US006988286B2
`
`(12)
`
`United States Patent
`Schecter et al.
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 6,988,286 B2
`Jan. 24, 2006
`
`(54) CUSHIONING DEVICE AND METHOD OF
`PRODUCING THE SAME
`
`(75) Inventors: Daniel B. Schecter, Richmond, VA
`(Us); Jeffrey D- Martin, Richmond,
`VA (Us)
`(73) Assignee: Carpenter C0., Richmond, VA (US)
`
`7/1988 RinZ
`4,754,513 A
`7/1988 Spence et a1. ............ .. 428/159
`4,756,949 A *
`4,776,048 A * 10/1988 Wilheim ...................... .. 5/636
`47777855 A * 10/1988 Cohen
`4,930,173 A
`6/1990 Woller ................. .. 297/45248
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`( * ) Notice:
`
`.
`
`.
`
`.
`
`.
`
`SubJect to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154 b b 114 d
`.
`( ) y
`ays
`(21) Appl- N05 10/209,193
`_
`(22) Flled:
`(65)
`
`.
`
`EP
`
`258847 A1 * 3 1988
`
`/
`(Continued)
`OTHER PUBLICATIONS
`SmartBargains® 300TC Double Support While DoWn Gus
`seted Pillow, (Which Was available for sale on SmartBar
`gains® Website at least as early as Nov. 9, 2000 according
`t “
`b k
`h' ”
`.
`h'
`.
`.*
`0 Way ac mac me on WWWarc 1ve org)
`
`Aug‘ 1’ 2002
`Prior Publication Data
`
`US 2004/0019972 A1
`
`Feb. 5, 2004
`
`(51) Int- Cl-
`(200601)
`A47C 20/00
`(52) US. Cl. ........................................................ .. 5/645
`(58) Field of Classi?cation Search .................. .. 5/645,
`5/636, 655, 691
`See application ?le for complete search history.
`
`(56)
`
`References Cited
`
`U'S' PATENT DOCUMENTS
`2,759,200 A
`8/1956 Johnston
`2,805,428 A *
`9/1957 Buchman ..................... .. 5/645
`3,109,182 A * 11/1963 DOak - - - - - - - - - -
`- - - -- 5/636
`
`(Commued)
`Primary Examiner—Michael Safavi
`Assistant Examiner—Gay Ann Spahn
`(74) Attorney, Agent, or Firm—Smith Gambrell & Russell
`LLP
`
`(57)
`
`ABSTRACT
`
`A cushioning apparatus such as a pilloW Which includes an
`upper pocket With reception cavity for receiving preferably
`loose or grouped non-integral ?ller material such as doWn,
`?ber?ll or ?ber-balls and another pocket for receiving addi
`tional ?ller material such as a foam core ?ller material. The
`foam core ?ller material is preferably an integrated or
`monolithic foam body of, for example, visco-elastic or
`alternate polyurethane foam. The core preferably has a
`
`3,148,389 A *
`
`9/1964 Lustig - - - - -
`
`- - - -- 5/645
`
`non-planar upper surface contour alloWing for a relatively
`
`~ ~ ~ ~ ~ ~ -- 5/491
`3,175,230 A *
`3/1965 Herdal ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
`428/101
`37283346 A : 11/1966 Marsh ct a1~
`' ' ' " 5/645
`3,443,267 A *
`5/1969 S§hu°kman ' ' ' ' '
`3,594,833 A
`7/1971 Richter ............................ .. 5/1
`3’648’3O8 A
`3/1972 Greenwalt
`3,695,691 A * 10/1972 Putnam .................... .. 297/223
`.
`1/1980 Blankenship
`4,184,237 A *
`4,207,636 A *
`6/1980 Ceriani ..................... .. 428/101
`4,508,044 A *
`4/1985 Downey et a1. ..... .. 112/475.08
`4,753,480 A
`6/1988 Morell
`4,753,705 A *
`6/1988 Poncy ...................... .. 156/292
`
`thin, consistent height upper pocket thickness. The pilloW
`also preferably includes a loWer pocket joined about its
`periphery to the upper pocket such as by Way of an inter
`mediate gusset panel With beading and With the lower pocket
`also receiving loose or non-integrated ?ller material and
`-
`-
`With the bottom surface of the core preferably having a
`f
`h
`t. 1
`.th th t
`‘fzonvex Sur ace Sue as one Symme “Ca W1
`6 0p 51”‘
`“6'
`
`50 Claims, 6 Drawing Sheets
`
`IPR2017-00351
`Fredman EX1011 Page 1
`
`

`
`US 6,988,286 B2
`Page 2
`
`US. PATENT DOCUMENTS
`
`8/1990 Tesch
`4,949,411 A
`4,961,982 A 10/1990 Taylor
`4,975,996 A * 12/1990 Evans et al. ................. .. 5/731
`5,294,392 A *
`3/1994 Marcus ...... ..
`.. 264/118
`
`5,459,894 A * 10/1995 Buonocore . . . . . .
`
`. . . . . . .. 5/737
`
`297/452.32
`5,474,362 A * 12/1995 Albecker, III
`5,488,746 A *
`2/1996 Hudson ....................... .. 5/500
`5,500,295 A
`3/1996 Halm et al.
`5,557,816 A *
`9/1996 Pedersen et al. ............. .. 5/645
`5,659,911 A
`8/1997 Kirkbride et al.
`5,689,844 A * 11/1997 Liu ............................. .. 5/636
`5,769,489 A
`6/1998 Dellanno
`5,778,470 A *
`7/1998 Haider ........................ .. 5/645
`6,006,380 A 12/1999 Sramek
`6,159,574 A 12/2000 Landvik et al.
`6,182,312 B1 *
`2/2001 Walpin ........................ .. 5/636
`
`6,189,168 B1 *
`2/2001 Graebe . . . . . . . .
`. . . .. 5/644
`6,327,725 B1 * 12/2001 Veilleux et al. .............. .. 5/644
`6,347,421 B1
`2/2002 D’Emilio
`6,578,218 B2* 6/2003 Wassilefsky ................. .. 5/648
`6,602,579 B2* 8/2003 Landvik ....... ..
`.. 428/158
`6,760,935 B1 *
`7/2004 Burton et al. ................ .. 5/645
`2001/0018777 A1
`9/2001 Walpin
`2001/0021438 A1
`9/2001 Landvik
`2003/0177583 A1* 9/2003 Freeman ...................... .. 5/721
`2004/0194270 A1* 10/2004 Flippin ..................... .. 29/91.1
`
`FOREIGN PATENT DOCUMENTS
`
`EP
`FR
`
`0 270 014
`2 305 956
`
`6/1988
`12/1976
`
`OTHER PUBLICATIONS
`
`SmartBargains® 233TC Jumbo Firm Support Tri Chamber
`Pillow, (which was available for sale on SmartBargains®
`website at least as early as Nov. 9, 2000 according to
`“waybackmachine” on www.archive.org).*
`Carpenter Co. “Comfort Creations®—Personal ChoiceTM
`Bed Pillow” copy of bag packaging; @ 1998; 2 pgs.
`Carpenter Co. “Foamcor ® Pillow” copy of bag packaging;
`@ 1991; 2 pgs.
`Carpenter Co. “QuallofoamTM Bed Pillow” copy of bag
`packaging; @ 1991; 2 pgs.
`Carpenter Co. “HollofoamTM Bed Pillow” copy of bag
`packaging; @1994; 2 pgs.
`Carpenter Co. “New LifeTM Comfort Core PillowTM” copy
`of bag packaging; @ 1999; 2 pgs.
`“Memory Foam Beds and Mattresses” and “Pillow and Back
`Care Products” from the abed.com website, http://www.
`abed.com, pulled from internet Nov. 1, 2002, date ?rst
`publication available not known, 6 pgs.
`Sleep Innovations “Novaform Naturals”—1-pg. printout
`from Linens ’n Things website; http://www56.Int.com;
`pulled from Internet Dec. 6, 2002; product on market earlier.
`Sleep Innovations, “Novaform Naturals” pillow product, (7
`pages—breakout of insert facing portion).
`Carpenter Co. “Isotonic Sleep System Brochure”, date ?rst
`publication available not known.
`Carpenter Co. “Dual Comfort Bed Pillow” advertisement/
`insert, date ?rst publication available not known, 2 pgs.
`
`Carpenter Co. “Comfort Creations—Personal Choice”
`advertisement/insert, date ?rst publication available not
`known, @ 1998.
`Carpenter Co. “New Life Comfort Core Pillow” advertise
`ment/insert, date ?rst publication available not known.
`Carpenter Co. “New Life Comfort Core—Mattress Pad”
`advertisement/insert, date ?rst publication available not
`known, @ 2002.
`Carpenter Co. “Isotonic—Mattress Pad” advertisement/
`insert, date ?rst publication available not known, @ 2001.
`“Egyptian Cotton, Antibacterial Products, Indulgence” from
`the Carpenter Co. website, http://www.carpenter.com,
`pulled from the internet Jun. 21, 2002, date ?rst publication
`available not known, 3 pgs.
`“Density in Flexible Polyurethane Foam (FPF)” from the
`PFA website, http://www.pfa.org/ee/lesson1.html, pulled
`from internet internet on Jul. 26, 2002, date ?rst publication
`available not known, 4 pgs.
`“Properties that Affect FPF Performance” from the PFA
`website, http://www.pfa.org/ee/lesson1.html, Pulled from
`internet internet Jul. 26, 2002, date ?rst publication available
`not known, 4 pgs.
`“Typical Density Ranges for Different Foam Applications”
`from the Healthy Foundations website, http://www.
`healthyfoundationscom, pulled from internet Jul. 26, 2002,
`date ?rst publication available not known, 1 pg.
`“How I Became A Visco-Elastic Foam Junkie” from the
`Healthy Foundations website, http://www.healthyfounda
`tions.com, pulled from internet Jun. 21, 2002, date ?rst
`publication available not known, 2 pgs.Nov. 1, 2002.
`“Isotonic Standard Pillow” from the Healthy Foundations
`website, http://www.healthyfoundations.com, pulled from
`internet Jun. 21, 2002, date ?rst publication available not
`known, 2 pgs.
`“ Isotonic Topper Pad” from the Healthy Foundations
`website, http://www.healthyfoundations.com, pulled from
`internet Jun. 21, 2002, date ?rst publication available not
`known, 2 pgs.
`“Pressure Relief Memory Foam Products” from the Healthy
`Foundations website, http://www.healthyfoundations.com,
`pulled from internet Jun. 21, 2002, date ?rst publication
`available not known, 4 pgs.
`“Frequently Asked Questions” from the Healthy Founda
`tions website, http://www.healthyfoundations.com, pulled
`from internet Jun. 21, 2002, date ?rst publication available
`not known, 3 pgs.
`“FAQ’s—The Isotonic Mattress Set” from the Healthy
`Foundations website, http://www.healthyfoundations.com,
`pulled from internet Jun. 21, 2002, date ?rst publication
`available not known, 6 pgs.
`“Viscoelastic Cell, NASA Connection, Conforming, Anti
`Mite & Anti-Allergy Testimonials” from the TEMPUR
`PEDIC website, http://www.tempurpedic.com, pulled from
`internet Nov. 1, 2002, date ?rst publication available not
`known, 7 pgs.
`
`* cited by examiner
`
`IPR2017-00351
`Fredman EX1011 Page 2
`
`

`
`U.S. Patent
`
`Jan. 24, 2006
`
`Sheet 1 6f 6
`
`US 6,988,286 B2
`
`llllltl‘rlirvlul
`
`mm
`
`IPR2017-00351
`Fredman EX1011 Page 3
`
`

`
`U.S. Patent
`
`Jan. 24, 2006
`
`Sheet 2 6f 6
`
`US 6,988,286 B2
`
`IPR2017-00351
`Fredman EX1011 Page 4
`
`

`
`U.S. Patent
`
`Jan. 24, 2006
`
`Sheet 3 6f 6
`
`US 6,988,286 B2
`
`IPR2017-00351
`Fredman EX1011 Page 5
`
`

`
`U.S. Patent
`
`Jan. 24, 2006
`
`Sheet 4 6f 6
`
`US 6,988,286 B2
`
`IPR2017-00351
`Fredman EX1011 Page 6
`
`

`
`U.S. Patent
`
`Jan. 24, 2006
`
`Sheet 5 6f 6
`
`US 6,988,286 B2
`
`IPR2017-00351
`Fredman EX1011 Page 7
`
`

`
`U.S. Patent
`
`Jan. 24, 2006
`
`Sheet 6 6f 6
`
`US 6,988,286 B2
`
`IPR2017-00351
`Fredman EX1011 Page 8
`
`

`
`US 6,988,286 B2
`
`1
`CUSHIONING DEVICE AND METHOD OF
`PRODUCING THE SAME
`
`FIELD OF THE INVENTION
`
`The present invention is directed at a cushioning device
`With preferred embodiments directed at a pillow cushioning
`device, preferably a pilloW cushioning device having an
`intermediate foam core and one or more outer ?ller material
`?lled pockets.
`
`BACKGROUND OF THE INVENTION
`
`PilloWs come in a variety of forms, With the more typical
`consisting of rectangular, fabric enclosures ?lled With feath
`ers, doWn, chipped foam, or a polyester ?ll. These pilloWs
`may be shaped by the user to provide reasonably adequate
`support for the user While the user falls asleep. HoWever,
`many people suffer from an uncomfortable night’s sleep
`because of the inadequate support that their head and neck
`receive While using these traditional pilloWs throughout the
`night. This is because traditional pilloWs either have a body
`that is so soft that the neck support area compresses to result
`in no support, or the body is so ?rm that the head sits
`considerably higher than the shoulders of the user, resulting
`in an abnormal sleeping position. Chronic neck pain or
`stiffness and a tense upper back are often the result of these
`inadequate forms of support these traditional pilloWs pro
`vide.
`Various foam pilloWs have also been developed typically
`comprising a foam body taking the place of the above-noted
`?llers and inserted into an overall fabric enclosure. These
`foam based pilloWs avoid problems such as ?ller clumping
`and can facilitate Washing by alloWing for easier removal of
`the pilloW support from its fabric enclosure.
`There is also knoWn in the art a pilloW featuring a foam
`core generally surrounded by loose ?ber. There can be,
`hoWever, an undesirable degree of migration or area clump
`ing With a pilloW having a foam core generally surrounded
`by ?ber?ll Within a ticking.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`SUMMARY OF THE INVENTION
`
`2
`thickness of the ?rst pocket is preferably 0.5 to 2 inches.
`When the ?rst pocket ?ller material is a polyester ?ber?ll
`material, there is preferably utiliZed an amount of 2 to 12
`02s. per pocket With 5 to 8 02s. being preferable to facilitate
`providing the desired thickness in the pocket relative to the
`supporting core materials. Apreferred cushion is in the form
`of a pilloW With the ?rst and second pockets having the same
`characteristics (eg the average thickness of each pocket
`being 0.75 to 1.5 inches With 0.85 to 1.25 inches being a
`preferred sub-range).
`The core is preferably formed of a foam material (eg a
`polyurethane foam material including visco-elastic foam
`materials). Also, a preferred pilloW embodiment features a
`core With a convex exposed surface supporting the ?rst
`pocket, and also preferably a similar relationship (symmetric
`arrangement both core and ticking) for the second pocket
`and core bottom surface. A foam core of visco-elastic foam
`When utiliZed, preferably has a density of 30 to 60 kg/m3 and
`a hardness range of 25N to 90N measured at 25% compres
`sion at 20 degrees Celsius, and takes up a majority of the
`overall height of the cushion even relative to the sum of the
`upper and loWer pockets.
`The ?rst and second ?exible pockets are preferably con
`nected together such as by Way of an intermediate cover
`section Which is connected to a peripheral region of said ?rst
`and second ?exible pockets. The intermediate cover section
`preferably, further includes an intermediate gusset section
`extending peripherally about the core. The noted interme
`diate gusset section includes a ?rst peripherally extending
`upper gusset section, a second peripherally extending gusset
`section and an inner border line betWeen said upper and
`loWer peripherally extending gusset sections.
`There is also preferably included at least one bead de?n
`ing a border edge of at least one of said upper and loWer
`gusset sections. The bead(s) preferably include(s) a bead
`cord and a cloth covering for one or tWo possible upper and
`loWer gusset beads.
`The present invention also features a method of forming
`a cushion such as a pilloW that includes providing a cover
`having a ?rst pocket, a second pocket, and an intermediate
`pocket, inserting ?ller material in the ?rst and second
`pockets, and inserting a core ?ller in the intermediate
`pocket. The step of inserting ?ller material preferably
`includes inserting ?ller material of doWn, ?ber?ll, ?ber
`balls, etc. or combination thereof in each of the outer pockets
`(eg by hand or an automated process). Avisco-elastic foam
`or an alternate polyurethane foam core placed in the inter
`mediate pocket represent suitable core ?llers.
`
`BRIEF DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`FIG. 1 shoWs a perspective vieW of a ?rst embodiment of
`the pilloW of the present invention.
`FIG. 1A shoWs an enlarged cross-sectional vieW of a
`portion of FIG. 1 along cross-section line IA—IA (see also
`the circled region in FIG. 4).
`FIG. 1B shoWs an enlarged cross-sectional vieW of
`another portion of FIG. 1 along cross-section line IB—IB
`(see also the circled region in FIG. 4).
`FIG. 2 shoWs an elevational end vieW of the pilloW of
`FIG. 1 With intermediate cut aWay.
`FIG. 3 shoWs an elevational side vieW of the pilloW of
`FIG. 1 With an intermediate cut aWay.
`FIG. 4 shoWs a cross-sectional vieW of the pilloW of FIG.
`1 taken along cross-section line IV—IV in FIG. 3.
`
`45
`
`50
`
`The present invention is directed at providing a cushion
`ing device such as a pilloW or mattress topper Which utiliZes
`a core and outer layer arrangement generally directed at
`providing desirable load support features in conjunction
`With good “look and feel” contact characteristics.
`An embodiment of the present invention includes a cush
`ion apparatus having a ?rst ?exible pocket de?ning a ?ller
`reception cavity With a ?rst pocket ?ller material received
`Within the reception cavity of the ?rst ?exible pocket.
`Preferably, the ?rst pocket ?ller material is formed of a
`compilation of individual ?ller material components. A
`preferred embodiment also features a second ?exible pocket
`55
`de?ning a second ?ller reception cavity Within Which is
`received second pocket ?ller material. A ?exible core is
`positioned betWeen the ?rst and second ?exible pockets such
`as an arrangement Where the upper pocket fully covers the
`top of the ?exible (e. g. foam) core and the loWer pocket fully
`covers the loWer surface of the core With each preferably
`having peripheral overhang. The second pocket ?ller mate
`rial is also preferably formed of a compilation of individual
`?ller material components such as doWn material, polyester
`?ber?ll material, and/or polyester ?ber-ball material.
`When doWn is used as a ?ller material, an amount of 2 to
`5 02s. (e.g. 4.5 or 5 02s.) is preferred, and the average
`
`60
`
`65
`
`IPR2017-00351
`Fredman EX1011 Page 9
`
`

`
`US 6,988,286 B2
`
`3
`FIG. 5 shows a cross-sectional vieW of the pillow of FIG.
`1 taken along cross-section line V—V in FIG. 2.
`FIG. 6 shows a perspective vieW of a foam core of the
`present invention.
`FIG. 7 shoWs a schematic side vieW of a foam core of the
`present invention.
`FIG. 8 shoWs a schematic end elevational vieW of the
`foam core.
`FIG. 9 shoWs a top plan vieW of the foam core.
`FIG. 10 shoWs a schematic vieW of a pilloW of the present
`invention in side vieW With ?ller and outer covering.
`FIG. 11 shoWs an end elevational vieW of an alternate
`embodiment of the pilloW of the present invention.
`FIG. 12 shoWs a cross-sectional vieW taken along cross
`section line XII—XII in FIG. 11.
`FIG. 13 shoWs in schematic cutaWay fashion a cushioning
`device such as a mattress topper.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`
`FIG. 1 shoWs, in perspective, a ?rst embodiment of the
`present invention in the form of pilloW 20. As shoWn in FIG.
`1, pilloW 20 comprises cover 22 Which is of a ?exible
`material such as a textile material, non-Woven material,
`plastic sheeting or laminate. That is, various cover materials
`are usable depending on the desired environment of use,
`including, for example, Water impervious and non-Water
`impervious materials (eg vinyl sheeting, neoprene fabric,
`natural ?ber fabrics such as cotton, man-made ?ber fabrics
`such as polyester and Woven and unWoven materials as a feW
`examples). In a preferred embodiment, the cover material is
`a breathable fabric such as cotton (eg 100% or mixtures
`With other materials such as polyester or rayon) having, for
`example, a thread count of 200 to 300). Cover 22 is loose
`enough to enable the cover to conform to depressions and
`contortions anticipated in use such as the compression forces
`induced by the head and limited by the interior pilloW core
`contents described beloW. The cover is strong enough,
`hoWever, to avoid ripping during usage and in most uses is
`machine Washable.
`As can be seen from a revieW of FIGS. 1, 2 and 3, cover
`22 includes an upper top layer 24. It should be noted that
`“top” and “bottom” have been used merely to facilitate the
`discussion of the illustrated embodiments, as the pilloW can
`be used With the illustrated “top” layer in the doWn or
`support contact position. Top layer 24 can be of a variety of
`peripheral shapes such as those most common in pilloWs
`(e.g., rectangular and circular), With a rectangular embodi
`ment being illustrated. FIG. 1 thus illustrates pilloW 20
`having ends 26, 28 and more elongated sides 30, 32. In a
`preferred embodiment of the present invention, because of
`the shape of the beloW described interior pilloW contents,
`upper top layer 24 assumes a convex cross-section end-to
`end and a conforming cross-sectional convex surface in the
`side-to-side direction as Well.
`As further shoWn in FIG. 1, pilloW 20 has an intermediate
`gusset Zone 34 Which preferably extends about the entire
`periphery of pilloW 20, although alternate embodiments of
`the invention include variations relative to this feature, such
`as a no gusset panel, tWo edge or three edge only gusset
`embodiments, or Where gussets are only provided along the
`elongated sides or a portion of the periphery or around all
`sides but for one side or section made openable for interior
`access.
`FIGS. 1—3 also illustrate pilloW 20 having loWer bottom
`layer 36 Which preferably is similar in material and general
`
`4
`layout relative to that of upper top layer 24. Intermediate
`gusset Zone 34 is also preferably of the same material
`utiliZed for the top and bottom layers, but other material
`combinations are included in the present invention includ
`ing, for example, elastic material intermediate panels. Inter
`mediate gusset Zone 34 is also preferably centrally posi
`tioned relative to the upper top layer 24 and loWer bottom
`layer 36, but can also be provided so as to be closer to the
`top or bottom layer also such as by Way of an added cloth
`?ange extension.
`At the border betWeen gusset 34 and upper top layer 24,
`there is preferably provided an external, border edge or bead
`edge 38 Which extends, in a preferred embodiment, continu
`ously along sides 30, 32 and ends 26, 28 at the junction
`betWeen the gusset Zone 34 and the top layer 24. In the
`region of end 28 there is also preferably provided an access
`opening Which in a preferred embodiment is access con
`trolled by access means such as Zipper 40 extending along
`end 28 With Zipper ends positioned just inWard of each side
`30, 32. In FIG. 1, one of the ends includes Zipper handle 42.
`The section of bead 38 extending along end 28 is pref
`erably positioned immediately beloW the loWer half teeth
`run of the Zipper 40 supported by a cloth or plastic strip base
`Which in turn is secured to cover 22 on one side and on an
`opposite side, to the bead and/or to an upper region of the
`gusset Zone. The bead and loWer Zipper tooth run (the actual
`teeth) are thus preferably arranged in a side-to-side relation
`ship (e.g., in abutting contact) When the Zipper is in an
`unZippered state.
`FIG. 1 also illustrates gusset Zone 34 as comprising upper
`gusset section 44, interior dividing line 46 and loWer gusset
`section 48. Upper gusset section 44, in the rectangular
`embodiment illustrated, forms four corners, three of Which
`are shoWn in FIG. 1 and represented by reference numbers
`50, 52 and 54. In a preferred embodiment, upper gusset
`section 44 is continuous and uninterrupted With the visible
`gusset corners being smooth transition corners in the gen
`erally rectangular con?guration of the pilloW (similar to the
`smooth cornered beading 38) With hidden, interior ruf?ed
`corner Zones (not shoWn) to accommodate the curvature.
`With reference to FIG. 1A, taken along cross-section line,
`IA—IA of FIG. 1, bead 38 is preferably comprised of a bead
`insert 56 such as a string cord and bead cover 59. Bead insert
`56 preferably runs continuously about pilloW 20 to de?ne a
`circular cross sectional bead that is suf?ciently large as to
`permanently de?ne the gusset upper boundary While pro
`viding additional peripheral tension cover strength. The
`beading preferably extends about the entire pilloW including
`the same section of pilloW having the Zipper (Which is an
`area of increased user handling).
`FIGS. 1A, 1B and FIG. 4 illustrate in cross-section
`additional features relative to the intermediate gusset Zone
`34. As seen from FIG. 1A upper top layer 24 is joined at its
`periphery inWard of (and essentially at) bead 38 to upper
`bottom layer 58 (eg a fold-in arrangement for top cover 24
`With the peripheral inWardly folded-edge of upper bottom
`layer 58 received in the recess de?ned by the inWardly
`extending top cover edge). As this connection (e.g. threaded
`double seam 57) extends peripherally about the pilloW, there
`is formed upper ?ller pocket 60 in the upper half of pilloW
`20. Filler pocket 60 is preferably sealed peripherally about
`the entire pilloW (including When Zipper 40 is opened).
`Upper bottom layer 58 is also preferably formed of the same
`material as upper top layer 24 although variations are also
`included in the present invention including forming the outer
`cover layer 24 and upper bottom layer 58 of different
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`US 6,988,286 B2
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`5
`materials (e.g., different grade fabrics or different type
`material such as netting and cloth combination).
`FIG. 1B illustrates an expanded vieW of the bottom
`portion of intermediate gusset Zone represented by expan
`sion circle 1B in FIG. 4 taken in the region represented by
`cross-section line IB—IB of FIG. 1. As shoWn in FIG. 1B,
`upper gusset section 44 extends into connection With loWer
`gusset section 48 and loWer top layer 62 such as by Way of
`a threaded connection 64 Which extends about the periphery
`of pilloW 20 (eg a threaded seam connecting abutting,
`interior fold edges for section 48 and layer 62 receiving
`therebetWeen an extension of upper gusset section 44). For
`example, loWer gusset section 48 can be folded inWard,
`loWer top layer 62 can also be folded inWard, and the inWard
`folds of each de?ning a sandWich arrangement relative to an
`extension of upper gusset section therepast. The junction
`point of these preferably common material pilloW sections
`de?nes intermediate gusset line 46 Which is shoWn to
`represent the interiormost portion of the visible intermediate
`gusset Zone 34. FIGS. 1, 1B and 4 also illustrate a second
`gusset bead or external border edge 66 that de?nes the loWer
`border edge betWeen intermediate gusset Zone 34 and the
`loWer bottom layer 36 of pilloW 20. This second bead or
`border edge is provided to de?ne and help maintain the
`shape of the loWer gusset border edge. It can take on the
`same form as that of bead 38, but in a preferred embodiment
`is formed Without a bead cord insert relying instead on
`stacked or folded bottom layers joined together by a thread
`ing, for example.
`FIG. 1B illustrates one possible embodiment of gusset
`border edge 66 de?ned by a loWer region of loWer gusset
`section 48 and an upper region of loWer bottom layer 36 so
`as to provide a symmetry of border effect relative to the top
`and bottom of gusset Zone 34. In the FIG. 1B illustration,
`layer 36 and section 48 are separate sheets of material that
`are connected as by the illustrated threaded connection 68.
`The combination of layers or sections 36, 48 and 62 and the
`illustrated peripheral connections 64 and 68 de?ne loWer
`?ller pocket 70 Which, like above, has its peripheral edges
`sealed and the material is ?exible enough to provide for
`some degree of vertical ?ller Zone expansion and conform
`ance to a preferred convex shaped bottom surface for the
`core. In a preferred embodiment, loWer gusset Zone 48 has
`its corners formed by threaded connections, tWo of four of
`Which are denoted in FIG. 1 by dashed reference lines 72.
`The dual upper and loWer individual pocket arrangement can
`be formed in a variety of other Ways such as adhesive or heat
`bonding common peripheral edges of the upper pocket
`layers and the loWer pocket layers. The pockets can also
`joined directly together at common peripheral edges,
`although the intermediate panel arrangement is preferred for
`maintaining less directly interlinked pocketed comfort
`Zones.
`As shoWn in FIGS. 1A and 1B, betWeen upper bottom
`layer 58 and loWer top layer 62 is de?ned intermediate core
`pocket 74 Which is limited peripherally by mainly the
`interior gusset line 46. As shoWn best by FIGS. 4 and 5,
`intermediate core pocket 74 provides a reception area for
`receipt of core 76. FIGS. 4 and 5 also illustrate, respectively,
`the above noted, ?ller pockets 60 and 70 containing ?ller
`material 78 and 80, respectively. The providing of the
`multiple pockets (e.g. upper, intermediate and loWer) pro
`vides a Wide variety of ?ller options (eg core or loose or
`non-integrated ?ller material) to a manufacturer (or user
`When the multipockets are made accessible—although in a
`preferred embodiment only the intermediate pocket 74 is
`made accessible by Way of Zipper 40). This versatility
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`facilitates providing different products to suit different
`intended customer needs and desires, although a Wide vari
`ance of universal comfort is achieved by the arrangements
`described herein. For example, With the preferably sealed
`upper and loWer pockets, a Wide variety of ?ller options are
`possible such as doWn and polyester ?ber ?llers. Suitable
`polyester or other man-made ?ber ?llers include, for
`example, such staple polyester ?ber such as RICHLOFT®
`polyester ?ber sold by Carpenter Co. or polyester ?ber-balls
`such as disclosed in US. Pat. No. 5,344,707 Which are
`described as avoiding a high degree of clumping (Which is
`even further lessened by the relatively thin, individual
`pockets arrangement of the present invention).
`In an illustrative preferred embodiment of the present
`invention, upper and loWer ?ller pockets 60 and 70 contain
`a common ?ller material (as opposed to different ?ller
`materials Which represents an alternate embodiment of the
`present invention). As best shoWn in FIGS. 1A, 1B, 4 and 5,
`one preferred embodiment of the invention features upper
`pocket 60 provided With a doWn feather ?ller 78 and the
`loWer pocket 70 also provided With a doWn ?ller 80. A
`variety of doWn types and/or mixtures represent suitable
`doWn ?ller options such as gray duck doWn or White goose
`doWn, etc. With the preferred embodiment featuring a sealed
`pocket both from the standpoint of having peripheral sealed
`edging and a pocket forming material that, While preferably
`being breathable or air ?oW capable, blocks the escape of the
`?ller material. In this context, cover 22 can be considered a
`ticking and a 100% cotton ticking With a suitable thread
`count (eg 200 to 300) to avoid doWn feather escape and/or
`partial exposure is preferred. Other Well suited ticking fabric
`includes Woven yarns of synthetic polyester continuous
`?lament such as described in US. Pat. No. 5,659,911.
`In a preferred embodiment of the invention, each pocket
`(60, 70) is preferably provided With doWn in an amount of
`1 to 12 OZ. of ?ller material With a preferred intermediate,
`general sub-range of 3 to 7 OZ. being preferred. In one
`preferred embodiment, each pocket is provided With 2—5 OZ.
`of doWn (e.g. 2—4 OZ. of Gray Duck DoWn) With 45:05 OZ.
`being Well suited for many uses of the present invention. The
`above ranges of doWn for a preferred pilloW shape provides
`the preferred pocket thickness height range of 0.5 to 2
`inches, With a 0.75 to 1.25 inch thickness being Well suited
`for most uses of the present invention and a 1 inch thickness
`being preferred. (The thickness of the ?ller and pockets are
`preferably made generally consistent (e.g. less than a 0.25
`inch deviation) across the plane or curvature of the pocket
`although there can be expected to be some degree of
`reduction in the peripheral area Where the tWo pocket
`forming panels are shoWn coming together for attachment).
`The thickness range is thus maintained relatively loW rela
`tive to the height of the core (eg a relationship Where half
`of the core height (maximum if non-planar)) is greater than
`the pocket thickness and preferably half the (maximum) core
`height is greater than the sum thickness of both pockets.
`Rather than doWn (e.g., as some people are allergic to
`doWn and doWn is generally not recommended for Washing,
`requiring dry cleaning), other ?ller materials are suited for
`use of the present invention including synthetic “staple
`?ber” including polyester ?ber?ll (e.g. polyethylene tereph
`thalate staple (i.e. cut)) ?bers With a preferred dtex of 5—6
`and preferably slickened (e.g. coated With silicones or
`polyethylene terephthalate/polyether segmented copolymers
`to reduce friction and clumping). In one embodiment of the
`invention, each pocket is provided With 2 to 12 OZ. of staple
`polyester ?ber?ll (eg the aforementioned RICHLOFT®.
`polyester ?ber) With 5—8 OZ. being a preferred sub-range
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`US 6,988,286 B2
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`7
`used in forming embodiments of the present invention and
`6 OZ. being Well suited for many uses of the present
`invention. These preferred ranges of ?ber?ll also generally
`provides a pocket thickness Within the above described
`preferred range of 0.5 to 2 inches, as is the case for the doWn
`pocket ?ller.
`Intermediate core pocket 74 also provides for reception of
`a Wide variety of different core embodiments. The preferred
`intermediate pocket embodiment features an accessible
`pocket such as a pocket accessible by Way of Zipper 40. Core
`76 is preferably a unitary or integrated (e.g. monolithic,
`laminated or interconnected) body Which can have planar
`top, bottom and side surfaces, but is more preferably non
`planar With conveX top and bottom smooth surfaces. Thus,
`unlike a non-unitary or non-