U.S. patent application number 11/122388 was filed with the patent office on 2006-11-09 for stuffing, filler and pillow.
This patent application is currently assigned to Creative Bedding Technologies, Inc.. Invention is credited to Robert Apitz, Theodosius A. Lazakis, Arthur J. Martelli.
Application Number | 20060248651 11/122388 |
Document ID | / |
Family ID | 37392731 |
Filed Date | 2006-11-09 |
United States Patent
Application |
20060248651 |
Kind Code |
A1 |
Lazakis; Theodosius A. ; et
al. |
November 9, 2006 |
Stuffing, filler and pillow
Abstract
A stuffing or filler for use with pillows, cushions, comforters,
duvets and textiles. In an embodiment, the stuffing is comprised of
pieces of foam sheets. The foam sheets can contain encapsulated gas
bubbles. The foam sheets are shredded or sheared into foam pieces.
In a preferred embodiment, these foam pieces have a thickness of
approximately 180-3200 microns and a length of approximately 0.5-10
cm. The foam sheets are comprised of polyethylene, polypropylene,
nylon, polyester, polyvinylchloride or other polymeric material.
The foam pieces exhibit positive characteristics as a stuffing or
insulator and exhibit good loft and rebound characteristics. The
foam pieces form stuffing, filler or insulators in pillows,
cushions, duvets, and the like.
Inventors: |
Lazakis; Theodosius A.;
(Long Grove, IL) ; Apitz; Robert; (Cary, IL)
; Martelli; Arthur J.; (Naperville, IL) |
Correspondence
Address: |
BANNER & WITCOFF, LTD.
TEN SOUTH WACKER DRIVE
SUITE 3000
CHICAGO
IL
60606
US
|
Assignee: |
Creative Bedding Technologies,
Inc.
Crystal Lake
IL
|
Family ID: |
37392731 |
Appl. No.: |
11/122388 |
Filed: |
May 5, 2005 |
Current U.S.
Class: |
5/636 ; 5/655.9;
5/953 |
Current CPC
Class: |
A47G 9/10 20130101; B68G
2001/005 20130101; B68G 1/00 20130101 |
Class at
Publication: |
005/636 ;
005/953; 005/655.9 |
International
Class: |
A47G 9/00 20060101
A47G009/00 |
Claims
1. A stuffing, comprising foam pieces comprised of plastic, wherein
a plurality of said foam pieces include enveloped gas bubbles and
wherein said plurality of foam pieces have a thickness of
approximately 180-3200 microns, a length of approximately 1-8 cm,
are non-uniform and contain bends.
2. The stuffing of claim 1 wherein the plurality of foam pieces
have a thickness of approximately 520-800 microns.
3. The stuffing of claim 2 wherein the plastic is
polypropylene.
4. The stuffing of claim 2 wherein the plastic is polyethylene.
5. The stuffing of claim 1, wherein the foam pieces have a length
to thickness ratio of approximately between 25:1 and 100:1.
6. A stuffing, comprising: foam pieces comprised of plastic,
wherein a plurality of said foam pieces includes enveloped gas
bubbles and wherein said plurality of foam pieces has a thickness
of approximately 180-3200 microns and a length of approximately 1-8
cm, and plastic film pieces, wherein said plastic film pieces have
a thickness of approximately 10-50 microns and a length of
approximately 0.5-10 cm.
7. The stuffing of claim 6 wherein the plastic film pieces and the
plurality of foam pieces are comprised of one or more of the
following: polyethylene or polypropylene.
8. The stuffing of claim 7 wherein the weight ratio of foam pieces
to film pieces is approximately between 1 to 2 and 1 to 4.
9. The stuffing of claim 8 wherein said plurality of foam pieces
have a thickness of less than approximately 800 microns and a
length of approximately 1-8 cm, and wherein the plurality of foam
pieces are non-uniform and contain bends.
10. A filler comprising, a plurality of thin foam pieces, gas
enveloped in at least one of said plurality of thin foam pieces,
wherein said plurality of foam pieces have a thickness of
approximately between 180 and 1600 microns, a length of
approximately between 1 and 6 centimeters, a melting point of no
less than approximately 200 degrees Fahrenheit, and a length to
thickness ratio of at least 25:1.
11. The filler of claim 10 further comprising an antimicrobial
agent.
12. The filler of claim 11 wherein the antimicrobial agent is
incorporated into the plurality of thin foam pieces during the melt
stage of the plurality of thin foam pieces.
13. The filler of claim 10 wherein the plurality of foam pieces are
comprised of one or more of the following: polyethylene or
polypropylene, and the plurality of foam pieces comprise generally
separate foam pieces that are generally not adhered to other foam
pieces.
14. The filler of claim 10, wherein the foam pieces have a
thickness of approximately 520-540 microns and the filler has a
loft coefficient of approximately 12-15.
15. A pillow comprising, A plurality of foam plastic members,
wherein said plurality of foam plastic members have a thickness of
approximately between 360-800 microns and a length of between 1-6
centimeters, and a pillow casing.
16. The pillow of claim 15 wherein the plurality of foam plastic
members exhibit of loft coefficient of approximately 10-15 and the
pillow has a rebound factor of less than approximately 3.5.
17. A stuffing, comprising, A plurality of plastic foam pieces, Gas
bubbles enveloped in at least one of said plurality of plastic foam
pieces, and An antimicrobial agent, Wherein at least one of said
plurality of plastic foam pieces has a thickness of approximately
between 360-800 microns, has a length of approximately 2-4 cm, and
has a melting point of more than 200 degrees Fahrenheit.
18. A pillow comprising, A casing, and A stuffing, Said stuffing
comprising a plurality of shredded plastic foam pieces with a
length to thickness ratio of at least approximately 25 to 1, and a
melting temperature of no less than approximately 200 degrees
Fahrenheit, and wherein the stuffing has a loft coefficient of
approximately 10-15, and the pillow has a rebound factor of less
than approximately 3.5.
19. The pillow of claim 18 wherein the pillow further comprises a
fire retardant.
20. The pillow of claim 18 wherein the plastic in the plurality of
shredded plastic foam pieces is one or more of the following:
polyethylene or polypropylene, and wherein at least a number of the
plurality of shredded plastic foam include gas bubbles encompassed
by the shredded plastic foam.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to plastic,
polymeric fillers, stuffings and insulators and their use in
pillows, cushions, mattresses, blankets, duvets, jackets and
textiles.
BACKGROUND OF THE INVENTION
[0002] Pillows and other cushions are often made with stuffings.
These stuffings can include natural materials such as feathers or
wool. However, these natural materials have many drawbacks. The
natural materials can contain matter, such as quills, or
contaminants that can have a detrimental effect on the properties
of the stuffing. In addition, the natural materials can have
unpleasant odor effects in certain environments and can be fairly
costly. Natural materials can also have the additional drawback of
causing allergic reactions in some users.
[0003] An alternative to natural stuffings is artificial stuffings.
The artificial stuffings eliminate some of the negative
characteristics of the natural stuffings. The artificial stuffings
can be hypoallergenic, can minimize odor issues and can dispense
with the use of hard materials such as quills. However, numerous
artificial stuffings present drawbacks. Many materials that could
be used for artificial stuffings have a low melting point which
makes drying the stuffing in a conventional dryer without melting
the stuffing difficult or impossible. In addition, many artificial
stuffings do not behave similar to natural stuffings and exhibit
less desirable loft and rebound characteristics than natural
stuffings.
[0004] The present invention is designed to overcome some of the
drawbacks of previous materials.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention provides a stuffing, filler or
insulator for use in pillows, cushions, blankets, textiles and the
like. In an embodiment a stuffing or filler is comprised of pieces
of plastic foam sheets. The foam pieces include gas bubbles that
are enveloped within the foam. These bubbles provide for increased
resiliency, springiness and other beneficial features. The foam
sheets are shredded or torn into smaller pieces through the use of
devices such as knives or other shearing instruments. The foam
pieces in an embodiment have a thickness of approximately 180-3200
microns and a length of approximately 0.5-10 cm after shearing. The
foam pieces can be used as a stuffing or filler in a pillow or
comforter or can be used as a stuffing, filler or insulator in
textiles.
[0006] In an embodiment, the foam pieces can be made from
polyethylene or polypropylene blown foam or a combination of the
two. The foam pieces can include antimicrobial agents and can
exhibit hypoallergenic characteristics. The foam pieces also can
exhibit beneficial loft and rebound characteristics which provide
for an enhanced and more natural-feeling pillow.
[0007] Other features and advantages of the invention will become
apparent to those skilled in the art upon review of the following
detailed description, claims and drawings in which like numerals
are used to designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows schematically how the foam pieces of the
present invention are produced from foam sheets.
[0009] FIG. 2 depicts an enlarged side view of a foam piece of an
exemplary embodiment of the present invention.
[0010] Before the embodiments of the 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 arrangement
of the components set forth in the following description or
illustrated in the drawings. The invention is capable of other
embodiments and of being practiced or being carried out in various
ways. Also, it is to be understood that the phraseology and
terminology used herein are for the purpose of description and
should not be regarded as limiting. Rather, the phrases and terms
used herein are to be given their broadest interpretation and
meaning. The use of "including" and "comprising" and variations
thereof is meant to encompass the items listed thereafter and
equivalents thereof as well as additional items and equivalents
thereof.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0011] The present invention involves plastic material that can
function as a stuffing, cushion, filler, insulator, absorber or
other material suited for individual plastic matter. In one
embodiment, the present invention involves foam sheets. These foam
sheets are made from plastic or natural materials. Polypropylene,
polyethylene, polyvinylchloride, nylon, polyester, epoxy, polyvinyl
acetate, copolymers and other polymeric materials can be used in
the foam sheets. In addition, in some embodiments, chemical or
physical blends of different plastics can be used. The foam sheets
can take the form of blown foam or other forms of foam sheets. The
foam sheets are formed from processes well known in the industry,
for example through use of blowing agents, including agents such as
sodium bicarbonate, hydrazine, halocarbons, fluorocarbons or
hydrofluorocarbons.
[0012] In some embodiments, the foam sheets include encapsulated
gas. In the process of manufacturing the foam, gas can be embedded
within the foam. Gas bubbles such as air or other gas can be
incorporated into the foam and become enveloped in the foam sheets.
Many of these gas bubbles are fully enclosed and thus the foam
itself contains numerous gas filled bubbles within the structure of
the foam.
[0013] These gas bubbles can impart certain properties to the foam.
Foam containing these bubbles can exhibit increased resiliency and
cushioning. The foam can feel soft and may rebound after
compression. The gas bubbles can allow the foam to deform and then
rebound to a post-deformation shape. The foam in some embodiments
has a three dimensional structure that imparts a rich and pleasing
hand-feel to the foam. The structure also can allow for loads to be
displaced in three dimensions internally within the foam structure.
The gas bubbles generally do not burst when a reasonable load is
placed on them, such as a load similar to that of a human head
resting on a pillow.
[0014] The foam sheets, in some embodiments have a thickness of
approximately 90-5000 microns. In a preferred embodiment the foam
sheets have a thickness of approximately 180-3200 microns. In an
additional preferred embodiment the foam sheets have a thickness of
approximately 360-1600 microns. In a further preferred embodiment
the foam sheets have a thickness of approximately 360-800 microns.
In a highly preferred embodiment, the foam sheets have a thickness
of approximately 520-540 microns. In an additional highly preferred
embodiment, the foam sheets have a thickness of approximately
780-800 microns. I a further highly preferred embodiment, the foam
sheets have a thickness of approximately 380-410 microns.
[0015] In some embodiments, as shown in FIG. 1, initial long foam
sheets 10 are manufactured into smaller foam pieces 20. One method
of such manufacture involves the cutting or shredding of the foam
sheets. In this method, foam sheets 10 are passed through rollers
14 and into a shearing chamber 30. The shearing chamber includes a
plurality of knives or other shearing instruments 40. These
shearing instruments spin around an axis. The foam sheets in the
chamber are sheared by the knives into smaller pieces. These
smaller pieces may be subjected to the knives on several occasions
while the pieces remain in the chamber. Each time a foam piece is
subjected to a shearing instrument it generally is sheared into a
smaller piece.
[0016] In one embodiment, the shearing chamber also includes a
screen 50. The screen 50 is sized to allow only foam pieces below a
certain size to fit through the screen. Foam pieces of a larger
size remain in the shearing chamber until they are sheared to a
smaller size. After the foam pieces pass through the screen, they
exit the shearing chamber. Foam pieces that have exited the
shearing chamber are shown as 24 in FIG. 1. In some embodiments,
sheets can be introduced into the shearing chamber at a rate of
approximately 20-120 ft./min., preferably 40-90 ft./min. and more
preferably 50-70 ft./min. In other embodiments, the sheets are torn
or cut into smaller pieces by other mechanical or non-mechanical
cutting or shearing processes.
[0017] In some embodiments, as shown in FIG. 1, plastic film sheets
16 can be introduced into the shearing chamber 30 at the same time
as foam sheets 10. Through the shearing process, the film sheets
will be sheared into film pieces 26. When the plastic film pieces
reach a size small enough to pass through the screen 50, they can
pass out of the shearing chamber 30 (as shown by plastic film
pieces 28). The plastic film sheets 16 can be narrower or wider
than the plastic foam sheets 10. Moreover, more than one film sheet
and more than one foam sheet can enter the hearing chamber at the
same time. The foam pieces and film pieces in FIGS. 1 and 2 are not
drawn to scale.
[0018] The mechanical cutting, shearing or milling process creates
foam pieces of a smaller length and width. In some embodiments, the
length of the foam pieces ranges from approximately 0.5 cm to 10
cm. Preferably, the foam pieces have a length of approximately 1 to
8 cm, more preferably a length of approximately 1-6 cm and more
preferably a length of approximately 2-4 cm. The manufacturing in
some embodiments also may cause the foam pieces to exhibit a
non-uniform shape. In such embodiments, the foam pieces contain
numerous bends and deformations and varying lengths, and the foam
pieces may vary in shape and size. The foam pieces can be generally
separate from each other and generally not adhered to each other.
Depending on the manufacturing process used, the foam pieces also
can be created with generally uniform shapes and sizes and without
bends or deformations. The foam sheets can have a ratio of length
to thickness of approximately 500:1-4:1, preferably 150:1-10:1 and
more preferably 100:1-25:1.
[0019] The foam pieces generally continue to contain gas bubbles
after being subjected to the shearing, cutting or milling process
in some embodiments. In some embodiments, as shown in FIG. 2, gas
bubbles 60 (shown in dotted lines to indicate their position within
a foam sheet piece) remain enveloped within the structure of the
foam pieces 70. These gas bubbles may be generally randomly
distributed through the foam pieces, as shown in FIG. 2, or may be
evenly distributed. The foam pieces can exhibit resiliency and a
springiness based on the interior characteristics of the bubbles as
well as the exterior structure of the foam pieces themselves.
[0020] The encapsulated bubbles can provide for increased
mechanical characteristics over stuffing made entirely of flat
films. Foam pieces with enveloped bubbles, can have increased
physical properties due to the structure of the interior of the
foam, in addition to the exterior of the foam. The interior
structure may allow for increased resiliency, flexibility,
strength, elasticity and softness of the foam. The three
dimensional structure may apportion weight internally along the x,
y and z axis. In some embodiments some or all of the bubbles may be
broken during the manufacturing stage. The broken bubbles 80 can
provide for a rich three dimensional structure that allows for
displacement of loads along three axis of dimension.
[0021] The foam pieces in some embodiments contain antimicrobials,
antifungals, fire retardants, aromatic or medicinal compounds or
other additives. In some embodiments additives, such as
antimicrobials, can be added prior to formation of the plastic
polymer foam, such as in the melt stage. The antimicrobial,
anti-fungal or other additives impart beneficial properties to the
foam pieces and increase their life cycle when used as a stuffing
or insulator. Numerous antimicrobials and antifungals are known in
the art and can be used in the present invention. In some
embodiments, the antimicrobials or antifungals are added topically
after foam formation or after milling or shearing rather than
during the melt stage of foam formation.
[0022] The foam pieces in some embodiments are hypoallergenic. The
foam pieces also can be chemically inert. Such foams can be highly
useful in stuffings for pillows, mattresses and comforters,
especially when used with compromised individuals, such as in a
hospital or care facility.
[0023] In some embodiments, the foam pieces have a melting
temperature that allows the foam pieces to be dried in a
conventional drier. In some embodiments foams have a melting
temperature of approximately 265-285 degrees Fahrenheit. In other
embodiments, foams have a melting temperature of approximately
325-345 degrees Fahrenheit. In some embodiments, stuffings
including foam pieces or stuffings consisting solely of foam pieces
have a melting temperature of no less than 200 degrees. In other
embodiments, stuffings including foam pieces or stuffings
consisting solely of foam pieces have a melting temperature of no
less than 250 degrees, 300 degrees or 350 degrees Fahrenheit.
[0024] The foam pieces of the present invention, in some
embodiments, can be washed in conventional machines as well as
dried. Such characteristics are useful when the foam pieces are
used as stuffings in bedding materials, pillows, comforters,
blankets, quilts, mattresses, or the like, including bedding
materials used in multiple-user settings, such as hotels or
hospitals. The foam pieces in some embodiments do not bunch
together or migrate when subject to mechanical processes such as
washing and drying.
[0025] The foam pieces of the present invention, in some
embodiments, are soft and exhibit a pleasant hand feel. Although
silicone or anti-friction agents can be added to the foam, the
addition of silicone or these agents is not necessary to produce
desired levels of softness and hand feel in some embodiments. When
used in mattresses, in some embodiments the foam pieces of the
invention can be incorporated into the main mattress or into a
mattress topper. In some embodiments, mattresses that include at
least a portion of the foam pieces of the present invention can
exhibit reduced pressure in the mattress topper.
[0026] The foam pieces of the present invention can be used with a
number of materials. In some embodiments, the foam pieces can be
used as a stuffing. This stuffing can be used in pillows, cushions,
pads, mattresses, comforters, textile products, insulators,
jackets, quilts, pants, textiles, clothing, outer gear, furniture
or other products that take a stuffing. The foam pieces can be used
by themselves or with additives such as antimicrobials,
antifungals, fire retardants or others, some of which are
specifically discussed herein. The foam pieces also can be used in
connection with other stuffings, insulators or materials. In some
embodiments, the foam pieces of the present invention make up the
majority of a stuffing or the material within an object such as a
pillow, cushion or comforter. In other embodiments, the foam pieces
make up the great majority or all of the stuffing. In still other
embodiments, the foam pieces make up a minority, 25%, or less of
the stuffing in the object, such as a pillow.
[0027] The foam pieces in some embodiments can be used in
connection with films such as plastic films. Polyethylene film,
polypropylene film, polyester film and nylon film are examples of
plastic films that can be used with the foam pieces. One or more of
these films can be sheared or shredded into film pieces. The films,
in some embodiments, have a thickness of 5-100 microns, preferably
10-50 microns and more preferably 15-25 microns. After being
sheared, the films in some embodiments have a length of
approximately 0.5-20 cm, preferably 1-10 cm and more preferably
3-10 cm. This film can be combined with the foam before, during or
after the shearing process. In one embodiment polyethylene foam
sheets and polyethylene film sheets are placed into a shearing
chamber at the same time. Each of the sheets is shredded and the
resulting mixture contains pieces of the polyethylene foam and
pieces of the polyethylene film. Other films or foam sheets, such
as polypropylene film and foam, also can be run through the
shearing chamber at the same time or separately.
[0028] In some embodiments, stuffings or fillers including foam
pieces or stuffings or fillers consisting solely of foam pieces can
exhibit a high degree of loft. The three dimensional structure of
the foam pieces, the encapsulated bubbles and the exterior of the
structure adds to the loft of the stuffing. Loft can be measured in
relation to the density of the stuffing or filler after agitation
or infusion of gas such as air. A loft coefficient for a stuffing
or filler can be calculated by initially placing approximately 114
grams (4 oz.) of stuffing into a 15 liter graduated cylinder. The
cylinder is closed and then vertically agitated for approximately
15 seconds. The edges of the cylinder are then briefly tapped to
release foam pieces adhering thereto. The volume of stuffing or
filler in the cylinder provides a correlation to the loft of the
foam. The volume of stuffing or filler in the cylinder is the same
as the loft coefficient. Stuffing or filler with a volume of 10
liters in the cylinder corresponds to a loft coefficient of 10. In
this test, the maximum loft coefficient is 15. Stuffing or filler
with a volume of 6.5 liters in the cylinder corresponds to a loft
coefficient of 6.5. In some embodiments of the present invention,
the stuffing or filler can have a loft coefficient of 5-15,
preferably, 10-15 and more preferably 12-15.
[0029] In some embodiments, stuffings or fillers consisting
partially of foam pieces or stuffings consisting solely of foam
pieces can exhibit good rebound characteristics. After a
deformation load placed on the stuffing or filler and removed,
stuffings or fillers in some embodiments will move or rebound to a
post-deformation shape and form. The stuffings or fillers may not
rebound to their pre-deformation shape. However, they will rebound
to a post-deformation shape shortly after removal of the
deformation load. This post-deformation shape will not necessarily
be the final shape for the stuffing or filler and it may gradually
move closer to its pre-deformation shape and form. The rebound
characteristics are not immediate and in some embodiments the
rebound characteristics more closely mirror those of natural
stuffings or fillers than other artificial stuffings. The stuffings
or fillers do not immediately rebound to their post-deformation
shape or form. In some embodiments, it can take more than 2, 5, 10
or 20 seconds for the stuffing to reach to its post-deformation
state.
[0030] The amount of time it takes for the stuffing or filler to
reach its post-deformation shape after a deformation load has been
removed is defined as the rebound factor. The rebound factor is
calculated through use of a nine pound sphere with a ten inch
diameter. Approximately 681 g. (1.5 lbs.) of stuffing or filler can
be used to fill a standard pillow. The casing for a standard pillow
has unfilled dimensions of 20 inches by 26 inches. The standard
pillow is placed on a flat surface in the position a pillow is
usually placed on a bed for sleeping. The weight is then dropped
onto the pillow from a distance of approximately 12 inches above
the pillow and approximately immediately raised thereafter. The
amount of rebound of the filling or stuffing in the pillow in the
vertical direction is measured over several seconds. The rebound
factor can is defined as the vertical deformation of the pillow 1
second after the weight is removed minus the vertical deformation
of the pillow at the time the weight is applied, with that total
calculated amount divided by the vertical deformation of the pillow
at approximately 5 seconds after the weight is removed. This
quotient is then squared. This formula for the deformation factor
is detailed below. Deformation Factor=(((deform. @1 sec.)-(deform.
when weight applied))/deform. at 5 sec).sup.2 In some embodiments,
the stuffing has a rebound factor of less than approximately 11.5,
preferably less than approximately 3.5 and more preferably less
than approximately 2.0.
[0031] A test was conducted on a standard pillow that had been
stuffed with polyethylene foam pieces with a thickness of
approximately 520-540 microns and polyethylene film pieces with a
thickness of approximately 17-21 microns. The ratio of polyethylene
foam to polyethylene film was approximately 1:3. This stuffing is
referred to as "A Stuffing Embodiment" in the table below. These
tests revealed that the deformation with the weight applied was
approximately -5 cm. One second after the weight was removed, the
deformation was approximately -4 cm. 5 seconds after the weight was
removed the deformation was approximately -1.9 cm. According to the
formula above, the deformation factor for "A Stuffing Embodiment"
was calculated as 0.28.
[0032] Tests were conducted on standard pillows stuffed with
different materials. The results of these tests are shown in the
table below. TABLE-US-00001 Deformation Deformation Deformation
Rebound Stuffing with Weight at 1 Second at 5 Seconds Factor
Polyester ball -5 cm -2.3 cm -0.8 cm 11.39 fiber Feathers -5 cm
-3.5 cm -1.1 cm 1.86 Down -5 cm -4 cm -2.1 cm 0.23 "A Stuffing -5
cm -4 cm -2.1 cm 0.28 Embodiment"
[0033] The following are examples of some of the embodiments of the
invention and are offered for purposes of illustration. The
examples are not intended to limit the scope of the invention
Example 1
[0034] Polyethylene foam sheets are created using standard foam
blowing techniques. The polyethylene foam sheets have a thickness
of approximately 390-410 microns or 1/64 of an inch. These foam
sheets contain numerous encapsulated or enveloped air bubbles. The
polyethylene foam sheets are then subjected to a shearing process.
The sheets are fed into a shearing chamber at a rate of
approximately 70 ft/min. Shearing instruments in the chamber cut
the foam sheets into numerous foam pieces. These foam pieces have a
length in the range of approximately 0.5-10 cm. The majority of the
foam pieces have a length in the range of approximately 2-4 cm. The
polyethylene foam pieces are then used as a stuffing. The foam
pieces are placed inside a pillow casing, which is then closed. The
resulting pillow is comfortable in use.
Example 2
[0035] Polyethylene foam sheets with a thickness of approximately
360-540 microns are obtained. In addition, polypropylene foam
sheets are created using standard foam blowing techniques. The
polypropylene sheets include enclosed gas bubbles and have a
thickness of approximately 780-800 microns. The polypropylene foam
sheets and the polyethylene foam sheets are fed into a shearing
chamber simultaneously. The shearing chamber tears the sheets into
individual pieces with a length of approximately 1-10 cm. The
majority of the individual pieces have length of approximately 2-4
cm. The polypropylene and polyethylene foam pieces are mixed with
each other as a stuffing. The polyethylene foam pieces and
polypropylene foam pieces are then placed inside a pillow casing in
an approximately equal ratio. The pillow casing in then closed to
form a pillow.
Example 3
[0036] Polyethylene foam sheets and polypropylene foam sheets, each
with encapsulated air are subjected to a shearing process. The
polyethylene foam sheets have a thickness of less than
approximately 800 micrometers. The polypropylene foam sheets also
have a thickness ranging from approximately 360-1600 micrometers.
The polyethylene foam sheets and the polypropylene foam sheets are
subjected to a shearing chamber. The sheets are placed one on top
of the other as they pass through the shearing chamber. After the
shearing process, the pieces have a length of approximately 1-6
cm.
[0037] The resulting polyethylene and polypropylene pieces make up
a stuffing that has a good handfeel. The weight ratio of
polypropylene pieces to polyethylene pieces is 1:2. The
polyethylene pieces and polypropylene pieces are combined with a
polyethylene film that has been subjected to a shearing chamber and
does not include encapsulated air. The weight ratio of foam pieces
to polyethylene film is 1:1. The foam pieces and polyethylene film
are then placed into a synthetic pillow case open on one end. The
pillow case is then closed.
Example 4
[0038] Polyethylene foam sheets with a thickness of approximately
520-540 micrometers or 1/48 of an inch are subjected to a shearing
chamber. The polyethylene foam sheets contain gas bubbles enveloped
in the foam sheets. The polyethylene foam sheets include sheets
sold by Polyair under the brand name Starfoam. The gas bubbles are
randomly distributed throughout the foam sheets. During the
shearing process many of the gas bubbles remain undisturbed. Others
of the gas bubbles are pierced and the gas escapes the bubble,
leaving behind a three dimensional polyethylene structure.
[0039] The polyethylene foam sheets are subjected to a shearing
process simultaneously with polyethylene film with a thickness of
approximately 17-21 microns. The foam sheets and the film are
placed in contact with each other and placed through a shearing
chamber at the same time and shredded. The shredded foam and film
exit the shearing chamber fully mixed. The weight ratio of
polyethylene foam pieces to polyethylene film pieces upon exit of
the shearing chamber is approximately 1:2-1:4 and preferably
approximately 1:3. The shredded foam and film are placed into a
holding area. From the holding area they are fed into pillow cases
as stuffing. The pillow cases are then sealed.
[0040] The foam and film stuffing exhibits a loft coefficient of
approximately 14. Pillows filled with the polyethylene foam and
film mix exhibit a rebound factor of approximately 0.28.
Example 5
[0041] Polyethylene foam sheets with a thickness of approximately
520-540 microns and which include encapsulated gas are shredded in
a shearing chamber. The shearing chamber shears the foam sheets
into individual foam pieces. The resulting foam pieces maintain a
thickness of approximately 520-540 microns and have a length of
approximately 1 to 6 cm.
[0042] The polyethylene foam pieces are placed into a casing and
the casing is closed. The foam pieces filled casing can then be
used as a pillow.
Example 6
[0043] A polyethylene foam is created in which an antimicrobial is
incorporated into the melt stage of the polyethylene. The
polyethylene foam has a thickness ranging from approximately 520 to
800 microns. The polyethylene foam contains numerous randomly
distributed gas bubbles. The polyethylene foam exhibits a melting
temperature of approximately 265-285 degrees Fahrenheit.
[0044] A film of polypropylene is obtained. The film has a
thickness ranging from approximately 5 to 400 microns. The
polypropylene film does not contain gas bubbles and exhibits a
melting temperature of approximately 320-350 degrees
Fahrenheit.
[0045] A film of nylon is obtained with a thickness ranging from
approximately 260 to 1600 microns. The nylon film does not contain
gas bubbles and exhibits a melting temperature of approximately
425-440 degrees Fahrenheit.
[0046] The polyethylene foam, polypropylene film and nylon film are
sheared into smaller pieces in a simultaneous process that mixes
the pieces into a single stuffing. The resulting pieces have a
length of approximately 1-10 cm. The stuffing maintains a general
ratio of equal parts of polyethylene foam pieces, polypropylene
film pieces and nylon film pieces. The stuffing mixture is then
placed into pillow casings or used as a stuffing and/or insulator
in jackets, pillows, blankets, comforters, duvets, sleeping bags,
mattresses, blankets, cushions and comforters.
[0047] Variations and modifications of the foregoing are within the
scope of the present invention. It should be understood that the
invention disclosed and defined herein extends to all alternative
combinations of two or more of the individual features mentioned or
evident from the text and/or drawings. All of these different
combinations constitute various alternative aspects of the present
invention. The embodiments described herein explain the best modes
known for practicing the invention and will enable others skilled
in the art to utilize the invention. The claims are to be construed
to include alternative embodiments to the extent permitted by the
prior art.
Various features of the invention are set forth in the following
claims.
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