FAUX GUSSETED PILLOW SHELL
A faux gusseted pillow shell is provided. The faux gusseted pillow shell includes a first panel having a first length and a first width, and a first plurality of sides. The faux gusseted pillow shell also includes a second panel having a second length greater than the first length and a second width greater than the first width, a top wall, a second plurality of sides, and a plurality of depending sidewalls formed along respective sides of the second plurality of sides and extending from the top wall. The depending sidewalls are stitched to respective sides of the first plurality of sides to form a corresponding plurality of seams and thereby form a shell. At least one additional seam is formed in the second panel extending along one of second plurality of sides. The at least one additional seam is formed by stitching through the second panel only.
In the manufacture of a typical pillow, a shell is first constructed as an open ended envelope, having an open edge to receive a filler. The shell is then filled with the filler and stitched along the open edge to seal the filler within the shell.
Pillows come in many forms and styles. A conventional pillow has first and second or top and bottom panels that are stitched together along their edges to seal the filler within the shell. As the quantity of filler increases, the pillow has a tendency to take a more curved or oblong shape.
To increase the amount of filler and reduce the tendency toward an oblong or curved shape, manufacturers use a gusset panel between the top and bottom panels. A gusset panel is a piece of fabric or material that is added between side seams of the top and bottom panels. Accordingly, a height of the pillow may be increased, thereby allowing for an increased quantity of filler while maintaining a flatter, or non-curved or oblong, profile.
One drawback to known gusseted pillow shells is the time and cost to manufacture this construction. Such known gusseted pillow shells require a separate gusset panel. In addition, the gusset panel needs to be stitched along four edges to the top or bottom panel and along three edges to the other panel, thus creating the open envelope. This costly in materials as well as time.
Accordingly, there is a need for a gusseted pillow shell that provides increased space for filler and maintains a flatter profile when filled. Desirably, such a pillow shell is manufactured with reduced labor and costs. More desirably still, such a gusseted pillow shell is manufactured using two panels folded and stitched to have the characteristics of a gusseted pillow shell.
BRIEF SUMMARY OF THE INVENTIONAccording to one exemplary embodiment, there is provided a faux gusseted pillow shell having a first panel having a first length and a first width, and a first plurality of sides and a second panel having a second length greater than the first length and a second width greater than the first width, a top wall, a second plurality of sides, and a plurality of depending sidewalls formed along respective sides of the second plurality of sides and extending from the top wall. The depending sidewalls are stitched to respective sides of the first plurality of sides to form a corresponding plurality of seams. The faux gusseted pillow shell further includes at least one additional seam formed in the second panel extending along one of the second plurality of sides, wherein the at least one additional seam is formed by stitching through the second panel only.
These and other features and advantages of the present invention will be readily apparent from the following detailed description, in conjunction with the claims.
The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:
While the present device is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described one or more presently preferred embodiments with the understanding that the present disclosure is to be considered an exemplification of the device and is not intended to limit the disclosure to the specific embodiment or embodiments illustrated.
The second panel 14 is larger than the first panel 12 in both length and width by about two times (2×) the size of a desired gusset G. It is understood that the present invention is not limited to the example above. For example, the first panel 12 (i.e., the lower layer) 12 may be the larger panel. Further, in an exemplary embodiment, the first panel 12 and the second panel 14 are not limited to the specific relative size and shape discussed above and shown in the figures.
Each triangle 18 includes a pair of legs 20a, 20b and an angled edge 22. In an exemplary embodiment, the angled edge 22 is the hypotenuse of the right triangle formed by the triangle 18. The folded section, i.e., the triangle 18, is then stitched along the legs 20a, 20b to form a stitched seam 24.
To form the shell 10, the first panel 12 and second panel 14 are aligned so that the depending sidewalls 28 of the second panel 14 are generally aligned to an outer periphery 30 of the first panel 12. The first panel 12 and second panel 14 are then joined to one another, for example, by stitching.
In an exemplary embodiment, the first panel 12 includes two long sides 32a, 32b and two short sides 34a, 34b. Similarly, the second panel 14 includes two long sides 33a, 33b and two short sides 35a, 35b. The panels 12, 14 are stitched together along their respective two long sides 32a, 32b, 33a, 33b and one respective short side 34a, 35a to form an envelope. For example, in one embodiment, a distal or free end of the depending sidewalls 28 (faux gusset panels) of the second panel 14 may be stitched along the two long sides 33a, 33b to respective long sides 32a, 32b of the first panel 12 to form first and second seams S1, S2, (
The shell 10 may be further stitched with at least one additional seam in a number of ways, depending upon a desired look of the finished pillow, for example, as shown in
Alternatively, with reference to
In another alternative embodiment, with reference to
The directional references of top, bottom, upper, lower and side are provided for reference only and are not intended to limit the disclosure in any way.
All patents referred to herein, are incorporated herein by reference, whether or not specifically done so within the text of this disclosure.
In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.
From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.
Claims
1. A faux gusseted pillow shell comprising:
- a first panel having a first length and a first width, and a first plurality of sides;
- a second panel having a second length greater than the first length and a second width greater than the first width, a top wall, a second plurality of sides, and a plurality of depending sidewalls formed along respective sides of the second plurality of sides and extending from the top wall, wherein the depending sidewalls are stitched to respective sides of the first plurality of sides to form a corresponding plurality of seams; and
- at least one additional seam formed in the second panel extending along one of second plurality of sides, wherein the at least one additional seam is formed by stitching through the second panel only.
2. The faux gusseted pillow shell of claim 1, wherein the second panel includes a plurality of corners, and each corner is inwardly folded to form a triangle.
3. The faux gusseted pillow shell of claim 1, wherein the first panel and second panel are rectangular.
4. The faux gusseted pillow shell of claim 3, wherein the first plurality of sides includes two first long sides and two first short sides and the second plurality of sides includes two second long sides and two second short sides.
5. The faux gusseted pillow shell of claim 4, wherein the plurality seams includes a first seam joining together one first long side and one second long side, a second seam joining together the other first long side and the other second long side, and a third seam joining together one first short side and one second short side.
6. The faux gusseted pillow shell of claim 5, wherein the at least one additional seam includes a fourth seam formed along the one second long side, spaced from the first seam, and a fifth seam formed along the other second long side, spaced from the second seam.
7. The faux gusseted pillow shell of claim 6, wherein the at least one additional seam further includes a sixth seam formed along the one second short side spaced from the third seam, and a seventh seam formed along the other second short side, spaced from the other first short side.
8. The faux gusseted pillow shell of claim 5, wherein the at least one additional seam further includes a sixth seam formed along the one second short side spaced from the third seam, and a seventh seam formed along the other second short side, spaced from the other first short side.
9. The faux gusseted pillow shell of claim 1, wherein a filler is positioned in the shell.
Type: Application
Filed: Jun 24, 2013
Publication Date: Dec 26, 2013
Inventor: Dong Chen (Belmont, CA)
Application Number: 13/925,587
International Classification: A47G 9/02 (20060101); A47G 9/10 (20060101);