cm3.
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`Further, a suitable density for the fiber material for a light-weight pillow l00, for example, can
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`be less than about 0.3 g/cm3. Likewise, a suitable density for the fiber material for a heavy-
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`weight pillow 100, for example, can be greater than about 1.8 g/cm3. Alternatively, the fiber
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`material utilized in combination with the granulated visco-elastic foam as the filler material l80
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`can have any density in accordance with the desired characteristics of the pillow 100.
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`[0034]
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`In some embodiments of the present invention, the filler material 180 is comprised
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`of about 50% fiber material, while the remaining composition includes granulated visco-elastic
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`foam as described above. However, a suitable range of fiber material in the filler material 180
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`for an average-cost pillow 100, for example, can be between about 20% and about 80%. Further,
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`a suitable range of fiber material in the filler material 180 for a more expensive pillow l00, for
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`example, can be more than about 30% of the filler material l80. Likewise, a suitable range of
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`fiber material in the filler material 180 for a less expensive pillow 100, for example, can be
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`greater than about 70% of the filler material l80.
`
`[0035]
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`In still other embodiments of the present invention, the filler material l80 is a
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`combination of granulated visco-elastic foam and polystyrene balls, which are often less
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`10
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`expensive than visco-elastic foam. The filler material 180 of such embodiments can also include
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`an organic or synthetic fiber material, depending on the desired characteristics of the pillow l00.
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`The polystyrene balls may consist of balls of a nominal diameter, or the polystyrene balls may
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`consist of balls of varying diameters. For example, the polystyrene balls may have a nominal
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`diameter of about 5mm. Also, the polystyrene balls may consist of varying diameters between
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`about l mm and about l0 mm. The polystyrene balls can also be as small as 0.5 mm and as long
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`as 20mm, or the polystyrene balls can be any length in accordance with the desired
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`characteristics of the pillow 100.
`
`[0036]
`
`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-
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`elastic foam as described above. However, a suitable range of polystyrene balls in the filler
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`material 180 for an average-cost pillow 100, for example, can be between about 20% and about
`
`80%. Further, a suitable range of polystyrene balls in the filler material l80 for a more
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`expensive pillow l00, for example, can be less than about 30% of the filler material 180.
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`Likewise, a suitable range ofpolystyrene balls in the filler material l80 for a less expensive
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`pillow 100, for example, can be greater than about 70% of the filler material l80.
`
`[0037]
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`The filler material l80 can also include granulated highly-elastic (“HE”) foam in
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`addition to the granulated visco-elastic foam described above. HE foam is often less expensive
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`than visco-elastic foam, thus yielding a potentially less expensive pillow 100. The filler material
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`can be comprised of any single filler described above or any combination of the fillers.
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`Alternatively, the filler material 180 can also include any conventional materials, such as
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`feathers, granulated cotton, cotton fibers, etc. In some embodiments of the present invention, the
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`filler material 180 includes HE foam having a density of about 35 kg/m3. However, a suitable
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`density for the HE foam for an average weight pillow l00, for example, can be between about 20
`
`kg/m3 and about 50 kg/m3. Further, a suitable density for HE foam for a lightweight pillow l00,
`
`for example, can be less than about 25 kg/m3. Likewise, a suitable density for HE foam for a
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`heavyweight pillow l00, for example, can be greater than about 45 kg/m3. Alternatively, HE
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`foam utilized in the filler material l80 can have any density in accordance with the desired
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`characteristics of the pillow 100.
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`ll
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`[0038]
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`Granulated HE foam may consist of pieces of a nominal length, or granulated HE
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`foam may consist of pieces of varying lengths. For example, granulated HE foam may have a
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`nominal length of about 1.3 cm. Also, the granulated HE foam may consist of varying lengths
`
`between about 0.6 cm and about 2 cm. The granulated HE foam can be as short as 0.3 cm and as
`
`long as 4 cm., or the granulated HE foam can be any length in accordance with the desired
`
`characteristics of the pillow 100. In some embodiments of the present invention, the granulated
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`HE foam 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.
`
`[0039]
`
`In some embodiments of the present invention, the filler material 180 is comprised
`
`of about 50% granulated HE foam, while the remaining composition includes granulated visco-
`
`elastic foam as described above. However, a suitable range of HE foam in the filler material 180
`
`for an average cost pillow 100, for example, is 20% - 80%. Further, a suitable range of
`
`granulated HE foam in the filler material 180 for a more expensive pillow 100, for example, can
`
`be less than about 30% of