US2005278852A1PendingUtilityA1

High air flow foam bedding products

48
Individually held — no corporate assignee on recordPriority: Jun 12, 2004Filed: Jun 10, 2005Published: Dec 22, 2005
Est. expiryJun 12, 2024(expired)· nominal 20-yr term from priority
Inventors:Gary M. WahrmundJames Arthur WarrenStephen D. Gilder
A47G 9/1081A47C 27/05A47G 2009/1018A47C 27/053C08L 2201/12A47G 9/10
48
PatentIndex Score
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References
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Claims

Abstract

Foam bedding products including viscoelastic foam having a high airflow value that do not feel hot to the person sleeping on the products. One product is a pillow having a contoured core having sufficient firmness to provide effective support for a user and a hyper soft viscoelastic foam shell surrounding the core having sufficient firmness to maintain the appearance of a conventional pillow when supporting only a pillowcase or other bed coverings. The core may be made of higher density viscoelastic foam or of a resilient foam. Another product may be a mattress topper with or without foam cores for body support carried within slabs of high airflow viscoelastic foam.

Claims

exact text as granted — not AI-modified
1 . A pillow comprising: 
 a shell portion having an outer shape of a conventional pillow and having a cavity,    a core portion sized and shaped to conform to the shape of the shell cavity and carried within the shell cavity,    the core portion comprising a foam material having a firmness selected to provide effective support to a user,    the shell portion comprising a foam having only enough firmness to substantially maintain its outer shape when loaded with a pillowcase and/or a bed covering.    
   
   
       2 . A pillow according to  claim 1 , wherein the core has a contoured shape selected to provide support for a portion of a user.  
   
   
       3 . A pillow according to  claim 1 , wherein the shell comprises a high air flow viscoelastic foam.  
   
   
       4 . A pillow according to  claim 1 , wherein the shell comprises foam having a IFD value of less than six pounds at 25% deflection.  
   
   
       5 . A pillow according to  claim 1 , wherein the shell comprises foam having a IFD value of between one and five pounds at 25% deflection.  
   
   
       6 . A pillow according to  claim 1 , wherein the shell comprises foam having a IFD value of between two and four pounds at 25% deflection.  
   
   
       7 . A pillow according to  claim 1 , wherein the core comprises foam having a IFD value of between ten and twenty pounds at 25% deflection.  
   
   
       8 . A pillow according to  claim 1 , wherein the core comprises foam having a IFD value of between twelve and eighteen pounds at 25% deflection.  
   
   
       9 . A pillow according to  claim 1 , wherein the shell comprises foam having a density of from about two to about three pounds per cubic foot.  
   
   
       10 . A pillow according to  claim 1 , wherein the core comprises foam having a density of from about three to about five pounds per cubic foot.  
   
   
       11 . A method for making a pillow comprising: 
 cutting a shell portion having an outer surface in the shape of a conventional pillow and having a cavity from a block of foam having only enough firmness to maintain the shape of the shell when the shell is loaded with a pillowcase and/or a bed covering,    cutting a core portion sized and shaped to conform to the shape of the shell cavity from a block of foam material having a firmness selected so that the core provides effective support to a user, and    inserting the core portion into the shell cavity.    
   
   
       12 . A method according to  claim 11 , further comprising: 
 cutting though one side of the shell between the shell outer surface and the cavity,    opening the shell before inserting the core portion into the cavity, and    closing the shell after inserting the core portion into the cavity.    
   
   
       13 . A method according to  claim 12 , further comprising bonding the cut sides of the shell together and the shell to the core.  
   
   
       14 . A method according to  claim 13 , further comprising using an adhesive for bonding the cut sides of the shell together and the shell to the core.  
   
   
       15 . A method according to  claim 12 , further comprising sewing the edges of the shell portion together.  
   
   
       16 . A method according to  claim 15 , further comprising using a bag closing machine to sew the edges of the shell portion together.  
   
   
       17 . A method according to  claim 12 , further comprising placing the pillow in a cloth pillowcase sized to form a snug fit on the pillow.  
   
   
       18 . A method according to  claim 17 , wherein the pillowcase is formed of two rectangular pieces of woven fabric sewed together along three sides and closed on a fourth side by a releasable closure.  
   
   
       19 . A method according to  claim 18 , wherein the pillowcase is closed on the fourth side by a zipper.  
   
   
       20 . A method according to  claim 11 , wherein the core is cut from a block of foam which is shorter than the block of foam from which the shell is cut.  
   
   
       21 . A bedding product comprising viscoelastic foam having a high air flow value.  
   
   
       22 . A bedding product according to  claim 21  wherein the foam has an air flow value of between at least two and one-half cubic feet per minute measured according to the ASTM D3574 standard.  
   
   
       23 . A bedding product according to  claim 21  wherein the foam has an air flow value of between about two and about six cubic feet per minute measured according to the ASTM D3574 standard.  
   
   
       24 . A bedding product according to  claim 21  wherein the foam has an air flow value of between about four and about four and one-quarter cubic feet per minute measured according to the ASTM D3574 standard.  
   
   
       25 . A bedding product according to  claim 21 , wherein the product comprises one of a pillow and a mattress topper.  
   
   
       26 . A bedding product according to  claim 25 , wherein the product comprises a shell comprising viscoelastic foam having a high air flow value and a support core carried within the shell.  
   
   
       27 . A method for making a pillow comprising: 
 positioning a contoured foam core in a mold having an inner pillow shaped surface, and    reacting a formulation for viscoelastic foam having a high air flow value in the mold.    
   
   
       28 . A method according to  claim 27  further comprising: 
 reacting a formulation for viscoelastic foam having an IFD value of less than six in the mold.    
   
   
       29 . A method according to  claim 27  further comprising: 
 attaching at least one spike to an inner surface of the mold, and    positioning the core on the at least spike.    
   
   
       30 . A method according to  claim 27  further comprising: 
 coating the inner surface of the mold with mold release.

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