(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)
`
`(19) World Intellectual Property Organization
`International Bureau
`
`/W
`
`(43) International Publication Date
`1 July 2010 (01.07.2010)
`
`International Patent Classification:
`A47G 9/00 (2006.01)
`
`International Application Number:
`PCT/US2009/069018
`
`International Filing Date:
`21 December 2009 (21.12.2009)
`
`Filing Language:
`
`Publication Language:
`
`Priority Data:
`61/140,622
`24 Dece111be1' 2008 (24.12.2008)
`
`English
`
`English
`
`US
`
`Applicant (for all designated States except Ub): TEM-
`PUR-PEDIC MANAGEMENT, INC.
`[US/US]; 1713
`Jaggie Fox Way, Lexington, KY 40511 (US).
`Inventor; and
`Jor US only): RASMUSSEN,
`Inventor/Applicant
`Kristina [DK/DK]; Skolevej 7, DK-5800 Nyborg (DK).
`
`(10) International Publication Number
`
`WO 2010/075294 A1
`
`(81) Designated States (unless otherwise indicated, for every
`kind ofncttionttl protection ztvztilctble): AE, AG, AL, AM,
`A0, AT, AU, AZ, BA, BB, BG, BH, BR, BW, BY, BZ,
`CA, CII, 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 of regional 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, FR,
`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).
`
`Agent: MORAN. Kevin; Michael Best & Friedrich LLP, P M. h d_
`100 East Wisconsin Avenue, Suite 3300, Milwaukee, WI
`u ls e '
`53202 (US).
`— with international Search report (Art. 21(3))
`
`(54) Title: PILLOW
`
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`(57) Abstract: A pillow assembly including a Visco-elastic foam core and a cover having a top portion a11d 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 fulther includes a side layer coupled to the top layer
`and bottom layer to deline a cavity containing the liller, such that the side layer is mo1'e 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.
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`CROSS-REFERENCE TO RELATED APPLICATIONS
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`PILLOW
`
`[0001]
`
`
`
`BACKGROUND
`
`[0002]
`
`Conventional pillows can be found in a wide variety of shapes and sizes, and are
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`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
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`constructed entirely or partially of visco-elastic material, thereby providing the pillow with an
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`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 viseo-elastic materials
`
`continue to increase, the capabilities of such materials are often underutilized. In many cases,
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`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 Viseo-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
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`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 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
`
`covcr, whereas in othcr 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. ln 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]
`
`
`
` >
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`
`
`[0008]
`
`
`
`
`
`[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.
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`BRIEF DESCRIPTION OF THE DRAWI VGS
`
`[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 rclativc importance or significanc
`
`[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 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
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`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
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`can enhance breathing of a user resting his or her head against the pillow 100 (e.g., when
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`sleeping on the user’s side or stomach), and can also provide support for the shoulder and/or
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`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
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`100 includes a top layer 140, a bottom layer 150 opposite the top layer 140, and sidewalls
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`160 connecting the top layer 140 and the bottom layer 150. The top layer 140, bottom layer
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`150 and sidewalls l6O define a cavity 170 shaped to receive filler material l80. The pillow
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`100 can include a rib where the top layer 140 and sidewalls 160 meet and are joined, and/or a
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`rib where the bottom layer 150 and the sidewalls 160 meet and are joined. The top layer 140,
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`bottom layer 150 and sidewalls 160 can be secured to one another in any suitable manner,
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`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
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`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 lcm in thickness. In other embodiments, the top
`
`layer l40, bottom layer 150 and sidewalls l6O 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 l50, and sidewalls l6O in some embodiments, the pillow l00 can provides
`
`enhanced support to a user, as well as providing space for the filler material l80.
`
`[0018]
`
`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,
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`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-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, ISO having a hardness of at least
`
`about 40 N and no greater than about 75 N are utilized. Unless otherwise specified, the
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`hardness of a material referred to herein is measured by exerting pressure from a plate against
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`a sample of the material having length and width dimensions of 40 cm each (defining a
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`surface area of the sample of material), and a thickness of 5 cm to a compression of 40% of
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`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
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`International Organization of Standardization (ISO) 2439 hardness measuring standard.
`
`[0020]
`
`In those embodiments having visco—elastic top and/or bottom layers 140, 150, the
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`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 l50 respond to pressure, and the feel of the foam. In some embodiments,
`
`the visco—elastic foam of the top layer l40 and/or bottom layer l50 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/ms
`
`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.
`
`[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
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`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
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`visco-elastic foam for the top layer 140 and/or bottom layer 150 ofthe pillow 100. As will be
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`described in greater detail below, reticulated foam can provide significantly increased
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`ventilation for the top and/or bottom layer 140, 150 of the pillow 100, thereby enhancing the
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`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.
`
`[0023]
`
`Reticulated foam (visco-elastic or otherwise) is a cellular foam structure in which
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`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
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`windows of reticulated foam can be entirely gone (leaving only the cell struts) or
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`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
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`windows that are completely missing and therefore leaving only the cell struts). Such
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`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
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`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
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`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
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`user's body, thereby distributing the force applied by the user's body upon the top layer I40
`
`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
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`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.
`
`[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 ISO 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/mg 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
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`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.
`
`ln 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 l50 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,
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`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
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`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
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`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,
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`granulated visco-elastic foam (e.g., visco-elastic foam that has been shredded, chopped, and
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`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
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`ventilation, heat transport away from the user’s body, and moisture wicking away from the
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`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
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`partially filling the cavity 170 of the core 110.
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`[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 180 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.
`
`[0032]
`
`Like visco-elastic foam used for the top layer 140 and/or bottom layer 150 of the
`
`pillow I00, visco-elastic foam filler material I80 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 l30 kg/ms. 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 I00.
`
`[0033]
`
`In some embodiments, non—reticulated visco-elastic foam filler material 180
`
`having a density of no less than about 30 kg/mg and no greater than about I50 kg/m3 is used.
`
`In other embodiments, a non—reticulated visco-elastic foam filler I80 having a density of at
`
`least about 70 kg/m3 and no greater than about 130 kg/ms 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
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`PCT/US2009/069018
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`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 defiection, 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/cm3 . 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/emf‘. Alternatively, the fiber material utilized in combination with the granulated
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`visco-elastic foam as the filler material 180 can have any density in accordance with the
`
`desired characteristics of the pillow 100.
`
`[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
`
`viseo—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 l00, for example, can be greater than about 70% of the filler material 180.
`
`[0039]
`
`ln still other embodiments of the present invention, the filler material 180 is a
`
`combination of granulated viseo—elastic foam and polystyrene balls, which are often less
`
`expensive than viseo—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 viseo—elastic foam as described above. However, a suitable range of polystyrene
`
`balls 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 polystyrene balls in the filler material
`
`180 for a more expensive pillow 100, for example, can be less than about 30% ofthe filler
`
`material 180. Likewise, a suitable range of polystyrene balls in the filler material 180 for a
`
`less expensive pillow 100, for example, can be greater than about 70% of the filler material
`
`180.
`
`[0041]
`
`The filler material 180 can also include granulated highly-elastic (“HE”) foam in
`
`addition to the granulated viseo—elastic foam described above. HE foam is often less
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`expensive than visco-elastic foam, thus yielding a potentially less expensive pillow 100. The
`
`filler material can be comprised of any single filler described above or any combination of
`
`the fillers. Alternatively, the filler material 180 can also include any conventional materials,
`
`such as feathers, granulated cotton, cotton fibers, etc. In some embodiments of the present
`
`invention, the filler material 180 includes HE foam having a density of about 35 kg/mg.
`
`However, a suitable density for the HE foam for an average weight pillow 100, 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 100, for example, can be less than about 25 kg/ms. Likewise, a
`
`suitable density for HE foam for a heavyweight pillow I00, for example, can be greater than
`
`about 45 kg/ms. Alternatively, HE foam utilized in the filler material 180 can have any
`
`density in accordance with the desired characteristics of the pillow 100.
`
`[0042]
`
`Granulated HE foam may consist of pieces of a nominal length, or granulated
`
`HE foam may consist of pieces of varying lengths. For example, granulated HE foam may
`
`have a nominal length of about 1.3 cm. Also, the granulated HE foam may consist of varying
`
`lengths b