WO2009018669A1

WO2009018669A1 - Improved microbead pillow

Info

Publication number: WO2009018669A1
Application number: PCT/CA2008/001763
Authority: WO
Inventors: Donna Harmon; Marie Hensler
Original assignee: Snooztime Inc.
Priority date: 2007-08-03
Filing date: 2008-10-03
Publication date: 2009-02-12

Abstract

An improved microbead pillow which provides consistent therapeutic support, is manufactured of hypoallergenic materials, is fully machine washable and dryable, and is fully adjustable in height and firmness without the addition or removal of filling material. The pillow may be in a variety of shapes and sizes. In one embodiment, the pillow comprises a microbead-microfibre complex filling in which the microbeads are treated with an antistatic coating, a pillow cover to encase the filling material, and a removable pillowcase. The pillow may include pillow adjustment means associated either with.The pillow cover or with a removable pillowcase for adjusting the height and firmness of the pillow.

Description

IMPROVED MICROBEAD PIt-LOW FIELD OF THE INVENTION

The present invention relates generally to pillows. In particular, the present invention relates to mouldable pillows which adjust to provide consistent support to a user.

BACKGROUND OF INVENTION

It is known to provide a pillow or other cushioning device for use during sleep or other rest. The use of pillows or other cushioning device serves to increase comfort of the user and improve physical support of portions of a user's body. Pillows are used not only by humans, but also may be used by domesticated animals, such as dogs and cats.

Most commonly, pillows provide physical support to the head, neck and shoulders. This support assists in maintaining their alignment and relieving stress and. strain. An adult human head weighs approximately 10 pounds, constituting about 8% of the entire body weight. To support this weight, the human neck bends slightly forward.- It is important that this natural curvature be maintained while resting on a pillow. . A pillow that is too high may cause muscle strain in the back of the neck and. in the shoulders, because the neck is bent forward or to the side, which may result in obstruction of the trachea, reduced breathing and snoring. A pillow that is too low can also lead to strained neck muscles.

A pillow are that it should provide comfort to the user and that it should provide therapeutic support to hold the user's head, neck, shoulders or entire back in a healthy orthopaedic position to allow the muscles, nerves and spine to relax. Conventional pillows consisting essentially of a compressible filling material such as avian down, synthetic feathers or various foam materials encased in a cover made from one of a variety of non-elastic fabrics do not do so.

In fact, the conventional pillow makes "support" and "comfort" contradictory. While using such a conventional pillow, a user's body weight and body shape will compress the compressible filling. While a soft pillow may provide increased comfort, the softer the filling of a conventional pillow, the less support. Though a firm pillow my provide increased support, the firmer the conventional pillow, the less comfortable most users will find it.

Every individual has anatomical differences and differing sleep posture preferences. Conventional pillows cannot adequately accommodate height and firmness factors, in sleep comfort and anatomical support. The height or firmness of a conventional pillow can only be adjusted by changing the type or amount of filling, Also, conventional pillow fillings may compact with regular use over time and the pillow will change its behaviour, further diluting the limited comfort and support provided. Improvements have been made to conventional pillows. Pillow fillings may be composed of a variety of foam materials such as polyurethane. Pillows have been formed into a distinctive contour to address different therapeutic support requirements. For example, some prior art pillows are designed to have greater height at the left and right sides and lesser height in the centre. Other prior art pillows are higher on one side and lower on the other. While such improved conventional pillows provide improved side or back support over standard conventional pillows, none of them are of a shape that is suitable for all pillow users.

Historically, in parts of Asia, a pillow was used .in which the filling was made of buckwheat hulls. Buckwheat is a natural grain product with a coarse exterior. As. the buckwheat hulls are substantially non-cόmpressible, under pressure from the weight of a pillow user the hulls would move with the motion of the user lying on the pillow. While a buckwheat pillow provided- improved support, buckwheat pillows were considered to be very uncomfortable. In addition, over time the buckwheat hulls became crushed and disintegrated. Further, the buckwheat filling emitted an oily, odorous substance, the movement of the buckwheat hulls produced considerable noise, and the filling was not washable.

A modern variant of the buckwheat pillow is the use of a microbead filling in a pillow. Microbeads are made of expandable polystyrene (EPS), a known synthetic material derived from petroleum, EPS microbeads resolve many of the issues associated with buckwheat filling. Food-grade EPS has no odor. EPS microbeads are solid and, as their 97% air content is encapsulated in a closed cell bead, they are substantially non- compressible in the context of normal pillow use. However, prior art EPS microbeads have a high surface friction that causes some noise when they move against other microbeads or a supporting surface. As well, EPS generates a high static electric load which causes the microbead filling to illuminate. Such illumination may be very disturbing to people moving on their pillow at night.

Microbead filling is substantially non-compressible and does not disintegrate with ^■ normal use over time. Rather than compressing when body weight is applied, the microbeads move inside the pillow cover.- This results in the beads moulding around the anatomy of a user's body. Such individualized moulding provides much improved therapeutic support in any sleep or resting posture. However, the_. microbeads in prior art microbead pillows may prematurely move into an available space of the pillow cover, causing loss of the desired therapeutic support If the pillow is overfilled or encased in a tight pillowcase, the pillow may become overly firm and uncomfortable. To provide comfort and make the pillow function properly, the pillow cover and pillowcase should be made of an elastic material. Since the microbead filling does not compress, the pillow cover and pillowcase must expand. Prior art microbead pillow covers and pillowcases are made of a polyester spandex fabric, As many users prefer a natural fabric such as cotton for comfort reasons, microbead pillow covers or cases often are made of spandex on one side and a cotton blend on the other. As cotton fabrics are only 2-way stretchable, prior art microbead pillows using cotton-based pillowcases or pillow covers do not function well.

SUMMARY OF THE INVENTION According to one of .its aspects, one embodiment of the present invention is a pillow comprising a pillow cover and a pillow filling, wherein the pillow filling is a mixture of microbeads and at least one other component The microbeads may comprise between 30% and 80%, preferably 75% by volume of the pillow filling. The microbeads may be between 0.3 and 0.8 mm in diameter. According to one of its embodiments, the at least one other component may be polyester microfibres. According to another embodiment,, the- at least oh© other component may be another microfibre that is- highly elastic, such as natural wool or silk. The pillow filling, may include an antistatic coating of a type WeIf known, in the textile industry.

According to another embodiment, the pillow may also include^' a pillowcase for insertion of the pillow. The pillowcase and pillow cover may be manufactured of a material which is 2-way stretchable, preferably of a material which is 4-way stretchable. The pillow cover and pillowcase may be manufactured of a velour fabric, preferably a velour- spaπdex composite fabric. The pillowcase may include a zipper or other fastening means integrated along adjacent upper and lower edges of at least one side of the pillowcase for reversibly enclosing the pillow.

The. pillow may also include means for changing the dimensions of the pillow. The . means for changing the dimensions of the pillow may be a drawstring inserted within a seam integrated into the pillow cover or the pillowcase.

According to another of its aspects, there is provided an adjustable pillow comprising a pillow cover; a pillow filling, wherein the pillow filling is a mixture of microbeads and at least one other component; a pillowcase for insertion therein of the pillow; and pillow adjustment means for changing the dimensions of the pillow. According to yet another of its aspects, there is provided a method of manufacturing an improved microbead pillow, comprising the steps of; a) treating microbβads with an antistatic coating; b) combining treated microbeads with microfibres to produce a treated microbead-mϊcrofibre complex filling; c) packing the treated microbead- microfibre complex filling into a pillow cover; and d) sealing the pillow cover. Important features of the invention have been described in order that the detailed description that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described and which form the subject matter of the claims. Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in .its arrangement of the components set forth in the following description and illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. The novel features set out above which characterize the invention, are noted with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific results obtained by its use, reference should be made to the following detailed specification taken in. conjunction with the accompanying drawings' wherein like characters of reference designate like parts throughput the several views.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of the preferred embodiments are provided herein by way of example only and with reference to the drawings, in which:

Fig. 1 is a perspective view of one embodiment of the pillow of the present invention, illustrating a pillow having a microbead-microfibre complex filling;

Fig. 2 is a cross-sectional end view of one embodiment of the pillow of the present invention;

Fig. 3 is a perspective view of one embodiment of a rectangular pillow with pillowcase according to the present invention; . Fig. 4 is a photograph of the microbead-microfibre complex filling, according to one embodiment of the pillow of the present invention;

Figs. 5A and 5B are cross-sectional views illustrating the deformation of a prior art microbead pillow during back sleeping in the center of the pillow (5A) and side sleeping at one side of the pillow (5B); Fig. 6 is a cross-sectional view of one embodiment of the pillow of the present invention, illustrating moulding of the pillow around the user's body; Fig. 7A is a cross-sectional schematic of one embodiment of the pillow of the present invention, depicting the effect of drawing ^' the drawstring tighter to change the dimensions of the pillow, and Fig. 7B is a cross-sectional end view of the pillow illustrating the increase in height and decrease in length of the pillow; and Figs. 8A and SB are perspective side views of one embodiment of a cylindrical pillow according to the present invention depicting a longer, lower pillow with a loosened ^■ drawstring (8A), and a shorter, higher pillow with a tightened drawstring (8B).

The drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification. They illustrate embodiments of the invention and, together with their description, serve to explain the principles of the invention.

In the drawings, preferred embodiments of the invention are illustrated by way of example only. It is to be expressly understood that the description^' and drawings are only for the purpose of illustration and as an aid to understanding, and are not intended as a definition of the limits of the invention.

DETAILED DESCRIPTION OF THE INVENTION

In this specification, the term "pillow cover" refers to a fabric permanently enclosing the pillow filling, and the term "pillowcase" refers to an optional, removable device for covering the pillow. The term "2-way stretchable" means elastic along one pair of opposing directions. The term "4-way stretchable" means elastic along a first pair of opposing directions and along a second pair of opposing directions perpendicular to the first pair.

As shown in Figs. 1 and 2, the pillow 2 according to one embodiment of the present invention comprises a pillow cover 4 filled with a filling 6 as described below. The pillow- cover preferably is made of an elastic fabric such as spandex (elastane) or any other fabric that is 4-way stretchable.

As illustrated in Fig. 3, an optional pillowcase 8 for removably encasing the pillow 2 may be manufactured of a 4-way stretchable fabric such as spandex or any other fabric, the pillowcase may be reversibly closable using an integrated zipper or other fastening means such as snaps or buttons (not shown). In an alternate embodiment, the pillowcase- may be open on one or more sides. The pillow and pillowcase may be of any desired shape, including but not limited to rectangular, spherical, oval, or cylindrical.

As shown in Fig. 4, the Riling 6 of a preferred embodiment of the present invention comprises a complex of microbeads 10 and microfibres 12. The ratio of microbeads to microfibres may be selected to optimize shape, size, firmness or other parameters determined by the desired function of the pillow. In one embodiment, the percentage by volume of microbeads in the complex is between 30% and 85%. Preferably, the percentage by volume of microbeads in the complex is about 75%.

As previously described, microbead fillings have the advantage of movement within the pillow cover, and the microbeads do not compress, The movement of the beads is triggered by force applied to^' cause motion of the bulk of the beads. . However, when the force stops, the motion ceases, causing the microbeads to lock-up arid act like a solid. This locking effect is analogous to a sand structure. The sarjd particles, like the beads, have extensive surface contact with other sand particles and act as a solid until the application of force causes the structure to collapse. This same effect in a conventional microbead pjllow is highly undesirable, as the pillow feels hard when, the user's body is not moving.

The mixing of microfibres with the microbeads to form a complex filling inhibits clustering of the microbeads into a static unit. Through elasticity and low surface friction, the microfibres provide absorption of forces, acting as microscopic shock absorbers in the complex filling. Minor motion of the pillow user causes the filling to move, dynamically adjusting and readjusting to the changing body shape and position,

The microscopic microfibres preferably are made of polyester, -but other highly elastic materials such as wool or silk may be substituted. Ideally, the microfibres are approximately 10 microns in diameter. The microfibres have near zero surface friction. They may be spun into spherical clusters of approximately 5 mm and mixed with the rnicrobeads into a complex filling. Once mixed with the microbeads, the microfibres form a web throughout the pillow which constrains bulk movement of the microbeads. as illustrated in Fig. 4. However, smaller volumes of microbeads would still be still displaceable throughout the pillow.

As depicted in Figs. 5A and 5B, prior art microbead pillows, with no additional component tb restrict flow of the microbeads, have the disadvantage of permitting dislocation of large volumes of microbeads in response to pressure exerted on the pillow by a user 14. The beads may congregate in areas 16, 16, 20 of the pillow where there is available volume, resulting in a loss of desired therapeutic support. Another effect of this mass dislocation of microbeads is the wrapping of the pillow around the neck, which may cause obstruction of the trachea or may induce or worsen snoring. In contrast, as shown in Fig. 6, the microbead-microfibre complex filling of the present invention adjusts dynamically to the body shape and motion of the user 14 without causing bulking¹ of the filling.

The high surface friction of EPS beads in prior art microbead pillows may cause noise as the microbeads move against one another. The addition of microfibres^' helps to reduce the rustling noise as the microfibres inhibit mass simultaneous movement of the microbeads, In addition, the surface friction of the microbeads. can be reduced by applying an antistatic coating to the microbeads. A variety of such antistatic chemicals are well known in the textile industry for use in eliminating static load on fabrics. The chemical has not previously been applied to microbeads. Microbeads treated with an antistatic coating are available from Sekusi Plastics Co. Ltd. of Tokyo; Japan.

The application of the antistatic coating results in a significant reduction of the surface friction of the microbeads and the surface of the beads becomes extremely slippery. As a result, movement of the microbeads within the pillow produces much less noise than is produced by microbeads which have not been treated with this antistatic chemical. The reduced surface friction caused by application of the antistatic coating to the microbeads not only reduces the noise generated by the microbeads moving relative to one another, but also inhibits locking up in the absence 'of applied force and rapid unlocking upon application of feree which is characteristic of prior art microbead fillings.

High static electricity can be generated by rubbing EPS microbeads together. Discharge of this electric load results in illumination of the filling, which may be disturbing to pillow users. This electrostatic load also causes the microbeads to be attracted to each other, the surrounding fabric and the microfibrβs. Application of the antistatic coating to the microbeads eliminates the generation of electrostatic loads inside the pillow, preventing the illumination caused by discharge of the electrostatic load, improves the independent movement of the microbeads, and prevents the microbeads from adhering to one another or ths microfibres.

Important factors in the therapeutic value of a pillow indude the materials used for the filling, pillow cover and pillowcase; the size; the shape; and, in particular, the height and firmness. In order for a microbead-based pillow to . provide maximum advantages, its pillow cover as well as its pillowcase must be made of highly stretchablθ fabrics .such as spandex. Since the microbeads of the filling are not compressible, it Is desirable that the pillow cover and/or pillow case be expandable. Conventional prior art microbead pillows are encased in spandex fabrics that is 4~way stretchable. ¹ Other prior art microbead pillows use a pillow cover or pillowcase that is spandex on the lower side, and another more comfortable fabric on the side making contact'with a user's body. This other fabric may be 2-way stretchable, but it is not 4-way stretchable, and therefore not expandable in all directions. Therefore, these pillows are not as comfortable as, nor do they provide the beneficial therapeutic properties of, the pillows of the present invention.

Many people prefer to rest on natural fabrics such as cotton, bamboo or blends of cotton or bamboo. One of the most, comfortable fabrics known is velour. Velour is a knitted counterpart of velvet, which is woven. It combines the elastic properties of knits with the rich appearance and fee! of velvet. However, a conventional velour fabric is only 2-way stretchable. A microbead-based pillow that provides optimal therapeutic support and comfort would preferably be encased in a fabric which is 4-way stretchable. By adding a spandex yarn capable of approximately 600%., expansion to the conventional velour knitting process, a velour-spandex composite fabric- may be produced which is 4-way expandable by at least 100%, while providing high levels .of comfort. The cotton content of the velour-spandex composite fabric remains comparable to conventional ^'velour, at approximately 80%. This unique velour-spandex composite fabric may be used as a pillow cover or as a pillowcase.

Height and- firmness requirements. areJsp.e_ciflc to each individual's anatomy. In the prior art, methods of adjusting the height or firmness of a pillow require the addition or removal of filling material such as fibrefiil, avian down, water, air, or foam. Such methods are cumbersome to the user and not practical to do more often than once.

According to the present invention, the microbead-microfibre complex filling and the 4- way stretchablβ fabric of the surrounding pillow cover and pillowcase permit a novel method of pillow height and firmness adjustment comprising changing the geometric dimensions of the pillow from the exterior of the pillow. A pillow adjustment means is provided which uses external force to mould the pillow into a different shape. As the microbead-microfibre complex filling is substantially non-compressible, the exterior force will cause the pillow cover or pillowcase to expand as required in areas where force is not applied. . . . "

One example of a pillow adjustment means to change the shape, height and firmness Qf the pillow is a drawstring 22 slidabie within a channel integrated into a seam 24 running the circumference of the pillow cover 4 or the pillowcase (not shown) as illustrated in Fig. 7A. In Fig. 7B, the change in shape and height of a rectangular pillow from a wide, low shape 26 to a narrow, high shape 28 caused by decreasing the lateral circumference of the pillow is illustrated. The tightening of the drawstring gathers the fabric of the pillow cover or pillowcase longitudinal ends, forcing the non-expandable, microbead-microfibre filling tjo expand outwardly to cause an increase in the height of the pillow to compensating for the loss of available length. The drawstring may be held in place, and be maintained in a desired position, by¹ a releasable stopper 30 slidably movable and fixable along the drawstring. This aspect allows the pillow user to dynamically adjust the height and firmness when desired without adding or removing filling material.

Figs. 8A and 8B illustrate a cylindrical pillow 32 in which a drawstring' runs around the circular ends 34 in a channel seam sewn into the fabric of either the pillow cover or the pillowcase. Pulling the string on the left or the right end of the pillow reduces the length of the cylindrical pillow by gathering the end fabric towards the centre 36 of the circular end of the pillow. For a fixed volume of substantially non-compressible filling, the result is expansion of. the cylindrical diameter and, therefore, the height of the pillow. Simultaneously, the 4-way stretchable fabric of the pillow cover aήd/br the pillowcase is forced to. expand, increasing its tension. The increased tension of the pillow cover and/or pillowcase fabric produces an increase in pillow tension, providing a firmer pillow.

Uses of the pillow of the present invention may include, without limitation, mattress toppers, seat cushions, bolster pillows, head rests, sleep pillows or lumbar support cushions. The pillow of the present invention is hypoallergenic and is machine washable and dryable.

The foregoing is considered as illustrative only of the principles of the invention. Numerous modifications and changes will readily occur to those skilled in the art, and it is not desired to limit the invention to the exact construction and operation shown and described. All suitable modifications and equivalents that fall within the scope of the appended claims are deemed within the present inventive concept. It is also to be understood that the terminology used is for the purpose of description and should not be regarded as limiting in any respect.

Claims

CLAIMSWhat is claimed is:

1. A pillow comprising a pillow cover; and

. a pillow filling, wherein the pillow filling is a mixture of microbeads and at least one other component.

2, The pillow of claim 1 , wherein the microbeads comprise between 30% and 85% by volume of the pillow filling.

3. ■ The pillow of claim 2, wherein the microbeads comprise about 75% by volume of the pillow filling.

4. The pillow of claim 1 , wherein the microbeads have a diameter bf between 0.3 and 0.8 mm.

5. The pillow of claim 1, wherein the at least one other component comprises microfibres selected from the group of micrαfibres consisting of polyester microfibres. silk microfibres and natural wool microfibres.

6. The pillow of claim 1 , further comprising a pillowcase for insertion therein of the pillow.

7. The pillow of claim 6 wherein the pillow cover and pillowcase are manufactured of a material which is 2-way stretchable.

8. The pillow of claim 6 wherein the pillow cover and pillowcase are manufactured of a material which is 4-way stretchable.

9. The pillow of claim S wherein the pillowcase is manufactured of a velour-spaπdex composite fabric.

10. The pillow of claim 1, wherein the pillow filling further comprises an antistatic coating,

11. The pillow .of claim 6, further comprising fastening, means .integrated along adjacent upper and lower edges of at least one side of the .pillowcase for reversibly enclosing the pillow,

12. The pillow of claim 1. further comprising means for changing the dimensions of the pillow.

13. The pillow of claim 12 wherein the means for changing the dimensions of the pillow comprises a drawstring inserted within a seam integrated into the pillow cover.

14. The pillow of claim 12 wherein the means for changing the dimensions of the pillow comprises a drawstring inserted within a seam integrated into the pillowcase.

.

15. A pillow comprising a pillow cover; a pillow filling, wherein the pillow filling is a mixture of microbeads treated . with an antistatic coating and microfibres selected from the group of microfibres consisting of polyester microfibres,, silk microfibres and natural wool microfibres; a pillowcase for insertion therein of the pillow; wherein the pillow cover and pillowcase are manufactured of a material which is 4-way.stretchable; fastening means integrated along adjacent upper and lower edges of at least one side of the pillowcase for reversibly enclosing the pillow; and means for changing the dimensions of the pillow comprising a drawstring inserted within a seam integrated into the pillowcase..

16. An adjustable pillow comprising a pillow cover; a pillow filling, wherein the pillow filling is a mixture of microbeads and at least one other component;

5 a pillowcase for insertion therein of the pillow; and pillow adjustment means for changing the dimensions of the pillow.

17. The adjustable pillow of claim 16, wherein the at least one -other component ■comprises microfibres selected from the group of microfibres consisting of polyester microfibres, silk microfibres and natural wool microfibres. ip 18. A method of manufacturing an improved microbead pillow, comprising the following steps: a) treating microbeads with an antistatic coating; b) combining treated microbeads with microfibres to produce a treated rnicrobead-microfibre complex filling;

15 c) packing the treated microbead-microfibre complex filling into a pillow coven arid d) sealing the pillow cover.