U.S. patent application number 09/918519 was filed with the patent office on 2003-02-13 for pillow stuffed with latex foam crumbs.
Invention is credited to Rossdeutscher, Ralph H..
Application Number | 20030028969 09/918519 |
Document ID | / |
Family ID | 25440506 |
Filed Date | 2003-02-13 |
United States Patent
Application |
20030028969 |
Kind Code |
A1 |
Rossdeutscher, Ralph H. |
February 13, 2003 |
Pillow stuffed with latex foam crumbs
Abstract
A method of manufacturing a pillow, comprising the steps of
granulating pieces of latex foam to produce a variety of sizes of
latex foam crumbs; passing the crumbs through a screen to generally
exclude most latex foam crumbs which are greater than a
predetermined nominal diameter; filling a pillow casing with the
screened crumbs; and sealing the casing shut to capture the latex
foam crumbs. The screen optimally has apertures approximately 3/8
inch (9.5 mm) in diameter to produce a pillow comprising a casing
filled with latex foam crumbs where the latex foam crumbs are in a
variety of sizes, generally not exceeding about 1 inch (25.4 mm) in
nominal diameter.
Inventors: |
Rossdeutscher, Ralph H.;
(Cambridge, CA) |
Correspondence
Address: |
BORDEN LADNER GERVAIS LLP
WORLD EXCHANGE PLAZA
100 QUEEN STREET SUITE 1100
OTTAWA
ON
K1P 1J9
CA
|
Family ID: |
25440506 |
Appl. No.: |
09/918519 |
Filed: |
August 1, 2001 |
Current U.S.
Class: |
5/636 |
Current CPC
Class: |
B68G 2001/005 20130101;
A47G 9/10 20130101; B68G 1/00 20130101 |
Class at
Publication: |
5/636 |
International
Class: |
A47C 020/02; A47C
020/04; A47C 020/06; A47C 020/08 |
Claims
1. A pillow comprising a casing filled with latex foam crumbs.
2. A pillow as recited in claim 1, wherein said latex foam crumbs
are in a variety of sizes, generally not exceeding about 1 inch
(25.4 mm) in nominal diameter.
3. A pillow as recited in claim 1, wherein the weight of latex foam
crumbs for a standard-sized pillow having a casing approximately 26
cm.times.36.5 cm when empty and flat is in the range of 2.0-3.3 lbs
(0.91-1.50 kg).
4. A pillow as recited in claim 3, wherein the weight of latex foam
crumbs is approximately 2.7 lbs (1.23 kg).
5. A pillow as recited in claim 1, wherein the weight of latex foam
crumbs for a queen-sized pillow having a casing approximately 30
cm.times.36.5 cm when empty and flat is in the range of 2.5-3.6 lbs
(1.13-1.63 kg).
6. A pillow as recited in claim 5, wherein the weight of latex foam
crumbs is approximately 3.1 lbs (1.41 kg).
7. A pillow as recited in claim 1, wherein the weight of latex foam
crumbs for a king-sized pillow having a casing approximately 35
cm.times.36.5 cm when empty and flat is in the range of 3.0-4.5 lbs
(1.36-2.04 kg).
8. A pillow as recited in claim 7, wherein the weight of latex foam
crumbs is approximately 3.7 lbs (1.68 kg).
9. A method of manufacturing a pillow, comprising the steps of:
granulating pieces of latex foam to produce a variety of sizes of
latex foam crumbs; passing said latex foam crumbs through a screen
to generally exclude most latex foam crumbs which are greater than
a predetermined nominal diameter; filling a pillow casing with said
screened latex foam crumbs; and sealing said casing shut to capture
said latex foam crumbs.
10. A method as recited in claim 9, wherein said screen has
apertures approximately 3/8 inch (9.5 mm) in diameter to let
through said screen only latex foam crumbs generally not exceeding
about 1 inch (25.4 mm) in nominal diameter.
11. A method as recited in claim 9, wherein said sealing step is
performed by sewing said casing shut.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to pillows, and more precisely to the
filling used inside the pillow casing.
[0002] A pillow typically consists just of a sewn outer casing or
"ticking", which may for example be of cotton, polyester, or blends
of same, along with many other possible materials. Prior to being
sewn shut, the outer casing is stuffed with feathers, down,
polyester fill, a latex foam block, or a wide variety of other
materials.
SUMMARY OF THE INVENTION
[0003] In the invention, chunks of latex foam, for example scrap
left over from latex foam mattress production, are put through a
granulator, and are then screened to provide an irregular mixture
of relatively small latex foam rubber particles, which are then
used to fill the pillow casing.
[0004] Preferably the screening is conducted through holes which
are 3/8 inch (9.5 mm) in diameter. This provides a suitable size
distribution of particles to provide the desired feather-like feel
for the pillow. If the chunks are too small, then there is too much
compaction and the pillow becomes quite hard. On the other hand, if
the chunks are too large, discrete pieces can be felt, i.e. the
pillow has a lumpy feel for the user. Although it is not essential
that the 3/8 inch screen size be used, this size has been found to
be optimum, in the inventor's opinion. Note that the 3/8 inch
screen size does not necessarily limit the size of the crumbs to
3/8 inch, since some larger pieces can be compressed and forced
through the holes, but the 3/8 inch holes provide a good mixture of
sizes.
[0005] Thus, a pillow is produced according to the invention,
wherein the latex foam crumbs are in a variety of sizes, generally
not exceeding about 1 inch (25.4 mm) in nominal diameter. A certain
amount of slightly over-size crumbs will be pushed through the
screen openings, as detailed above, due to the compressible nature
of the latex material of the crumbs.
[0006] Preferably, the weight of latex foam crumbs for a
standard-sized pillow having a casing approximately 26
cm.times.36.5 cm when empty and flat is in the range of 2.0-3.3 lbs
(0.91-1.50 kg). Optimally, the weight of latex foam crumbs is
approximately 2.7 lbs (1.23 kg).
[0007] Preferably, the weight of latex foam crumbs for a
queen-sized pillow having a casing approximately 30 cm.times.36.5
cm when empty and flat is in the range of 2.5-3.6 lbs (1.13-1.63
kg). Optimally, the weight of latex foam crumbs is approximately
3.1 lbs (1.41 kg).
[0008] Preferably, the weight of latex foam crumbs for a king-sized
pillow having a casing approximately 35 cm.times.36.5 cm when empty
and flat is in the range of 3.0-4.5 lbs (1.36-2.04 kg). Optimally,
the weight of latex foam crumbs is approximately 3.7 lbs (1.68
kg).
[0009] A method of manufacturing a pillow according to the
invention comprises the steps of:
[0010] granulating pieces of latex foam to produce a variety of
sizes of latex foam crumbs;
[0011] passing the latex foam crumbs through a screen to generally
exclude most latex foam crumbs which are greater than a
predetermined nominal diameter;
[0012] filling a pillow casing with the screened latex foam crumbs;
and
[0013] sealing the casing shut to capture the latex foam
crumbs.
[0014] The screen preferably has apertures approximately 3/8 inch
(9.5 mm) in diameter to let through the screen only latex foam
crumbs generally not exceeding about 1 inch (25.4 mm) in nominal
diameter.
[0015] Preferably, the sealing step is performed by sewing the
casing shut. Alternatively, the casing may be glued, fused,
zippered or riveted shut, for example.
[0016] Further features of the invention will be described or will
become apparent in the course of the following detailed
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will now be described in detail with reference
to the accompanying drawings of the preferred embodiment, in
which:
[0018] FIG. 1 is a cut-open perspective view of a pillow according
to the invention; and
[0019] FIG. 2 is a block diagram of the method of manufacturing the
pillow.
DETAILED DESCRIPTION
[0020] FIG. 1 shows a pillow 1 having an outer casing or ticking 2,
filled with latex foam crumbs 3.
[0021] FIG. 2 shows the method of manufacturing the pillow, in
which latex foam blocks (scrap pieces, for example) are put through
a granulator, i.e. a comminution device typically of the type
having counter-rotating knives, to break the blocks into small
pieces. The granulated pieces are then screened, preferably through
holes which are 3/8 inch (9.5 mm) in diameter. As discussed above,
the hole size could be varied as desired, but this particular hole
size is believed to be optimum. This process produces a mixture of
sizes, from slightly over 3/8 inch, down to bread-crumb size. This
mixture provides a very comfortable overall texture, which deforms
and shifts to a desirable degree, while still remaining somewhat
resilient.
[0022] Another factor in producing the desired "feel" for the
pillow is how much of the granulated and screened latex foam is
inserted into the pillow, i.e. the overall density. The inventor
has found that the following weights are optimum, though obviously
these weights could be varied according to personal preference and
the particular material used for the crumbs:
1 Casing Weight of latex foam crumbs, in lbs dimensions Minimum
Maximum when empty and for soft for hard Pillow size flat (cm.)
pillow Optimum pillow Standard 26 .times. 36.5 2.4 2.7 3.0 Queen 30
.times. 36.5 2.8 3.1 3.4 King 35 .times. 36.5 3.4 3.7 4.0
[0023] Note that in the above table, the "minimum" and "maximum"
numbers should not be interpreted to mean that numbers outside
those ranges are not possible. They merely indicate the inventor's
preference. In the inventor's opinion, weights outside the above
ranges will not be ideal for marketing, but they may appeal to
certain individual preferences.
[0024] It will be appreciated that the above description relates to
the preferred embodiment by way of example only. Many variations on
the invention will be obvious to those knowledgeable in the field,
and such obvious variations are within the scope of the invention
as described and claimed, whether or not expressly described.
[0025] For example, latex foam material has been described as being
the preferred material. Any material having suitable properties
equivalent to foam latex may be used. A further advantage cost-wise
is to use scrap material, which reduces material cost and increases
the positive environmental impact of the manufacture of pillows
according to the invention.
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