Method and apparatus for a pillow including foam pieces of various sizes

Abstract

The present subject matter includes a pillow case, a first plurality of foam pieces, a second plurality of foam pieces which are larger on average than the first plurality of foam pieces and a third plurality of foam pieces which are larger on average than the second plurality of foam pieces, wherein the first, second, and third pluralities are disposed in the pillow case in a mix, with the first plurality of foam pieces representing approximately 20 to 30 percent of the foam disposed in the pillow case by volume, with the remaining foam disposed in the pillow case including the second plurality and the third plurality in an approximately equal proportion by volume.

1 . An apparatus, comprising:
 a pillow case;   a first plurality of foam pieces;   a second plurality of foam pieces which are larger on average than the first plurality of foam pieces; and   a third plurality of foam pieces, which are larger on average than the second plurality of foam pieces,   wherein the first, second, and third pluralities are disposed in the pillow case in a mix, with the first plurality of foam pieces representing approximately 20 to 30 percent of the foam disposed in the pillow case by volume, with the remaining foam disposed in the pillow case including the second plurality and the third plurality in an approximately equal proportion by volume.   
   
   
       2 . The apparatus of  claim 1 , wherein each of the first, second and third pluralities of foam pieces has an indent force deflection (“IFD”) at 25% of from about 27 to about 35. 
   
   
       3 . The apparatus of  claim 1 , wherein each of the first, second and third pluralities of foam are formed of polyurethane. 
   
   
       4 . The apparatus of  claim 3 , wherein the foam of the first, second and third plurality of foam includes open cells. 
   
   
       5 . The apparatus of  claim 4 , wherein the first plurality of foam pieces has a thickness which ranges from a thickness of approximately 1 foam cell to approximately 10 millimeters. 
   
   
       6 . An apparatus, comprising:
 a pillow case;   a first plurality of foam pieces;   a second plurality of foam pieces which are larger on average than the first plurality of foam pieces; and   a third plurality of foam pieces, which are larger on average than the second plurality of foam pieces,   wherein each of the first, second and third pluralities of foam pieces has an indent force deflection (“IFD”) at 25% of from about 27 to about 35.   
   
   
       7 . The apparatus of  claim 6 , wherein the third plurality of foam pieces has an average thickness of 46 millimeters. 
   
   
       8 . The apparatus of  claim 7 , wherein the second plurality of foam pieces has an average thickness of approximately 27 millimeters. 
   
   
       9 . The apparatus of  claim 8 , wherein the first plurality has a thickness which ranges from the thickness of 1 cell to approximately 10 millimeters. 
   
   
       10 . A cushion including a pillow case containing a filling of foam pieces, the filling made by the process comprising:
 feeding a foam block into a cutting machine;   cutting the foam block with the cutting machine;   collecting a first plurality of foam pieces using an approximately 0.375 inch to an approximately 0.625 inch grid;   collecting a second plurality of foam pieces using an approximately 0.75 inch to an approximately 1.25. inch grid;   collecting a third plurality of foam pieces using an approximately 2.0 inch to an approximately 2.5 inch grid;   mixing the first, second, and third pluralities into the filling; and   dispensing the filling into the pillow case.   
   
   
       11 . The cushion of  claim 10 , wherein the filling includes polyurethane. 
   
   
       12 . The cushion of  claim 11 , wherein the foam includes open cells. 
   
   
       13 . The cushion of  claim 12 , wherein the first plurality of foam pieces has a thickness which ranges from the thickness of 1 cell to approximately 10 millimeters. 
   
   
       14 . The apparatus of  claim 10 , wherein the third plurality of foam pieces has an average thickness of 46 millimeters. 
   
   
       15 . The apparatus of  claim 14 , wherein the second plurality of foam pieces has an average thickness of approximately 27 millimeters. 
   
   
       16 . The apparatus of  claim 15 , wherein the first plurality has a thickness which ranges from the thickness of 1 cell to approximately 10 millimeters. 
   
   
       17 . A method, comprising:
 feeding a foam block into a cutting machine;   cutting the foam block with the cutting machine;   collecting a first plurality of foam pieces using an approximately 0.375 inch to an approximately 0.625 inch grid;   collecting a second plurality of foam pieces using an approximately 0.75 inch to an approximately 1.25. inch grid;   collecting a third plurality of foam pieces using an approximately 2.0 inch to an approximately 2.5 inch grid;   mixing the first, second, and third pluralities; and   dispensing the first, second and third pluralities into a pillow case.   
   
   
       18 . The method of  claim 17 , wherein cutting includes spinning knives to cut the foam block. 
   
   
       19 . The method of  claim 18 , wherein spinning includes spinning a center shaft coupled to the knives at between 1600 rotations per minute (“RPM”) and 2100 RPM. 
   
   
       20 . The method of  claim 17 , wherein collecting each of the first, second and third pluralities includes vacuuming.