Adjustable Pillows and Methods of Manufacturing Same
Various embodiments of adjustable pillows and methods of manufacturing them are described, in which the pillow has inner and outer pockets with the inner pocket disposed within the outer pocket. One or more cords or other adjustment mechanisms can extend along a length of the pillow and be used to move one or both side of the pillow toward one another, changing a size of the pillow and thereby increasing its firmness.
The field of the invention is adjustable pillows.
BACKGROUNDThe background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
Some efforts have been placed in providing adjustable pillows that can change in shape, size or firmness to be suitable for different users or uses. For example, U.S. Pat. No. 5,839,138 to Weidman et al. teaches a circular cushioned pillow that includes a cover panel having a ring-shaped sleeve to contain a drawstring that extends through the sleeve. The drawstring can be pulled to reduce the surface area of the cover panel and reduce the volume of the pillow. As another example, U.S. Pat. No. 8,893,331 to Cupo teaches an adjustable pillow with an offset cutout, which includes a closure flap including a strip of hook material that can couple with different strips of loop fasteners on an outer surface of the pillow to depending on the firmness desired.
Unfortunately, known efforts suffer from various disadvantages, including for example, uneven distribution of filler material, Velcro fastening means that can inadvertently come undone, difficulty of manufacture, overly complicated adjustment or tightening systems, or exposure of filler material when making adjustments.
Thus, there is still a need in the art for improved adjustable pillows.
SUMMARY OF THE INVENTIONThe inventive subject matter provides an adjustable pillow that includes outer and inner sleeves. The outer and inner sleeves are coupled to one another in a manner that can substantially maintain a distribution of filler material throughout the length and width of the pillow through adjustments. Viewed from a different perspective, an adjustment of the pillow's adjustment mechanism can vary the length and size/shape of the pillow and increase/decrease a firmness of the pillow along its entire length and width such that subsequent manual redistribution is not required.
Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
The following discussion provides example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
The inventive subject matter provides an adjustable conventional or gusseted pillow having an outer sleeve that encloses an inner sleeve. One or more drawstrings extend through the inner sleeve between first and second ends of the pillow, and allow for adjustments to one or more of the pillow's size, shape and firmness while maintaining a substantially even distribution of filler material. It should be appreciated that the term “drawstring” is used broadly to include any relatively thin piece of material that can be used to tighten the pillow across its length. For example, a drawstring could include a rope material, a cord, a string, or a strip of material.
In some embodiments, the outer sleeve/cover is generally rectangular in shape and includes first and second pieces of material that are joined together at side edge portions and top/bottom end portions. In some other contemplated embodiments, the outer sleeve is made from a single material that is folded, and sewn or otherwise bound together along edge portions and an end portion.
The inner sleeve can also be rectangular in shape and comprise first and second pieces of material that are joined together at side edge portions. Preferably, the inner sleeve has a width that is smaller than the width of the outer sleeve. For example, the inner sleeve can have a width that is less than 90%, less than 80%, less than 70% or even less than 50% of the width of the outer sleeve. The length is preferably substantially the same as the length of the outer sleeve such that the drawstring(s) can extend along a length of the pillow through the inner sleeve from one end of the pillow to the other. In some preferred embodiments, the outer sleeve completely encloses the inner sleeve. In other contemplated embodiments, the outer sleeve only partially encloses the inner sleeve.
Extending the drawstring or other adjustment mechanism through the inner sleeve ensures that the drawstring or other adjustment mechanism does not directly contact any filler material within the pillow, and the drawstring maintains its relative position within a middle portion of the pillow.
The adjustment mechanism could comprise one or more drawstrings that extend through a length of the inner sleeve between the first and second pieces of material. The inner sleeve could comprise one or more compartments sized and dimensioned to house a drawstring, for example, one or more narrow compartments made by sewing the first and second pieces of material together along non-edge portions and along their lengths. Although the drawstrings may only extend through narrow portions of the inner sleeve, it can be advantageous to include an inner sleeve that extends through a substantial width of the pillow (e.g., at least 25%, at least 50%, at least 60%) to assist in maintaining a distribution of filler material within the pillow through adjustments.
In some alternative embodiments, a single layer of material that extends from the first end portion of the outer sleeve to the second end portion of the outer sleeve (e.g., instead of an inner sleeve). One or more narrow sleeves can be formed from or attached to the single layer of material to act as a guide for one or more drawstrings. In such contemplated embodiments, it may be beneficial to use a thicker piece of material to maintain the structural strength and integrity of the inner material through adjustments.
In yet other alternative embodiments, separate narrow sleeves can be provided for each drawstring across different portions of the pillow.
It is generally preferred that the outer and inner sleeves are coupled together in a manner such that at least 75%, more preferably at least 80% or at least 90% of each the inner sleeve's first and second faces (or each side of a single layer of material) are surrounded by a filler material. Such a configuration can help to ensure a distribution of filler material (the pillow's depth/thickness) is substantially maintained throughout the pillow's length and width.
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From a method of manufacturing perspective, it should be appreciated that pillows of the inventive subject matter could be manufactured using any suitable methods. For example, the material(s) can be bound together using any suitable fastening mechanism (e.g., sewing, gluing, heat-sealing). Additionally, the pillows can be filled with any suitable material(s) (e.g., foam, microbeads, polyester pellets, polystyrene beads, wool, natural shredded rubber, herbs such as lavender, chopped foam, memory foam, feather, latex, cotton) using any suitable filling method(s) (e.g., blow filling).
In some contemplated aspects, one or more rigid or semi-rigid (or even flexible) sticks or hollow tubes, for example, are positioned partially within the inner sleeve. For example, one semi-rigid stick can be positioned within each of the two inner sleeve compartments holding a drawstring in place within the inner sleeve. The pillow can be closed on one end, and open on a second end to allow access to the inner compartment of the pillow. The stick(s) can be used to position the inner sleeve in a desired position relative to the outer sleeve, and filler material can be blown into the pillow. During the filling process, the sticks can be used to ensure an even distribution of filler material throughout the pillow. Once properly filled, the second end can be sewn together to contain the filler material.
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Although the outer sleeve of the pillows are shown as plain sleeves that a user would place a cover over, it should be appreciated that the outer sleeve itself could be decorative. Additionally or alternatively, it should be appreciated that while the description herein is directed to adjustable drawstrings, it is also contemplated that strips of material or drawstrings could be used to connect different portions of a pillow internally to create a pinched or chopped look that is permanent (as shown in
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Pillowcase 500 has a top opening with fastener 520 that allows access to a compartment for containing a pillow. One or more drawstrings 530 are thread through one or more internal sleeves 525A, 525B positioned on a side or bottom edge portion of pillowcase 500. Preferably the sleeve(s) and drawstring(s) extend throughout all or substantially all of the side and bottom edge portions of pillowcase 500. In some contemplated embodiments, the sleeve(s) and drawstring(s) also extend across the top edge portion such that the drawstring(s) are accessible through one or more small openings in the top edge's sleeve. Preferably, the top edge sleeve would be positioned only on one face of the pillow such that it does not interfere with access to the compartment. Such an embodiment may allow for a more uniform adjustment of the pillow.
Once a pillow is placed within the compartment, a user can close fastener 520 to secure the pillow within pillowcase 500. Drawstring(s) 530 and block 535 can be accessible from outside pillowcase 500 through an opening, and be used to adjust a shape or density of the pillow. Additionally or alternatively, it is contemplated that the drawstring 530 and block 535 will be internal to fastener 520 such that the user can unfasten fastener 520 to make adjustments to the pillow's shape and density.
After cutting the fabric as described, edges 752, 756, 764 of piece 730 and edges 754, 766, 762 of piece 740 are formed and defined. As shown in
By making the cuts shown in dashed line, more pieces can be cut from the fabric when aligned with an edge of a narrow region of one piece next to an edge of wide region of another piece than if the pieces were aligned where edges of the wide regions were adjacent one another.
In one exemplary embodiment, it is contemplated that W1 and W3 can be between 17-23 inches, and more preferably approximately 20 inches, with W2 and W4 being about 9-15 inches, and more preferably approximately 12 inches. Of course, the specific widths of each region will depend on various factors including the size of the pillow.
To form the pillow, the first and second pieces 810, 820 can be disposed on top of the other (either the first piece 810 on top of the second piece 820, or the top piece 820 on top of the first piece 810) as shown in
The first and second pieces 810, 820 can be coupled to one another on at least three sides, preferably by sewing the pieces together using thread, although any commercially suitable fastener or process for fastening the two pieces together could be used.
As shown in
To ensure the inner pocket 862 remains within the outer pocket 860, it is contemplated that at least one side of the inner pocket 862 can be sewn or other attached to a side of the outer pocket 860. As but one example shown in
As shown in
A first end 874, 876 of each of the one or more cords 870, 872 or other adjustment mechanisms can be coupled to a side of the pillow 800. For example, as shown in
Preferably a filler material is inserted within the outer pocket 860 and outside of the inner pocket 862. In this manner, the inner pocket 862 can help to ensure the filler material remains properly distributed within the outer pocket 860 of the pillow 800. By inserting the cord(s) 870, 872 or other adjustment mechanisms within the inner pocket 862, this also ensures that the cord(s) 870, 872 or other adjustment mechanisms do not come into contact with the filler material, and that the filler material will not contact or pass through any hole in the pillow through which the one or more cord(s) 870, 872 or other adjustment mechanisms exits the pillow 800.
It is contemplated that aspects of the embodiments described above with respect to
While the description and figures are largely directed to rectangular pillows, it should be appreciated that each of the pillow, the outer sleeve and the inner sleeve could comprise any suitable shape (e.g., circular, trapezoidal, triangular, pentagonal, hexagonal, irregular). Furthermore, it should be appreciated that while the description and figures are largely directed to pillows having two or more drawstrings, a single drawstring could be provided to increase the firmness of the pillow and create a pillow that is pinched centrally (e.g., a bow-tie shape). Still further, it should be appreciated that while the description and figures are largely directed to pillows having drawstrings attach to both end portions of the pillow, contemplated pillows can include drawstrings that extend from a non-end portion of the pillow (e.g., a central portion of the pillow) to an end portion or a non-end portion of the pillow. Such pillows, when compressed, can have first and second end-portions that have substantially different shapes (e.g., a pinched end and an un-pinched end).
Additionally, it should be appreciated that the inventive subject matter has uses far beyond pillows. For example, the same adjustment mechanisms could be applied to objects having various filler materials, such as seat cushions and seat backs.
As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
Also, as used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.
In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, and unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
Thus, specific compositions and methods for adjustable pillows have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure. Moreover, in interpreting the disclosure all terms should be interpreted in the broadest possible manner consistent with the context. In particular the terms “comprises” and “comprising” should be interpreted as referring to the elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps can be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.
Claims
1. A pillow, comprising:
- first and second portions of fabric, with each of the first and second portions have a wide region and a narrow region, wherein a width of the wide region is greater than a width of the narrow region;
- wherein the first and second portions of fabric are disposed one on top of the other such that the narrow region of the first portion overlaps the narrow region of the second portion, and the wide region of the first portion overlaps the wide region of the second portion; and
- wherein the first and second portions are coupled to one another on at least three sides, and wherein the narrow region is disposed within the wide region;
- a first cord configured to extend from a first side to a second opposing side of the pillow through the narrow region between the first and second portion of fabric; and
- wherein the first cord is configured to allow adjustment of a length of the cord within the narrow region and thereby adjust a size and firmness of the pillow.
2. The pillow of claim 1, wherein each of the first and second portions of fabric have a first side disposed along an edge of the wide region and a second side disposed along an edge of the narrow region, and wherein the second side is coupled to the first side with the narrow region disposed within the wide region.
3. The pillow of claim 1, wherein the first and second sides are coupled via a thread.
4. The pillow of claim 1, further comprising an inner pocket defined by the narrow regions of the first and second portions of fabric, and an outer pocket defined by the wide regions of the first and second portion of fabric, and wherein the inner pocket is disposed within the outer pocket.
5. The pillow of claim 4, further comprising filler material disposed within the outer pocket of the pillow and outside of the inner pocket.
6. The pillow of claim 5, wherein the first cord extends along a length of the pillow and is disposed within the inner pocket.
7. The pillow of claim 1, wherein the first and second portion of fabric are contiguous along at least one side of their respective wide regions.
8. The pillow of claim 1, wherein during manufacture an edge of the wide region of the first portion abuts an edge of the narrow region of the second portion.
9. The pillow of claim 1, wherein the first and second portions comprise separate pieces of fabric prior to their coupling to one another.
10-19. (canceled)
20. A method of manufacturing a pillow, wherein the pillow comprises first and second sheets sewn together to form the pillow, and wherein each of the first and second sheets have a narrow region and a wide region, the method comprising:
- cutting a piece of fabric in a first direction along a first length of the fabric to form a first edge;
- cutting the piece of fabric along a first width of the fabric in a second direction that is perpendicular to the first direction to form a second edge;
- cutting the piece of fabric in the first direction along a second length of the fabric to form a third edge; and
- wherein the first and third edges are discontinuous and connected via the second edge.
Type: Application
Filed: Dec 18, 2017
Publication Date: Mar 12, 2020
Inventor: James Chung Chun Wang (Irvine, CA)
Application Number: 15/741,710