U.S. patent application number 14/801316 was filed with the patent office on 2017-01-19 for modified foam layer and waterbase pillow.
This patent application is currently assigned to IWI Ltd.. The applicant listed for this patent is IWI Ltd.. Invention is credited to Maurice Bard, Phil Souza.
Application Number | 20170013977 14/801316 |
Document ID | / |
Family ID | 57756581 |
Filed Date | 2017-01-19 |
United States Patent
Application |
20170013977 |
Kind Code |
A1 |
Bard; Maurice ; et
al. |
January 19, 2017 |
MODIFIED FOAM LAYER AND WATERBASE PILLOW
Abstract
A bed pillow with a water-bag support base advantageously
includes a compressible foam layer above the water-bag base. The
foam layer includes an upper portion of a memory foam and a lower
density polyurethane foam therebelow. The low density polyurethane
foam includes a convoluted base and vertically extending air vent
channels are provided throughout at least a central portion of the
pillow. With this arrangement improved air flow is provided. The
air vent channels also improve localized compressibility whereby
the response characteristics of the water-bag base support are
maintained and not greatly dissipated.
Inventors: |
Bard; Maurice; (Markham,
CA) ; Souza; Phil; (Summit, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
IWI Ltd. |
Markham |
|
CA |
|
|
Assignee: |
IWI Ltd.
Markham
CA
|
Family ID: |
57756581 |
Appl. No.: |
14/801316 |
Filed: |
July 16, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47G 2009/1018 20130101;
A47G 2009/008 20130101; A47G 9/10 20130101 |
International
Class: |
A47G 9/10 20060101
A47G009/10 |
Claims
1. A bed pillow comprising a lower water-bag support with a
compressible foam layer supported thereabove; said compressible
foam layer includes a lower convoluted foam section providing a
series of air passages extending across an upper surface of said
water-bag support and a generally solid portion of low density foam
is provided above said convoluted foam; and wherein said
compressible layer has a series of air vent channels extending
through the compressible foam layer and distributed throughout at
least a central portion of said bed pillow.
2. A bed pillow as claimed in claim 1 wherein said compressible
foam layer includes a layer of higher density memory foam above
said generally solid portion of low density foam.
3. A bed pillow as claimed in claim 1 wherein said series of air
vent channels are generally vertically extending ports through said
compressible foam layer.
4. A bed pillow as claimed in claim 2 wherein said series of air
vent channels are generally vertically extending ports through said
compressible foam layer.
5. A bed pillow as claimed in claim 3 wherein each air vent port is
of an area in cross section greater than 4 mm in diameter.
6. A bed pillow as claimed in claim 1 wherein the convoluted foam
has a grid network of downward extensions.
7. A bed pillow as claimed in claim 2 wherein the convoluted foam
has a grid network of downward extensions.
8. A bed pillow as claimed in claim 7 wherein said grid network has
adjacent downward extensions positioned in a square configuration
and each square configuration has a large central cavity portion
therebetween.
9. A bed pillow as claimed in claim 8 wherein the horizontal
spacing between immediately adjacent extensions is in the range of
1.5 to 4.0 cm.
10. A bed pillow as claimed in claim 8 wherein said series of air
vent channels are vertically disposed.
11. A bed pillow as claimed in claim 10 wherein said compressible
foam layer is 8.0 to 10.0 cm thick and said layer of memory foam is
in the range of 1.5 to 4.0 cm.
Description
FIELD OF THE INVENTION
[0001] The present invention is related to bed pillows and in
particular to bed pillows having a water-bag at the base thereof
with a compressible fill material thereabove. Bed pillows are most
commonly used for sleeping and are also referred to as headrest
pillows.
BACKGROUND OF THE INVENTION
[0002] Waterbase based bed pillows are well known with a preferred
structure shown in U.S. Pat. No. 4,847,931. A water-bag support is
provided at the base of the pillow essentially extending across the
bottom surface. Compressible fill material is provided above the
water-bag support. A number of different fill materials can be
used, including fiberfill material or traditional down fill. With
these loose fill type materials the displacement and movement
characteristics of the water-bag support when a user places their
head on the pillow are partially dampened by the fill material but
the water bag support of the pillow remains quite responsive and is
transmitted through the loose fill material.
[0003] The fiberfill and down filled compressible material above
the water-bag resiliently yield and there is a desirable balance
between the compressibility of fill material and the water-bag
support characteristics that are transmitted through the
compressible material.
[0004] Prior attempts to use a foam block type compressible fill
material above the water-bag have not been effective as the
displacement and movement of the water-bag support is largely
dampened by the block of foam material that tends to distribute the
forces over a larger area.
[0005] In addition to the compressibility of the fill material,
there is a preferred height of the pillow that is appropriate for
most people. This height requires a certain amount of fill material
above the water-bag support for a desired cervical elevation that
negatively affects the desirable beneficial characteristics of the
waterbase support.
SUMMARY OF THE INVENTION
[0006] A bed pillow according to the present invention comprises a
lower water-bag support with a compressible foam layer supported
thereabove. The compressible foam layer includes a lower convoluted
foam section providing a series of air passages extending across
and located between an upper surface of the water-bag support. A
block portion of low-density foam is provided above the convoluted
foam. The compressible foam layer has a series of air vent channels
extending through the compressible foam layer with the channels
distributed throughout at least a central portion of the bed
pillow.
[0007] According to a preferred aspect of the invention, a layer of
high density memory foam is provided above the block portion of
low-density foam.
[0008] According to an aspect of the invention, the series of air
vent channels are generally vertically extending ports through the
compressible layer.
[0009] According to a further aspect of the invention, each air
vent channel terminates at an air vent port, and each air vent port
is of a cross-sectional area greater than 4.0 mm in diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Preferred embodiments of the invention are shown in the
drawings wherein:
[0011] FIG. 1 is a partial perspective sectional view showing the
layers of the bed pillow;
[0012] FIG. 2 is a partial sectional view through the compressible
foam layer showing the water-bag support;
[0013] FIG. 3 is a partial sectional view showing additional
details of the series of air vent channels;
[0014] FIG. 4 is a sectional view through the bed pillow; and
[0015] FIG. 5 is a sectional view similar to FIG. 4 supporting the
head of a user.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The bed pillow 2 as shown in the Figures comprises a
water-bag support 4 with a thermal barrier layer 6 provided above
and below the water-bag support. A composite foam layer 8 is
provided above the thermal barrier and includes a low density
polyurethane foam portion 10 having a convoluted lower surface 12
typically of a depth of 3.0 to 4.0 cm. The convoluted lower surface
12 includes extensions 15 with air passages 17 therebetween. A
block portion 14 of the low-density polyurethane foam is provided
above the convoluted lower portion 12. This block portion is
preferably approximately 3.0 to 4.0 cm in thickness. Preferably a
layer of memory foam 16 is provided above the block portion 14. The
memory foam is preferably approximately 2.0 to 3.0 cm in thickness.
With this arrangement the composite foam layer 8 is preferably of a
height in the general range of 8.0 to 12.0 cm. A similar height of
the composite foam layer is also used if the memory foam is not
present.
[0017] The layer of memory foam 16 is a denser material and has
different characteristics with respect to compression response and
subsequent recovery after removal of compressive forces. It is
preferred that this layer of memory foam includes small cooling gel
particles 34 that are typically distributed throughout the memory
foam and provide a cooling effect. Memory foam without distributed
cooling gel beads tends to retain heat and this is not particularly
helpful with respect to a bed pillow. Preferably cooling gel is
also integrated into the visco elastic polyurethane of the memory
foam when manufactured to promote cooling while providing the
desired resiliency.
[0018] The composite foam layer 8 has a series of air vent channels
20. These air vent channels are preferably distributed throughout
the composite foam layer but can be limited to distribution
throughout a central region of the compressible foam layer 8. This
central region is where a person would typically place his or her
head. The composite foam layer in some applications may not require
such air vent channels. The bed pillow 2 includes an outer cloth
ticking 60.
[0019] As shown in FIG. 2, the series of air vent channels 20
extend vertically and terminate at ports 22. The composite foam
layer 8 with these air vent channels has a number of distinct
advantages with respect to the pillow. The air vent channels remove
a portion of the memory foam layer as well as a portion of the low
density polyurethane foam. With this arrangement the weight of the
pillow is slightly reduced, however the compression characteristics
of the composite foam layer 8 are also significantly altered. With
the air vent channels, more localised compression of the composite
foam layer 8 occurs as the forces are less distributed throughout
the composite foam layer. In this way more localized compression
occurs and the movement due to displaced water is more readily
transmitted to the surface of the pillow and the user.
[0020] The polyurethane foam layer alone or the composite foam
having a polyurethane foam lower portion with an upper layer of
polyurethane memory foam, has been used in conventional non
waterbase bed pillows and is preferred by some users. However the
use of these foams in a bed pillow having a waterbase lower support
layer has, problems as the desirable responsive characteristics of
the waterbase support is overdampened by the polyurethane foam.
[0021] As will be further described, the inventors have adapted the
compressible foam component to function effectively with the
waterbase support. This adaption can work effectively with or
without a memory foam upper layer. The use of memory foam is
desirable and a preferred commercial embodiment has a polyurethane
base and memory foam upper layer supported by a waterbase.
[0022] As shown in FIG. 5 when a person places their head on the
pillow, the weight of the head 30 compresses the composite foam
directly below the head and in particular compresses the convoluted
lower portion 12 of the pillow as the compressive strength of the
extending portions of the convoluted foam is low. The block portion
14 of the low-density polyurethane foam also compresses
significantly in the area immediately below the person's head. The
memory foam compresses in this area but the memory foam is denser
and has different desirable compression characteristics. The water
in the water-bag 4 will also be partially displaced outwardly as
generally shown by the arrows 42. The compression of the foam is
quite localized with portions either side of the head undergoing
significantly less compression and providing some support.
[0023] With this arrangement there is considerable compression of
the convoluted lower portion 12 of the composite foam layer 8 as
well as localized compression of the block portion 14 in the area
immediately below the person's head 30. The convoluted lower
portion 12 either side of the person's head undergoes some
compression but the amount of compression continues to decrease as
distance away from the person's head increases. Air is free to pass
generally through the convoluted area above the surface of the
airbag and air can also pass through the series of air vent
channels that extend through the composite foam layer. The venting
air passage outwardly is schematically shown by arrows 45.
[0024] As shown in the drawings there has also been some
compression of the air vent channels immediately below the persons
head. The compression of the foam will displace air through the
vent channels that is dissipated or vented through the convoluted
lower portion 12. Movement of a person's head will force air out in
any air channels that are compressed and air will flow into any air
channels that expand. This provides a cooling air exchange or
pumping of air into or out of the air vent channels during use of
the pillow.
[0025] The convoluted foam includes a series of offset rows where
adjacent extensions of each row are approximately 5 cm apart and
aligned adjacent extensions of every other row are approximately 5
cm apart. These aligned extensions of every other row are aligned
in a column type pattern. The extensions of adjacent rows are
offset at a 45 degree angle. Preferably, the composite foam is made
by cutting a block of foam with memory foam either side thereof to
form two pieces of composite foam for a bed pillow. Preferably the
composite foam layers are drilled to provide the vertical air
channels.
[0026] The extensions 15 can be grouped in fours with a large
recess 19 located centrally therebetween. This recess 19 is the cut
section to form an extension in the other portion of the block of
foam. These recesses 19 are also positioned in a grid pattern.
[0027] The spacing between immediately adjacent extensions 15 is in
the range of 1.5 to 4.0 cm.
[0028] Preferably the compressible foam layer is 8 to 10 cm thick.
Preferably the memory foam is 1.5 to 3.0 cm thick.
[0029] It has been found that the arrangement of the convoluted
lower portion 12 with the series of air vent channels 20 in
combination with memory foam 16 provides a desirable support above
the water-bag. The composite foam layer with the series of air vent
channels provides appropriate localized compression and
displacement of water when a person places their head on the
pillow.
[0030] The natural tendency of the memory foam and the low-density
polyurethane foam to retain heat has been reduced by promoting air
circulation through the pillow. Importantly, the compressible foam
layer now provides significant localized compression when a person
places their head on the pillow and the localized compression
provides the desirable displacement of the water in the water-bag
support. This water displacement has been previously found to be
helpful in alleviating issues associated with neck pain and
headaches.
[0031] With the modified structure of the pillow it is possible to
provide effective transmission of the displacement characteristics
of the water-bag support through the composite foam layer while
also providing the desirable features of memory foam at an upper
surface of the pillow. By providing cooling gel as small beads in
the thermal gel or directly adding cooling gel into the composition
of the memory foam, the tendency of the memory foam to retain heat
is offset or significantly reduced. The air vent channels and the
resulting air exchange are also of assistance in heat removal from
the memory foam, and/or from the polyurethane layer.
[0032] The series of air vent channels allows modification of the
compression characteristics of foam layer while still providing a
desired height of low-density polyurethane foam and memory foam
combination. Our earlier pillow with loose fiberfill provided above
the water-bag 4 provides a desirable combination of flexibility,
compression and appropriate displacement of water either side of
the persons head that is difficult to achieve with a composite foam
layer.
[0033] A one piece polyurethane foam layer without the features of
the convoluted surface and the series of air vent channels
distributes the forces and the desirable responsive characteristics
of the water-bag support are dissipated. Furthermore the nature of
polyurethane foam to retain heat is not desirable, and the series
of ventilating channels extending through the foam block connected
to the lower convoluted surface is effective in providing
ventilation and reduces heat retention.
[0034] The size, shape and the number of channels can vary however
it is desirable that the series of channels are provided in at
least a central portion of the pillow. A strip type solid area can
be provided either end of the pillow as this portion is not
typically in use. Having some additional firmness either end of the
pillow can also provide feedback to the user to return towards a
central portion.
[0035] The memory foam with a height of approximately 2.5 cm
provides a desirable softness and the convoluted lower portion is
preferably about 3.25 cm and quickly yields when compressed. The
solid portion of the polyurethane foam provided above the
convoluted over surface is preferably 3.25 cm.
[0036] The size of the air vent channels can also vary however the
air vent channels have a port opening size at least equal to a
diameter of 4 mm is preferred. If the size of the air vent channels
is reduced more air vent channels can be provided.
[0037] In a preferred embodiment about 20% of the upper surface
area of the pillow is provided with air vent channels. The
particular size of the convoluted lower portion is chosen to
provide compressive characteristics of the pillow to initially
yield a desired amount. The air vent channels in addition to
affecting the compressive strength and weight of the pillow,
provide cooling and allow the responsiveness of the water-bag
support to be transmitted to the user.
[0038] Providing the memory foam and the low density polyurethane
foam as a composite block maintains the fill material in the
predetermined order and also maintains the air channels connected
through the materials to keep the passages clear and functioning.
This structure also simplifies assembly of the pillows.
[0039] With waterbase pillows, the user fills and adjust the amount
of water to provide a desired firmness. For example in Applicant's
commercial pillow 60-80 ounces of water provides a soft firmness,
80 to 100 ounces is a medium firmness and 100 to 130 ounces is
firm. It is also recommended to remove air from the waterbag
support to prevent or reduce noise caused by sloshing.
[0040] Although various preferred embodiments of the present
invention have been described herein in detail, it will be
appreciated by those skilled in the art, that variations may be
made thereto without departing from the invention defined by the
appended claims.
* * * * *