Pillow

Abstract

A pillow is formed from a synthetic fiberfill material encased within a bag. In one embodiment, the synthetic fiberfill material is in the form of one or more lengths of chenille yarn fiberfill. The chenille yarn fiberfill is formed from a pile of fibers disposed between a pair of twisted core fibers. The pile of fibers includes microfibers. The lengths of chenille yarn fiberfill may be formed into a chenille cloth fiberfill, a chenille tuft fiberfill, or a chenille pompom fiberfill. In another embodiment, the synthetic fiberfill material is in the form of stretch nylon pompom fiberfill.

Description

TECHNICAL FIELD

[0001] The present invention relates to pillows, and more particularly to pillows containing a synthetic fiberfill formed from microfiber chenille or stretch nylon.

BACKGROUND

[0002] Pillows provide a comfortable and supportive cushion for the head or other parts of the body while their users are sleeping or resting. Before the advent of pillows, people used blocks of wood, stone, or porcelain for head support while resting. While providing excellent support, these articles were uncomfortable. Pillows were developed to provide improved comfort while maintaining the support necessary to keep the head and neck in proper alignment during rest. Pillows typically consist of a natural or synthetic filler material encased within a fabric cover. Early pillow designs used natural filler materials such as down and feathers. Some later designs incorporated synthetic filler materials such as foam or polyester fibers.

[0003] Pillows are typically designed to achieve a particular balance of comfort and support. A pillow that successfully strikes this balance can contribute greatly to getting a quality sleep, which is an important contributor to good overall health. Additional characteristics that are important to pillow design are durability, resilience, loft, and resistance to flattening, bunching, and lumping over time. Additionally, it is beneficial for pillows to contain as few allergens as possible, particularly since most people spend hours every night inhaling any allergens that may be present in their pillows. Cost is another important consideration, as it is difficult to design a pillow that satisfies every desirable characteristic at an affordable price.

[0004] It is also beneficial for pillows to be washable. One reason to wash pillows on a regular basis is to prevent them from harboring and spreading organisms that cause disease. Hygiene is a concern with respect to all pillow types, regardless of the type of filler material used, and regardless of the location where the pillow is used. Pillows found in public locations, such as hospitals, airplanes, and hotels, should be cleaned regularly and thoroughly because they can harbor and spread bacteria such as Staphylococcus aureus (Staph), Methicillin-resistant Staphylococcus aureus (MRSA), Clostridium difficule (C. diff), and Escherichia coli (E. coli), as well as viruses such as Influenza, Varicella zoster, H1N1, and the SARS virus. Even when used only in the home, however, pillows tend to hold body fluids such as sweat and mucus, as well as flakes of dead skin. These body fluids are kept warm for hours at a time while a user sleeps, making pillows ideal breeding grounds for bacteria and viruses. Regular washing can help eliminate these disease-causing organisms.

[0005] Another reason to wash pillows regularly is to eliminate any insects and their waste products, which may be allergens for many individuals. Dust mites, which are frequently found in pillows, are a common cause of allergies. These insects produce large amounts of fecal matter and partially digested enzyme-covered dust particles that may trigger an allergic reaction. Counter-intuitively, some pillows that are formed entirely from hypoallergenic materials are among the most susceptible to dust mites, and therefore present the most serious allergen risks. Regular washing can greatly reduce or eliminate the presence of these insects. Therefore, the ability to wash a pillow using conventional means such as a washer and dryer a highly desirable feature.

[0006] Down pillows have long been considered desirable because they are extremely soft, resilient, and durable. The advantageous properties of down are a consequence of its three-dimensional shape. Down clusters are naturally circular in shape, and therefore they try to return to their original shape when compressed. For this reason, down pillows tend to maintain their softness for a longer time than other pillow types. Furthermore, down clusters do not have a quill shaft that can poke through the pillow cover, which further enhances their softness. Generally, the quality of a down pillow is directly proportional to the size of the down clusters. Large down clusters will typically provide greater loft, resilience, insulating ability, and durability than small clusters. Large clusters are also more expensive than small clusters because they come from older birds are therefore are more difficult to obtain.

[0007] Feathers pillows, while highly desirable, are less soft, resilient, and durable than down pillows because feathers are two-dimensional (rather than three-dimensional) in shape. Therefore, feathers are less prone to return to their original shape when compressed. Feathers have a hard tubular quill running down their center, which can poke through the pillow cover and cause discomfort to the user. Furthermore, the quills will start to align with each other over time, and the feathers will begin to lie flat, causing the pillow to become flat and lose its softness. To reduce this flattening, down clusters are often added to feather pillows to reduce the amount of flattening that takes place.

[0008] Both down and feather pillows, while being relatively comfortable, suffer from several disadvantages. They are more expensive than most other pillows, with down pillows being particularly expensive. Down and feather pillows offer poor head and neck support relative to some natural and synthetic alternatives. Additionally, down and feathers trigger allergic reactions in some individuals. Hypoallergenic down and feather pillows are available, but they are even more expensive. Furthermore, down and feather pillows are difficult to clean. Down pillows can be cleaned in a washer and dryer, but care must be taken to ensure that the down is completely dried since mold and mildew can form in less than 24 hours, completely ruining the pillow. Feather pillows should not be washed, but rather should be taken to a professional dry cleaner.

[0009] Synthetic fiberfill offers a less expensive alternative to down and feathers. In addition to their lower cost, pillows containing synthetic fiberfill offer several other advantages over natural alternatives. They are formed from hypoallergenic materials and therefore are desirable to individuals with down or feather allergies. Additionally, they can easily be cleaned in a standard washer and dryer. Qualities such as loft, resilience, durability, and support, however, can vary widely among synthetic fiberfill pillows of different designs. Some less expensive synthetic fiberfill pillows, for example, are simply stuffed with polyester fibers of varying thread counts. These pillows lack comfort, offer poor support, and are prone to developing lumps. Such pillows are generally not considered attractive alternatives to down or feather pillows.

[0010] Higher quality synthetic fiberfill pillows attempt to achieve improved comfort and support by using fiberfill structures that are intended to simulate natural down or feathers. U.S. Pat. No. 3,892,909, to Miller, discloses a simulated synthetic down formed from bundles of staple fibers such as polyester. The fibers, which are preferably from one inch to three inches in length, are joined together by application of a binder such as dilute acrylic latex or nitrile latex, or by fusion using conventionally applied heat, impulse heating, laser, or ultrasonic energy. Another synthetic down is disclosed in U.S. Pat. No. 4,418,103, to Tani et al. Tani discloses a synthetic filling material for use in clothing and bedclothes comprising spherical bundles of crimped fibers such as polyester that are bonded together at one end. U.S. Pat. No. 5,851,665, to Marcus similarly discloses a synthetic filling material comprising bundles of crimped and bonded thermoplastic fibers, referred to as "clusters" or "puffs" in the patent, where the location of the bonding varies from one cluster to the next. All of these patents, however, require the use of chemical bonding agents or complex bonding processes that result in high manufacturing costs and produce structures lacking the resilience and durability of natural down.

SUMMARY

[0011] One embodiment of the present invention is directed to a pillow comprising a fiberfill material encased within a bag, wherein the fiberfill material comprises a pile of synthetic fibers disposed between at least two twisted core fibers to form a chenille yarn fiberfill. The pile of synthetic fibers may comprise microfibers. The chenille yarn fiberfill is preferably greater than five inches long and less than seven inches long. The pile of synthetic fibers comprises fibers that are preferably greater than one-quarter inch long and less than one-half inch long. The twisted core fibers may comprise low-melt fibers, such as low-melt nylon. The twisted core fibers may be fused together at each end of said chenille yarn fiberfill by cutting each end with a heated cutting blade. Furthermore, the chenille yarn fiberfill may be subjected to heat setting by a process such as autoclaving.

[0012] The chenille yarn fiberfill may be formed into a chenille cloth fiberfill by a process such as weaving. Alternatively, a plurality of lengths of said chenille yarn fiberfill may be bound together to form a chenille tuft fiberfill or a chenille pompom fiberfill. The chenille pompom fiberfill preferably has a diameter that is greater than one inch and less than two inches. The bag may comprise a mesh fabric formed from a material such as nylon and polyester.

[0013] Another embodiment of the present invention is directed to a pillow comprising a fiberfill material encased within a bag, wherein the fiberfill material comprises a plurality of stretch nylon fibers bound together at their approximate midpoint to form a stretch nylon pompom fiberfill. The stretch nylon pompom fiberfill may comprise heat treated stretch nylon fibers that are subjected to steam or autoclaving.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Various embodiments of the invention are described in the following detailed description with reference to the accompanying drawings, in which:

[0015] FIG. 1a and FIG. 1b are schematic top views of a pillow in accordance with one embodiment of the present invention;

[0016] FIG. 2a is a perspective view of a length of chenille yarn fiberfill material in accordance with one embodiment of the present invention;

[0017] FIG. 2b and FIG. 2c are schematic views of stages in the manufacture of a chenille yarn fiberfill material in accordance with one embodiment of the present invention;

[0018] FIG. 3 is a perspective top view of a section of chenille cloth fiberfill material in accordance with one embodiment of the present invention;

[0019] FIG. 4 is a perspective view of a chenille tuft fiberfill material in accordance with one embodiment of the present invention;

[0020] FIG. 5 is a perspective view of a chenille pompom fiberfill in accordance with one embodiment of the present invention;

[0021] FIG. 6 is a perspective view of a stretch nylon pompom fiberfill in accordance with one embodiment of the present invention;

[0022] FIG. 7a is a perspective view of a segment of stretch nylon in accordance with one embodiment of the present invention; and

[0023] FIG. 7b is a perspective view of a segment of heat treated stretch nylon in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION

[0024] A pillow and its method of manufacture are described herein. The specific details set forth in the following description provide an understanding of certain embodiments of the invention, and do not limit the scope of the invention as set forth in the claims. Certain structures and steps that are well known in the art are not described in detail. Reference is made in the following description to the accompanying drawings. Wherever possible, the same reference numbers are used throughout the drawings and the corresponding description to refer to the same or similar structures or steps.

[0025] Referring to FIG. 1a and FIG. 1b, a pillow 100 in accordance with one embodiment of the present invention includes a bag 110 encasing a synthetic fiberfill material 120. Preferably, the bag 110 is made of a synthetic mesh material. Using a mesh material to form the bag 110 allows the pillow 100 to be thoroughly washed by conventional means such as a standard washer and dryer without requiring removal of the synthetic fiberfill material 120. Suitable fabrics for the bag 110 include nylon mesh and polyester mesh, although other synthetic materials, natural fabrics, and non-mesh materials may be used instead.

[0026] Optionally, the bag may include an opening 130 that is sealable by means of a fastener 140 such as a zipper, as shown in FIG. 1b. The opening 130 allows the amount of synthetic fiberfill material 120 encased within the bag 110 to be increased or decreased. By adding or removing synthetic fiberfill material 120, the loft, density, and firmness of the pillow 100 can be adjusted as desired. The opening 130 also allows different mixtures of synthetic fiberfill material 120 to be inserted into the bag 110. Furthermore, the opening 130 allows the synthetic fiberfill material 120 to be removed for cleaning, which is a particularly desirable feature if a non-mesh fabric is used for the bag 110.

[0027] The synthetic fiberfill material 120 of the present invention may take one or more of a variety of forms. In one embodiment, the synthetic fiberfill material 120 of FIG. 1 is in the form of a plurality of lengths of chenille yarn. FIG. 2a shows a length chenille yarn fiberfill 200 for use as synthetic fiberfill material 120 in the pillow 100. FIGS. 2b and 2c schematically illustrate various stages in the manufacture of a length of chenille yarn fiberfill 200. With reference to FIG. 2b, a length of chenille yarn fiberfill 200 is formed from a pile of fibers 210 disposed between two or more core fibers 220. The core fibers 220 are twisted, as shown by the arrows in FIG. 2b, so as to hold the pile of fibers 210 in place and form a cylindrical structure having an approximately circular cross-section. Chenille fiberfill yarn 200, like natural down, has a three-dimensional shape that provides loft and resilience to the pillow 100.

[0028] Individual lengths of chenille yarn fiberfill 200 can be formed by cutting one or more continuous strands of chenille yarn into segments of a predetermined length using a cutting blade. Using a large number of shorter segments of chenille yarn fiberfill 200, instead of a small number of long strands, will help to prevent lumping of the fiberfill within the pillow 100. Preferably, each length of chenille yarn fiberfill 200 is between five inches and seven inches long, although other lengths may be used. Additionally, if the cutting blade is maintained at a sufficiently high temperature and low-melt materials such as low-melt nylon are used to form the core fibers 220, the cutting step can cause the core fibers 220 to be fused together at the ends of each segment, improving the durability of the chenille yarn fiberfill 200.

[0029] The length, denier, and chemical composition of the fibers that comprise the pile of fibers 210 can be selected to achieve the desired properties for the chenille yarn fiberfill 200. As explained above with respect to in FIGS. 2a, 2b, and 2c, chenille yarn fiberfill 200 has a circular cross section. The loft, resilience, and insulating qualities provided by the chenille yarn fiberfill 200, among other characteristics, are influenced by the diameter of its cross section. The diameter of the cross section is determined by the length of the fibers that form the pile of fibers 210. Generally, a larger diameter cross section will produce a fiberfill that provides greater loft, resilience, and insulation. Consequently, a fiberfill having these desirable qualities can be achieved by selecting fibers of a suitable length to comprise the pile of fibers 210. In this regard, chenille yarn fiberfill 200 offers an advantage over natural down and other filler materials in that its properties can be easily adjusted as desired by selecting fibers of a particular length. Preferably, the fibers that comprise the pile of fibers 210 (and consequently the diameter of the chenille yarn fiberfill 200) are greater than one-quarter inch and less than one-half inch long.

[0030] Likewise, various properties of the chenille yarn fiberfill 200 can be adjusted by varying the denier and chemical composition of the fibers that comprise the pile of fibers 210. The softness, resilience, durability, and moisture retaining properties of the chenille yarn fiberfill 200 are influenced by the denier and chemical composition of the fibers used to form the pile of fibers 210. In one embodiment, the pile of fibers 210 comprises microfibers. A microfiber is a synthetic fiber weighing one denier or less per filament. Microfibers are typically (although not necessarily) formed from polyester, polyamide, polypropylene, rayon, acrylic, or conjugations thereof. Microfibers formed from any of these materials or conjugations, or any other materials, can be used in the pile of fibers 210.

[0031] Microfibers have properties that make them highly suitable for use in the chenille yarn fiberfill 200. Microfibers tend to be extremely soft due to their small diameter, enabling the chenille fiberfill material 200 to simulate the softness of natural fiberfill materials such as down and feathers. They have excellent moisture wicking properties, causing sweat to be wicked away from an individual's body by the pillow 100, thereby improving comfort while sleeping. Microfibers dry rapidly and are easy to clean, reducing the likelihood of bacteria, viruses, and insects such as dust mites harboring within the pillow 100. Additionally, microfibers are durable and resilient, preventing the pillow 100 from flattening over time. The softness, absorption properties, durability, and resilience of the chenille fiberfill material 200 can be adjusted as desired by careful selection of the denier and chemical composition of the microfibers, and optionally by using particular blends of different types of microfibers.

[0032] The core fibers 220 may be formed from any of a variety of materials such as multifilament nylon, although it is preferable to use fibers that are both soft and durable. One advantage of the chenille yarn fiberfill 200 is that while natural fillers such as feathers have a hard quill running down the center, chenille yarn fiberfill 200 is held together by a pair of soft core fibers 220. The absence of any hard materials in the chenille yarn fiberfill 200 helps improve its softness. Optionally, the core fibers 220 are formed from low-melt nylon. When chenille yarn fiberfill 200 formed using low-melt nylon core fibers 220 is exposed to heat or steam by a process such as autoclaving, the pile of fibers 210 will become set in place between the core fibers 220. Therefore, using low-melt nylon core fibers 220 and heat setting improves the strength of the chenille yarn fiberfill 200 by binding the core fibers 220 to the pile of fibers 210. Other embodiments can use different materials form the core fibers 220.

[0033] In one embodiment, one or more lengths of chenille yarn can be formed into a chenille cloth fiberfill 300, as shown in FIG. 3. The chenille cloth fiberfill 300 can be made using a variety of techniques such as weaving, knitting, and crocheting. Chenille cloth fiberfill 300 has many of the advantageous properties of chenille yarn fiberfill 200. Furthermore, the chenille cloth fiberfill 300 can be easily removed from the pillow 100 and washed separately if an opening 130 and fastener 140 are provided in the bag 110. This feature is particularly beneficial if the bag 110 is formed from a non-mesh material.

[0034] In another embodiment, a plurality of lengths of chenille yarn fiberfill 200 can be bound to form a chenille tuft fiberfill 400, as shown in FIG. 4. This embodiment further helps prevent the filler material from lumping together in one portion of the pillow 100. The plurality of lengths of chenille yarn fiberfill 200 can be bound using any type of thread or yarn, such as nylon yarn or another segment of chenille yarn, or by using a chemical bonding process or heat fusion. The properties of the chenille tuft fiberfill 400 can be adjusted by any of the means described herein with respect to the chenille yarn fiberfill 200.

[0035] In yet another embodiment, shown in FIG. 5, multiple lengths of chenille yarn fiberfill 200 are bound together near their midpoints to form a chenille pompom fiberfill 500. This embodiment is advantageous because it provides a naturally circular fiberfill material, closely simulating the properties of natural down. The chenille pompom fiberfill 500 is highly resilient due to its circular shape, while retaining all of the other advantages of the chenille yarn fiberfill 200. The diameter of the chenille pompom fiberfill 500 can be adjusted by varying the length of the chenille yarn fiberfill 200 from which it is formed. Preferably, the diameter of the chenille pompom fiberfill 500 is greater than one inch and less than two inches. As with the chenille tuft fiberfill 400 of FIG. 4, the chenille pompom fiberfill 500 can be bound using any type of thread or yarn, or by processes such chemical bonding or heat fusion, and its properties can be adjusted as described herein with respect to the chenille yarn fiberfill 200.

[0036] Another embodiment of the invention uses stretch nylon that is formed into the shape of a pompom, as is shown in FIG. 6. Stretch nylon is formed by twisting, heat setting, and untwisting nylon fibers. Stretch nylon has certain properties such as elasticity, resilience, and durability, which make it desirable for use as fiberfill. Like microfibers, stretch nylon can be easily laundered in a standard washer and dryer. The stretch nylon pompom fiberfill 600 is formed in a manner similar to the chenille pompom fiberfill 500 of FIG. 5, except that it comprises lengths of stretch nylon 700 as shown in FIG. 7, rather than lengths of chenille yarn fiberfill 200.

[0037] Optionally, the stretch nylon pompom fiberfill 600 is exposed to heat or steam, thereby increasing the volume and enhancing the softness of the stretch nylon pompom 600. When stretch nylon is exposed to heat or steam by a process such as autoclaving, the liveliness of the individual nylon filaments is increased in a manner that causes the yarn to expand in volume, as shown in FIG. 7b. This heat treated stretch nylon 710 has improved softness that further enhances its suitability for use as a fiberfill material in pillows. One advantage of stretch nylon pompom fiberfill 600 is that every time the pillow 100 is cleaned in a standard washer and dryer, the drying step will cause the stretch nylon filaments to expand in volume, increasing the liveliness of the fiberfill material and returning the pillow 100 to its initial state.

[0038] Additional embodiments of the invention can use combinations of different types of synthetic fiberfill materials 110. For example, the pillow 100 can include a combination of unbound chenille yarn fiberfill 200 and chenille pompom fiberfill 600. Such an embodiment is analogous to natural pillows containing a mixture of feathers and down. Combinations of any or all of the different types of synthetic fiberfill materials disclosed herein are contemplated by the present invention.

[0039] Those skilled in the art will appreciate that the embodiments described herein are illustrative and not restrictive, and that modifications and combinations may occur depending upon design requirements without departing within the scope of the invention, as recited in the claims.

Claims

1. A pillow comprising: a fiberfill material encased within a bag; wherein said fiberfill material comprises a pile of synthetic fibers disposed between at least two twisted core fibers to form a chenille yarn fiberfill.

2. The pillow of claim 1 wherein said pile of synthetic fibers comprises microfibers.

3. The pillow of claim 1 wherein said chenille yarn fiberfill is greater than five inches long and less than seven inches long.

4. The pillow of claim 1 wherein said pile of synthetic fibers comprises fibers greater than one-quarter inch long and less than one-half inch long.

5. The pillow of claim 1 wherein said twisted core fibers comprise low-melt fibers.

6. The pillow of claim 5 wherein said low-melt fibers comprise low-melt nylon.

7. The pillow of claim 5 wherein said twisted core fibers are fused together at each end of said chenille yarn fiberfill by cutting each end with a heated cutting blade.

8. The pillow of claim 5 wherein said chenille yarn fiberfill is subjected to heat setting.

9. The pillow of claim 8 wherein said heat setting is performed by autoclaving.

10. The pillow of claim 1 wherein at least one length of said chenille yarn fiberfill forms a chenille cloth fiberfill.

11. The pillow of claim 10 wherein said chenille cloth fiberfill is formed by weaving at least one length of chenille yarn fiberfill.

12. The pillow of claim 1 wherein a plurality of lengths of said chenille yarn fiberfill are bound together to form a chenille tuft fiberfill.

13. The pillow of claim 1 wherein a plurality of lengths of said chenille yarn fiberfill are bound together to form a chenille pompom fiberfill.

14. The pillow of claim 13 wherein the chenille pompom fiberfill has a diameter that is greater than one inch and less than two inches.

15. The pillow of claim 1 wherein said bag comprises a mesh fabric.

16. The pillow of claim 15 wherein said mesh fabric is formed from at least one material selected from the group consisting of nylon and polyester.

17. The pillow of claim 1 wherein said bag includes an opening.

18. The pillow of claim 17 wherein said opening is sealable by means of a fastener.

19. The pillow of claim 18 wherein said fastener is a zipper.

20. A pillow comprising: a fiberfill material encased within a bag; wherein said fiberfill material comprises a plurality of stretch nylon fibers bound together at their approximate midpoint to form a stretch nylon pompom fiberfill.

21. The pillow of claim 20 wherein said stretch nylon fibers comprise heat treated stretch nylon fibers.

22. The pillow of claim 20 wherein said stretch nylon fibers are subjected to steam.

23. The pillow of claim 20 wherein said stretch nylon fibers are subjected to autoclaving.