CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Priority is hereby claimed to U.S. Provisional Patent App. No. 61/140,622, filed December 24, 2008, the entire contents of which are herein incorporated by reference.

BACKGROUND

[0002] Conventional pillows can be found in a wide variety of shapes and sizes, and are often adapted for supporting one or more body parts of a user.

[0003] Many pillows are constructed entirely or partially out of foam material. For example, polyurethane foam is commonly used in pillows of all types, and can be used alone or in combination with other types of cushion materials. In many cases, pillows are constructed entirely or partially of visco-elastic material, thereby providing the pillow with an increased ability to conform to a user and to thereby distribute the weight or other load of the user. Some visco-elastic materials are also temperature sensitive, thereby also enabling the pillow to change shape based at least in part upon the temperature of the supported body part.

[0004] Although the number and types of pillows constructed with visco-elastic materials continue to increase, the capabilities of such materials are often underutilized. In many cases, this underutilization is due to poor pillow design and/or the choice of material(s) used in the pillow.

[0005] Based at least in part upon the limitations of existing pillows containing visco- elastic material and the high consumer demand for improved pillows in a wide variety of applications, new pillows are welcome additions to the art.

SUMMARY

[0006] Some embodiments of the present invention provide a pillow comprising a core and a plurality of lobes extending from the core, wherein the core includes a top layer and a bottom layer between which is located granulated filler material, wherein the top layer, bottom layer, and/or granulated foam comprises visco-elastic foam. The sides of the core can be defined by highly porous material (such as a 3D textile material) in some embodiments. Also, the core can be enclosed within a cover having highly porous sides (e.g., made of a 3D textile material or a velour or stretch velour material) corresponding to and covering the sides of the core and/or a highly porous bottom (e.g., again, made of a 3D textile material or a velour or stretch velour material) corresponding to and covering the bottom layer of the core. In some embodiments, the top of the cover can be less porous than the sides or bottom of the cover, whereas in other embodiments, the top and bottom of the cover are less porous than the sides of the cover. Examples of material that can be used for the top of the cover include a double jersey fabric, velour, or stretch velour. In some alternative embodiments, these same materials can be used for the bottom of the cover, such as in embodiments in which the top and bottom of the cover are both less porous than the sides of the cover.

[0007] A pillow assembly including a visco-elastic foam core and a cover having a top portion and a side portion that is more permeable than the top portion. The core comprises a top layer of foam, a bottom layer of foam, and a filler of granulated foam filler positioned between the top layer and the bottom layer. The core further includes a side layer coupled to the top layer and bottom layer to define a cavity containing the filler, such that the side layer is more permeable than the top layer. At least one of the side layer and the side portion comprises a 3D textile. The assembly is shaped to include a plurality of lobes. The cover further includes a bottom portion having a material that is less permeable than the side portion, such that the bottom portion comprises a material that is the same as the top portion.

[0008] A pillow assembly including a core having a top layer of foam, a side layer and a bottom layer, and a cover surrounding the core. The core further includes a granulated foam filler positioned between the top layer and the bottom layer. The side layer is coupled to the top layer and the bottom layer to define a cavity containing the filler. The side layer is more permeable than the top layer and the bottom layer. The assembly is shaped to include a plurality of lobes.

[0009] Further aspects of the present invention, together with the organization and operation thereof, will become apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a perspective view of a pillow according to the present invention, shown with a portion of the cover removed to expose the core of the pillow.

[0011] FIG. 2 is a detail cross-sectional view of the pillow of FIG. 1.

DETAILED DESCRIPTION

[0012] Before the various embodiments of the present invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, terms such as "first", "second", and "third" are used herein and in the appended claims for purposes of description and are not intended to indicate or imply relative importance or significance. The term "first" does not necessarily refer to the top most layer, rather, it refers to the first of a plurality, without indicating a particular location or position. Similarly, the terms "top" and "bottom" are used for the purpose of description and are not intended to indicate or imply relative importance, significance, unless otherwise specified. The term "top" does not necessarily refer to the top most layer, and "bottom" does not necessarily refer to the bottom most layer.

[0013] The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms "connected," "coupled," and variations thereof herein are used broadly and encompass direct and indirect connections and couplings. In addition, the terms "collected" and "coupled" and variations thereof are not restricted to physical or mechanical connections or couplings.

[0014] A pillow 100 according to an embodiment of the present invention is illustrated in FIGS. 1-2. The pillow 100 comprises a core 110 having a plurality of lobes 120, 130 extending from a central portion of the core 110. In some embodiments, the lobes 120, 130 all have substantially the same size. However, in other embodiments (including that shown in FIG. 1), the lobes 120, 130 can have different sizes. In particular, two of the lobes 120 in the illustrated embodiment are smaller than the other two lobes 130. Any combination of lobes having the same size or different sizes is possible, and falls within the spirit and scope of the present invention. Also, in other embodiments, the core 110 can have three lobes, five lobes, or more lobes of the same or different size. In any case, the lobes 120, 130 can be equally or unequally spaced about the periphery of the pillow 100. The lobed shape of the pillow 100 provides a number of support surfaces for a user. For example, the lobed shapes can enhance breathing of a user resting his or her head against the pillow 100 (e.g., when sleeping on the user's side or stomach), and can also provide support for the shoulder and/or neck of the user when the user is sleeping on his or her side or back.

[0015] With continued reference to FIGS. 1 and 2, the core 110 of the illustrated pillow 100 includes a top layer 140, a bottom layer 150 opposite the top layer 140, and sidewalls 160 connecting the top layer 140 and the bottom layer 150. The top layer 140, bottom layer 150 and sidewalls 160 define a cavity 170 shaped to receive filler material 180. The pillow 100 can include a rib where the top layer 140 and sidewalls 160 meet and are joined, and/or a rib where the bottom layer 150 and the sidewalls 160 meet and are joined. The top layer 140, bottom layer 150 and sidewalls 160 can be secured to one another in any suitable manner, such as by adhesive or cohesive bonding material, by being bonded together during formation of the top layer 140, bottom layer 150, and sidewalls 160, by tape, hook and loop fastener material, or conventional fasteners, by stitches extending at least partially through the top layer 140, bottom layer 150, and/or sidewalls 160, or in any other suitable manner.

[0016] The top layer 140, bottom layer 150 and sidewalls 160 can have any thickness desired. By way of example only, in some embodiments the top layer 140, bottom layer 150, and sidewalls 160 are each approximately lcm in thickness. In other embodiments, the top layer 140, bottom layer 150 and sidewalls 160 can be less than lcm thick or greater than lcm thick.

[0017] By virtue of the generally box-shaped core structure defined by the top layer 140, bottom layer 150, and sidewalls 160 in some embodiments, the pillow 100 can provides enhanced support to a user, as well as providing space for the filler material 180.

[0018] In some embodiments, the top layer 140, bottom layer 150 and sidewalls 160 can include one or more releasable fasteners (e.g., zippers, buttons, clasps, laces, hook and loop fastener material pieces, hook and eye sets, tied ribbons, strings, cords, or other fastener elements). Such fasteners can be located between the top layer 140 and sidewall 160, between a sidewall 160 and the bottom layer 150, or within an opening in the top layer 140, sidewall 160, and/or bottom layer 150, and can be positioned to allow access to the cavity 170, such as to remove or add filler material 180 within the cavity 170. By way of example only, the top layer 140 can have a zippered slot through which filler material 180 can be inserted and removed.

[0019] In some embodiments, the top layer 140 and/or bottom layer 150 comprises visco- elastic foam (sometimes referred to as "memory foam" or "low resilience foam"). In such embodiments, the top layer 140 and bottom layer 150 can have a hardness of at least about 30 N and no greater than about 175 N for desirable softness and body-conforming qualities. In other embodiments, visco-elastic foam top and bottom layers 140, 150 having a hardness of at least about 40 N and no greater than about 110 N are used for this purpose. In still other embodiments, visco-elastic foam top and bottom layers 140, 150 having a hardness of at least about 40 N and no greater than about 75 N are utilized. Unless otherwise specified, the hardness of a material referred to herein is measured by exerting pressure from a plate against a sample of the material having length and width dimensions of 40 cm each (defining a surface area of the sample of material), and a thickness of 5 cm to a compression of 40% of an original thickness of the material at approximately room temperature (e.g., 21-23 degrees Celsius), wherein the 40% compression is held for a set period of time, following the International Organization of Standardization (ISO) 2439 hardness measuring standard.

[0020] In those embodiments having visco-elastic top and/or bottom layers 140, 150, the visco-elastic foam of such layers 140, 150 can also have a density providing a relatively high degree of material durability. The density of the visco-elastic foam in such embodiments can also impact other characteristics of the foam, such as the manner in which the top layer 140 and bottom layer 150 respond to pressure, and the feel of the foam. In some embodiments, the visco-elastic foam of the top layer 140 and/or bottom layer 150 has a density of no less than about 30 kg/m ³ and no greater than about 150 kg/m ³ . In other embodiments, a visco- elastic foam top layer 140 and/or bottom layer 150 having a density of at least about 70 kg/m ³ and no greater than about 130 kg/m ³ is utilized. In still other embodiments, a visco-elastic foam top layer 140 and/or bottom layer 150 having a density of at least about 80 kg/m and no greater than about 120 kg/m is utilized.

[0021] The visco-elastic foam of the top layer 140 and/or bottom layer 150 can be selected for responsiveness to any range of temperatures. However, in some embodiments, a temperature responsiveness in a range of a user's body temperatures (or in a range of temperatures to which the pillow 100 is exposed by contact or proximity to a user's body resting thereon) can provide significant advantages. For example, a visco-elastic foam selected for the top layer 140 and/or bottom layer 150 can be responsive to temperature changes above at least about 0 ⁰ C. In some embodiments, a visco-elastic foam selected for the top layer 140 and/or bottom layer 150 can be responsive to temperature changes within a range of at least about 10 ⁰ C. In other embodiments, a visco-elastic foam selected for the top layer 140 and/or bottom layer 150 can be responsive to temperature changes within a range of at least about 15°C. As used herein, a material is considered "responsive" to temperature changes if the material exhibits a change in hardness of at least 10% measured by ISO Standard 3386 through the range of temperatures between 10 and 30 degrees Celsius.

[0022] In some embodiments, significant advantages are achieved by utilizing reticulated visco-elastic foam for the top layer 140 and/or bottom layer 150 of the pillow 100. As will be described in greater detail below, reticulated foam can provide significantly increased ventilation for the top and/or bottom layer 140, 150 of the pillow 100, thereby enhancing the ability of the pillow 100 to transport heat away from the user's body thereon. Such use of reticulated foam can also enhance the ability of the pillow 100 to wick moisture away from the user's body thereon.

[0023] Reticulated foam (visco-elastic or otherwise) is a cellular foam structure in which the cells of the foam are essentially skeletal. In other words, the cells of the reticulated foam are each defined by a plurality of apertured windows surrounded by cell struts. The cell windows of reticulated foam can be entirely gone (leaving only the cell struts) or substantially gone. In some embodiments, the foam is considered "reticulated" if at least 50% of the windows of the cells are missing (i.e., windows having apertures therethrough, or windows that are completely missing and therefore leaving only the cell struts). Such structures can be created by destruction or other removal of cell window material, or preventing the complete formation of cell windows during the manufacturing process of the foam.

[0024] By virtue of the skeletal cellular structure of reticulated visco-elastic foam used for the top layer 140 and/or the bottom layer 150, heat and moisture can be transferred away from the source of heat (e.g., a user's body), thereby helping to prevent one or more areas of the top layer 140 and bottom layer 150 from reaching an undesirably high temperature. Also, the reticulated structure of visco-elastic foam in the top layer 140 and/or bottom layer 150 enables significantly higher airflow into, out of, and through the top layer 140 and bottom layer 150 - a characteristic of the top layer 140 and bottom layer 150 that can reduce heat in the respective layer. At the same time, the visco-elastic nature of foam in the top layer 140 and/or bottom layer 150 provides desirable tactile contact and pressure responsiveness for user comfort. In this regard, the reticulated visco-elastic foam of some embodiments has a reduced hardness level, thereby providing a relatively soft and comfortable surface for a user's body. In conjunction with the slow recovery characteristic of reticulated visco-elastic foam, the top layer 140 and/or bottom layer 150 can also at least partially conform to the user's body, thereby distributing the force applied by the user's body upon the top layer 140 and/or bottom layer 150.

[0025] In some embodiments, reticulated visco-elastic foam used for the top layer 140 and/or bottom layer 150 can have a hardness of at least about 20 N and no greater than about 150 N for desirable softness and pressure-responsive qualities. In other embodiments, a top layer 140 and/or bottom layer 150 of reticulated visco-elastic foam having a hardness of at least about 30 N and no greater than about 100 N is utilized. In still other embodiments, a top layer 140 and/or bottom layer 150 of reticulated visco-elastic foam having a hardness of at least about 40 N and no greater than about 85 N is utilized.

[0026] Reticulated visco-elastic foam used for the top layer 140 and/or bottom layer 150 can also have a density providing a relatively high degree of material durability. As noted above with regard to non-reticulated visco-elastic foam, the density of reticulated visco- elastic foam of top layer 140 and/or bottom layer 150 can also impact other characteristics of the foam, such as the manner in which the respective surface responds to pressure, and the feel of the foam. In some embodiments, the top layer 140 and/or bottom layer 150 is constructed of reticulated visco-elastic foam having a density of no less than about 30 kg/m ³ and no greater than about 175 kg/m ³ . In other embodiments, a top layer 140 and/or bottom layer 150 of reticulated visco-elastic foam having a density of at least about 50 kg/m ³ and no greater than about 120 kg/m ³ is utilized. In still other embodiments, a top layer 140 and/or bottom layer 150 of reticulated visco-elastic foam having a density of at least about 70 kg/m ³ and no greater than about 95 kg/m is utilized.

[0027] Reticulated visco-elastic foam of the top layer 140 and/or bottom layer 150 can be selected for responsiveness to any range of temperatures. However, in some embodiments, a temperature responsiveness in a range of a user's body temperatures (or in a range of temperatures to which the pillow 100 is exposed by contact or proximity to a user's body resting thereon) can provide significant advantages. For example, a reticulated visco-elastic foam selected for the top layer 140 and/or bottom layer 150 can be responsive to temperatures changes (as defined above) above at least 0 ⁰ C. In some embodiments, the reticulated visco-elastic foam selected for the top layer 140 and/or bottom layer 150 can be responsive to temperature changes within a range of at least about 10 ⁰ C. In other embodiments, the reticulated visco-elastic foam selected for the top layer 140 and/or bottom layer 150 can be responsive to temperature changes within a range of at least about 15°C.

[0028] Although reticulated or non-reticulated visco-elastic foam used for the top layer 140 and/or bottom layer 150 presents significant and unique advantages in many embodiments of the present invention, it should be appreciated that other types of foam can be used to construct either or both layers 140, 150, including without limitation polyurethane foam, latex foam, any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like.

[0029] In some embodiments of the present invention, the pillow 100 is provided with sidewalls 160 that are highly porous, and therefore provide a significant degree of ventilation for the pillow, allowing air to enter and exit the pillow 100 readily through the sides of the pillow 100. The inventors have discovered that this capability is achieved through use of a 3D textile core sidewall 160, which has the added benefit of providing structural strength to the pillow 100 to retain the box-shaped core structure described above. As alternatives to the 3D textile material, other breathable fabrics can instead be used as desired.

[0030] The filler material 180 of the pillow 100 can include, but is not limited to, granulated visco-elastic foam (e.g., visco-elastic foam that has been shredded, chopped, and the like, visco-elastic foam balls, discs, plates, or other pieces, and the like). The granulated visco-elastic foam can be reticulated or non-reticulated visco-elastic foam, or a combination of such foams. By virtue of its porosity, reticulated visco-elastic foam can be highly attractive for use as granulated filler material 180, enabling a greater degree of pillow ventilation, heat transport away from the user's body, and moisture wicking away from the user's body. The granulated visco-elastic foam filler material 180 can comprise a number of loose pieces of visco-elastic foam having the same or different sizes and shapes at least partially filling the cavity 170 of the core 110. [0031] The filler material 180 is a supportive layer providing a relatively stiff but flexible and resilient substrate. The resiliency deformable nature of the filler 180 can therefore provide a degree of user comfort to the extent that the user's weight affects the shape of the pillow 100. In some embodiments, the filler material 180 has a hardness of at least about 50 N and no greater than about 300 N for a desirable degree of support and comfort. In other embodiments, the filler material 180 has a hardness of at least about 80 N and no greater than about 250 N. In still other embodiments, the filler material 180 has a hardness of at least about 90 N and no greater than about 180 N.

[0032] Like visco-elastic foam used for the top layer 140 and/or bottom layer 150 of the pillow 100, visco-elastic foam filler material 180 can have a density providing a relatively high degree of material durability. Also, the density of such filler material 180 can impact other characteristics of the visco-elastic foam, such as the manner in which the filler material 180 responds to pressure, and the feel of the foam. In some embodiments, the filler material 180 has a density of about 85 kg/m ³ . However, a suitable density for visco-elastic foam filler material 180 for an average weight pillow 100, for example, can be between about 30 and about 140 kg/m ³ . Further, a suitable density for visco-elastic foam filler material 180 for a light-weight pillow 100, for example, can be less than about 40 kg/m ³ . Likewise, a suitable density for visco-elastic foam filler material 180 for a heavy-weight pillow 100, for example, can be greater than about 130 kg/m ³ . Alternatively, the granulated visco-elastic foam utilized as the filler material 180 can have any density in accordance with the desired characteristics of the pillow 100.

[0033] In some embodiments, non-reticulated visco-elastic foam filler material 180 having a density of no less than about 30 kg/m and no greater than about 150 kg/m is used. In other embodiments, a non-reticulated visco-elastic foam filler 180 having a density of at least about 70 kg/m ³ and no greater than about 130 kg/m ³ is utilized. In still other embodiments, a reticulated visco-elastic foam filler 180 having a density of at least about 80 kg/m ³ and no greater than about 120 kg/m ³ is utilized.

[0034] Alternatively, reticulated visco-elastic foam filler material 180 having a density of no less than about 30 kg/m ³ and no greater than about 175 kg/m ³ is used. In other embodiments, a non-reticulated visco-elastic foam filler 180 having a density of at least about 50 kg/m ³ and no greater than about 120 kg/m ³ is utilized. In still other embodiments, a reticulated visco-elastic foam filler 180 having a density of at least about 70 kg/m ³ and no greater than about 95 kg/m ³ is utilized.

[0035] In addition, a suitable visco-elastic foam filler material 180 possesses an indentation load deflection, or "ILD," of 65% between 100-500 N loading, and a maximum 10% rebound according to the test procedure governed by the ASTM-D- 1564 standard.

[0036] The granulated filler material 180 can be made up of recycled, virgin, or scrap reticulated and/or non-reticulated visco-elastic foam material. The granulated filler material 180 may consist of pieces of a nominal length, or the granulated filler material 180 may consist of pieces of varying lengths. For example, granulated filler material 180 may have a nominal length of about 1.3 cm. Also, granulated filler material 180 may consist of varying lengths between about 0.6 cm and about 2 cm. The granulated filler material 180 can be as short as 0.3 cm and as long as 4 cm., or the filler material 180 can be any length in accordance with the desired characteristics of the pillow 100. In some embodiments of the present invention, the granulated filler material 180 is comprised of 16-20% having a length longer than 2 cm, 38-42% having a length between 1 and 2 cm, and 38-42% of the pieces shorter than 1 cm. Significant cost savings and waste reduction can be realized by using scrap or recycled filler material 180 rather than virgin filler material 180. The visco-elastic foam used as the filler material 180 is made from a polyurethane foam material; however, the filler material 180 can be made from any other visco-elastic polymer material that exhibits similar properties.

[0037] The composition of the filler material 180 can be varied to alter the characteristics of the pillow 100 and the cost of the pillow 100. In some embodiments of the present invention, the filler material 180 is a combination of granulated visco-elastic foam and a fiber material. The fiber material can be made from any kind of textile, such as an organic textile (cotton) or a synthetic textile, which is often less expensive than visco-elastic foam. In some embodiments of the present invention, the fiber material has a density of about 1 g/cm ³ . However, a suitable density for the fiber material for an average weight pillow 100, for example, is 0.1 - 2 g/cm ³ . Further, a suitable density for the fiber material for a light-weight pillow 100, for example, can be less than about 0.3 g/cm ³ . Likewise, a suitable density for the fiber material for a heavy-weight pillow 100, for example, can be greater than about 1.8 g/cm . Alternatively, the fiber material utilized in combination with the granulated visco-elastic foam as the filler material 180 can have any density in accordance with the desired characteristics of the pillow 100.

[0038] In some embodiments of the present invention, the filler material 180 is comprised of about 50% fiber material, while the remaining composition includes granulated visco-elastic foam as described above. However, a suitable range of fiber material in the filler material 180 for an average-cost pillow 100, for example, can be between about 20% and about 80%. Further, a suitable range of fiber material in the filler material 180 for a more expensive pillow 100, for example, can be more than about 30% of the filler material 180. Likewise, a suitable range of fiber material in the filler material 180 for a less expensive pillow 100, for example, can be greater than about 70% of the filler material 180.

[0039] In still other embodiments of the present invention, the filler material 180 is a combination of granulated visco-elastic foam and polystyrene balls, which are often less expensive than visco-elastic foam. The filler material 180 of such embodiments can also include an organic or synthetic fiber material, depending on the desired characteristics of the pillow 100. The polystyrene balls may consist of balls of a nominal diameter, or the polystyrene balls may consist of balls of varying diameters. For example, the polystyrene balls may have a nominal diameter of about 5mm. Also, the polystyrene balls may consist of varying diameters between about 1 mm and about 10 mm. The polystyrene balls can also be as small as 0.5 mm and as long as 20mm, or the polystyrene balls can be any length in accordance with the desired characteristics of the pillow 100.

[0040] In some embodiments of the present invention, the filler material 180 is comprised of about 50% polystyrene balls, while the remaining composition includes granulated visco-elastic foam as described above. However, a suitable range of polystyrene balls in the filler material 180 for an average-cost pillow 100, for example, can be between about 20% and about 80%. Further, a suitable range of polystyrene balls in the filler material 180 for a more expensive pillow 100, for example, can be less than about 30% of the filler material 180. Likewise, a suitable range of polystyrene balls in the filler material 180 for a less expensive pillow 100, for example, can be greater than about 70% of the filler material 180.

[0041] The filler material 180 can also include granulated highly-elastic ("HE") foam in addition to the granulated visco-elastic foam described above. HE foam is often less expensive than visco-elastic foam, thus yielding a potentially less expensive pillow 100. The filler material can be comprised of any single filler described above or any combination of the fillers. Alternatively, the filler material 180 can also include any conventional materials, such as feathers, granulated cotton, cotton fibers, etc. In some embodiments of the present invention, the filler material 180 includes HE foam having a density of about 35 kg/m ³ . However, a suitable density for the HE foam for an average weight pillow 100, for example, can be between about 20 kg/m ³ and about 50 kg/m ³ . Further, a suitable density for HE foam for a lightweight pillow 100, for example, can be less than about 25 kg/m ³ . Likewise, a suitable density for HE foam for a heavyweight pillow 100, for example, can be greater than about 45 kg/m ³ . Alternatively, HE foam utilized in the filler material 180 can have any density in accordance with the desired characteristics of the pillow 100.

[0042] Granulated HE foam may consist of pieces of a nominal length, or granulated

HE foam may consist of pieces of varying lengths. For example, granulated HE foam may have a nominal length of about 1.3 cm. Also, the granulated HE foam may consist of varying lengths between about 0.6 cm and about 2 cm. The granulated HE foam can be as short as 0.3 cm and as long as 4 cm., or the granulated HE foam can be any length in accordance with the desired characteristics of the pillow 100. In some embodiments of the present invention, the granulated HE foam is comprised of 16-20% having a length longer than 2 cm, 38-42% having a length between 1 and 2 cm, and 38-42% of the pieces shorter than 1 cm.

[0043] In some embodiments of the present invention, the filler material 180 is comprised of about 50% granulated HE foam, while the remaining composition includes granulated visco-elastic foam as described above. However, a suitable range of HE foam in the filler material 180 for an average cost pillow 100, for example, is 20% - 80%. Further, a suitable range of granulated HE foam in the filler material 180 for a more expensive pillow 100, for example, can be less than about 30% of the filler material 180. Likewise, a suitable range of granulated HE foam in the filler material 180 for a less expensive pillow 100, for example, can be greater than about 70% of the filler material 180.

[0044] Depending at least in part upon the thickness and material properties of the top layer 140, bottom layer 150 and sidewalls 160, in some embodiments the filler material 180 can be exposed to substantial body heat from a user resting upon the pillow 100. In such embodiments, the filler material 180 can be selected to be substantially insensitive to temperature changes (as defined above) within a range of between about 10 ⁰ C to about 35°C, thereby retaining the supportive properties desired for the filler material 180 throughout a range of body temperatures to which the filler material 180 may be exposed. In some embodiments, the filler material 180 can comprise foam that is substantially insensitive to temperature changes within a range of between about 15°C to about 3O ⁰ C. In still other embodiments, the filler material 180 is substantially insensitive to temperature changes within a range of between about 15°C to about 25°C.

[0045] The cavity 170 can also or instead include granulated non-visco-elastic foam of any other type desired, including without limitation granulated polyurethane foam, latex foam, or any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like. Still other types of filler material is possible, and falls within the spirit and scope of the present invention. Non-visco-elastic foam materials that can be used can also be reticulated or non-reticulated. As with the granulated reticulated visco-elastic foam filler material 180 described above, reticulated non-visco-elastic foam filler material 180 can enable a greater degree of pillow ventilation, heat transport away from the user's body, and moisture wicking away from the user's body.

[0046] Especially in those embodiments of the present invention in which reticulated or non-reticulated visco-elastic foam is used to construct portions of the core (e.g., the top layer 140, the bottom layer 150, and/or the filler material 180), the pillow 100 provides a soft and comfortable surface for a user's body. Coupled with the slow recovery characteristic of the visco-elastic foam, the pillow 100 can also conform to a user's body, thereby distributing the force applied by the user's body upon the top layer 140.

[0047] The illustrated pillow 100 can provide support for a user while still conforming to a user's body (e.g., head and neck), particularly in those embodiment in which visco-elastic foam is used in the core 110. Accordingly, the reticulated or non-reticulated visco-elastic material of the pillow 100 can distribute pressure from the user's body across the surface of the pillow 100, thereby potentially reducing stress upon the user's neck and/or reducing pressure upon the user's face or other area of the user's head in contact with the pillow 100. In those embodiments in which reticulated or non-reticulated visco-elastic foam is temperature- sensitive as described above, the shape of the pillow 100 can also be adapted to the user based upon the user's body heat. Also, reticulated visco-elastic material of the pillow 100 can provide an increased amount of ventilation and/or heat dissipation based upon the skeletal cellular structure of the reticulated visco-elastic foam, thereby reducing heat in the pillow 100.

[0048] The pillow 100 can have a cover 190 substantially enclosing the pillow 100. The cover 190 can include a top portion 200, a bottom portion 210 opposite the top portion 200, and side portions 220 extending between the top portion 200 and the bottom portion 210. The top portion 200 can be configured to lie adjacent and cover the top layer 140 of the core 110, whereas the bottom portion 210 can be configured to lie adjacent and cover the bottom layer 150 of the core 110, and the side portions 220 can be configured to lie adjacent and cover the sidewalls 160 of the core 110.

[0049] The side portions 220 of the cover 190 can be highly porous (e.g., made of a 3D textile material or a velour or stretch velour material), corresponding to and covering the highly porous material of the core sidewalls 160. In some embodiments, the bottom portion 210 of the cover 190 can also be highly porous (e.g., again, made of a 3D textile material or a velour or stretch velour material). Accordingly, the side portions 220 of the cover 190, and in some cases the bottom portion 210 of the cover 190, can permit significant ventilation into and out of the pillow.

[0050] In some embodiments, the top portion 200 of the cover 190 can be less porous than the side portions 220 or bottom portion 210 of the cover 190, whereas in other embodiments, the top portion 200 and bottom portion 210 of the cover 190 are less porous than the side portions 220 of the cover 190. Accordingly, the material for the side portions 220 (and in some embodiments, the bottom portion 210 also) can be configured to improve the micro-climate of the pillow 100 with respect to humidity and temperature. Examples of material that can be used for the top portion 200 of the cover 190 include a double jersey fabric, velour, or stretch velour. In some alternative embodiments, these same materials can be used for the bottom portion 210 of the cover 190, such as in embodiments in which the top and bottom portions 200, 210 of the cover 190 are both less porous than the side portions 220 of the cover 190.

[0051] In some embodiments, the cover 190 is manufactured such that the bottom and side portions 210, 220 of the cover 190 are composed of the same material, and wherein the material of the top portion 200 is different from the material of the bottom and side portions 210, 220. In other embodiments, the bottom portion 210, side portions 220, and top portion 200 can each be made of different materials. Also, the material for the top portion 200 can be configured to reduce bacteria growth and odor of the pillow 100.

[0052] Alternatives to the materials described above for the pillow cover 190 include any sheet material desired, including without limitation any synthetic and/or natural fabric or cloth material, such as cotton, polyester, a cotton/polyester blend, wool, and visco-elastic or non-visco-elastic foam sheeting. In any case, the cover 190 can have one or more seams. Depending at least in part upon the type of cover material utilized, the seams can be attached by adhesive or cohesive bonding material, double-sided tape, stitching, hot-melting, conventional fasteners (e.g., zippers, buttons, clasps, laces, hook and loop fastener material, hook and eye sets, tied ribbons, strings, cords, or other similar elements, and the like), by being molded together in one or more manufacturing processes, or in any other suitable manner.

[0053] The cover 190 can be secured permanently to and/or about the layers 140, 150 and sidewalls 160 which the cover 190 encloses. In some embodiments, the cover 190 is removable from such layers 140, 150 and sidewalls 160, such as by being shaped to slip onto and off of the layers 140, 150 and sidewalls 160, by one or more releasable fasteners (e.g., zippers, buttons, clasps, laces, hook and loop fastener material pieces, hook and eye sets, tied ribbons, strings, cords, or other similar elements), and the like. Any such fasteners can be positioned to releasably secure at least one portion of a cover 190 to another portion of the cover 190 and/or to an adjacent layer 140, 150 and/or sidewall 160. For example, the cover 190 can have a zippered slot through which the core 110 and plurality of lobes 120, 130 can be removed.

[0054] Although particular constructions embodying independent aspects of the present invention have been shown and described, other alternative constructions will become apparent to those skilled in the art and are within the intended scope of the independent aspects of the present invention.

[0055] Various features and advantages of the invention are set forth in the following claims.