Abstract: A pillow is provided that includes a foam core and a gel insert molded to each side of the foam core. Methods of producing a pillow are further provided and include a step of providing a foam molding system having a top mold defining a plurality of air ports and a bottom mold defining a plurality of air ports. A vacuum is applied to the plurality of air ports in both the top mold and bottom mold, and a gel insert is then positioned against each of the plurality of air ports. A foam precursor is subsequently dispensed into the bottom mold atop the gel insert, and the top mold is secured to the bottom mold. The foam precursor then expands within the foam molding system and bonds with the two gel inserts to produce a pillow having a gel insert molded to each side of the pillow.

Abstract: A pillow includes an inferior portion and an outer portion. The interior portion is comprised of a first flexible foam, while the outer portion is comprised of a second flexible foam having a density different than that of the first flexible foam. Methods of producing a pillow are also provided whereby either a first foam precursor is dispensed into a central portion of a mold to provided a first flexible foam, or a pre-formed foam insert comprised of a first flexible foam is placed into a central portion of a mold. A second foam precursor is then subsequently dispensed into a peripheral portion of the mold to produce a second flexible foam having a density different than that of the first flexible foam. Upon reaction and expansion of the foam precursors, a molded foam pillow is produced having dual densities.

Abstract: A pillow is provided that includes a foam core and a gel insert molded to each side of the foam core. Methods of producing a pillow are further provided and include a step of providing a foam molding system having a top mold defining a plurality of air ports and a bottom mold defining a plurality of air ports. A vacuum is applied to the plurality of air ports in both the top mold and bottom mold, and a gel insert is then positioned against each of the plurality of air ports. A foam precursor is subsequently dispensed into the bottom mold atop the gel insert, and the top mold is secured to the bottom mold. The foam precursor then expands within the foam molding system and bonds with the two gel inserts to produce a pillow having a gel insert molded to each side of the pillow.