`
`(12) United States Patent
`Alletto, Jr.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,646,134 B1
`Feb. 11, 2014
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`(54) PILLOW WITH GUSSET OF OPEN CELL
`CONSTRUCTION
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`(75) Inventor: Eugene Alletto, Jr., Glen Head, NY
`US)
`(
`-
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`(73) Assignee: Bedgear, LLC, Farmingdale, NY (US)
`
`(*) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`(21) Appl. No.: 13/531,122
`
`(22) Filed:
`
`Jun. 22, 2012
`Related U.S. Application Data
`(60) Provisional application No. 61/499,907, filed on Jun.
`22, 2011.
`
`(2006.01)
`
`(51) Int. Cl.
`A47G 9/10
`(52) U.S. CI.
`USPC .............. 5/636; 5/490; 5/652.1; 5/724; 5/645
`(58) Field of Classification Search
`USPC ................... 5/636, 638, 645, 490, 724, 652.1
`See application file for complete search history.
`
`(56)
`
`References Cited
`|U.S. PATENT DOCUMENTS
`:};
`-
`1,212,515 A
`1/1917 Leavitt .............................. 5/636
`1,876,591 A * 9/1932 Bawden ..
`... 5/490
`4,665,575 A *
`5/1987 Raught ...
`... 5/722
`5,642,543 A * 7/1997 Huntley .
`... 5/640
`6,701,555 B1* 3/2004 Ermini ....
`... 5/644
`6,760,935 B1* 7/2004 Burton et al. ..................... 5/645
`* cited by examiner
`y
`-
`Primary Examiner – Michael Trettel
`(74) Attorney, Agent, or Firm – Sorell, Lenna & Schmidt,
`LLP
`ABSTRACT
`(57)
`A pillow is provided herein which includes a cover having
`opposing first and second panels. A gusset perimetrically
`bounds, and joins, the first and second panels. The gusset is
`formed of an open cell construction. Compliant fill material is
`disposed within the cover. Advantageously, with the subject
`invention, a pillow is provided allowing for lateral ventilation
`between opposing panels. This permits a cooling effect while
`a user is resting or sleeping.
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`24 Claims, 4 Drawing Sheets
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`IPR2017-00524
`Bedgear 2005
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`Feb. 11, 2014
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`US 8,646,134 B1
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`PILLOW WITH GUSSET OF OPEN CELL
`CONSTRUCTION
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`CROSS-REFERENCE TO RELATED
`APPLICATION
`
`This application claims priority to US. Provisional Patent
`Application No. 61/499,907, filed Jun. 22, 2011, the entire
`contents of which are incorporated by reference herein.
`
`BACKGROUND OF THE INVENTION
`
`1. Field of the Invention
`
`The present invention relates to upper neck and head sup-
`port in the form of a pillow for the human body.
`2. Description of the Related Art
`The use of a pillow made typically of a fabric cover stuffed
`with a compliant soft material is known in the prior art.
`Conventional pillows generally provide a soft cushion on
`which to place the head of an infant, child, or adult while
`resting or sleeping, either in bed, or on upholstered furniture
`in which case the pillows typically have a permanent fabric
`cover. Additionally, positional specific pillows have been
`heretofore devised and utilized for the purpose of supporting
`the head and neck of people.
`
`SUMMARY OF THE INVENTION
`
`A pillow is provided herein which includes a cover having
`opposing first and second panels. A gusset perimetrically
`bounds, and joins, the first and second panels. The gusset is
`formed of an open cell construction. Compliant fill material is
`disposed within the cover. Advantageously, with the subject
`invention, a pillow is provided allowing for lateral ventilation
`between opposing panels. This permits a cooling effect while
`a user is resting or sleeping.
`An “open cell construction” as used herein refers to a
`construction having overall porosity greater than the inherent
`porosity of the constituent material or inherently having high
`porosity.
`These and other features of the invention will be better
`
`understood through a study ofthe following detailed descrip-
`tion and accompanying drawings.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`FIG. 1 is a perspective view of a pillow formed in accor-
`dance with the subject invention;
`FIG. 2 is a partial cut-away view of the pillow of FIG. 1;
`FIGS. 3-5 depict different open cell constructions useable
`with the subject invention;
`FIG. 6 is a perspective view of a pillow formed in accor-
`dance with the subject invention have a cover with separable
`portions; and,
`FIG. 7 is a perspective view of a foam layer useable with
`the subject invention.
`
`DETAILED DESCRIPTION OF THE INVENTION
`
`With reference to the Figures, a pillow 10 is provided
`having generally a cover 12 with compliant fill material 14
`disposed therein. The cover 12 includes opposing first and
`second panels 16, 18 and a gusset 20 which perimetrically
`bounds, and joins, the first and second panels 16, 18, the
`gusset 20 being formed of an open cell construction. The first
`and second panels 16, 18 are sized and shaped to accept a
`user’s head to provide support therefor.
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`The gusset 20 preferably is generally flat. In addition, it is
`preferred that the gusset 20 have sufficient width to separate
`the first panel 16 from the second panel 18 so as to define an
`air flow channel therethrough. This, thus, allows for an open
`cell construction band to be defined about the pillow 10
`between the first and second panels 16, 18. With pressure
`and/or heat applied to one or both of the first and second
`panels 16, 18, the gusset 20 provides venting therethrough of
`the interior of the cover 12. The venting may enhance the
`comfort of a user. With the first and second panels 16, 18
`preferably defining each a generally rectangular footprint
`common with the gusset 20, the gusset 20 is provided as four
`contiguous portions, including two longer longitudinal por-
`tions 22 joined by two shorter end portions 24.
`The open cell construction of the gusset 20 may be defined
`by various constructions. With reference to FIG. 3, the gusset
`20 may be defined by a plurality of interlaced or spaced-apart
`strands 26 arranged randomly or in various patterns, such as
`a “x” pattern (FIG. 1) or a rectangular pattern (FIG. 3). The
`strands 26 may be of various materials, including, e.g., poly-
`ester, and may be elastic or inelastic. The strands 26 are
`arranged so that open cells 28 are defined therebetween. The
`strands 26 may be connected at points of intersection (e. g., by
`fusion, stitching, being tied, by a fastener, and so forth) or
`may be not connected so as to permit free movement between
`contacting strands 26. If connected, it is preferred that the
`strands 26 be formed of elastic material. In addition, the
`strands 26 may be disposed in multiple layers so as to define
`a three-dimensional structure in a direction towards the inte-
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`rior of the pillow 10.
`With reference to FIG. 4, the gusset 20 may be formed of a
`base material 30, which is preferably a textile, such as a
`polyester textile. Apertures 32 may be defined in the base
`material 30 with the apertures 32 defining the open cells ofthe
`gusset 20. The apertures 32 are larger in size than any pores
`that may be inherently defined in the base material 30. The
`apertures 32 may be formed during manufacture of the base
`material 32 or formed after manufacture, such as by cutting,
`or material removal from, the base material 30. The apertures
`32 may be unfinished or finished, such as with trim or stitch-
`ing. The base material 30 may be single or multi-ply.
`As a further variation, and with reference to FIG. 5, the
`gusset 20 may be formed with the base material 30 being
`inherently significantly porous. Preferably, the base material
`30 is formed of 3D spacer fabric, which is inherently highly
`porous. More preferably, the base material 30 is formed of
`polyester 3D spacer fabric. The pores of the base material 30
`may be formed with irregular or regular shapes, such as
`circle-like or polygon-like shapes
`(e. g., diamond-like
`shapes). The porosity ofthe base material 30 may be substan-
`tially greater than the porosity ofthe material forming the first
`panel 16 and/or substantially greater than the porosity of the
`material forming the second panel 18. “Substantially greater”
`refers to being at least greater than, but preferably being at
`least twice greater than. The base material 30 may be single or
`multi-ply. If multi-ply, the collective porosity of the base
`material 30, through all layers, is considered as being sub-
`stantially greater than the porosity ofthe material of either the
`first panel 16 or the second panel 18.
`The gusset 20 may include one or more of the open cell
`configurations described above in connection with FIGS. 3-5
`singularly or in any combination.
`The gusset 20 may be joined to the first and second panels
`16, 18 using any conventional technique, including being
`sewn together. To provide the pillow 10 with a robust con-
`struction, it is preferred that piping 34, or other reinforcing
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`US 8,646,134 B1
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`material and/or stitching, be provided at the points of connec-
`tion between the gusset 20 and each of the first and second
`panels 16, 18.
`One or more labels 36 may be provided with the pillow 10
`to indicate the intended use ofthe pillow 10, and/or to provide 5
`additional or explanatory information regarding the pillow
`10. For example, with reference to FIG. 1, the label 36 may be
`in the form ofbanner 36A which may be a strip oftextile, e.g.,
`satin, having indicia 38 thereon, e. g. by embroidery, with the
`banner 36A being secured to a portion of the pillow 10.
`Preferably, the banner 36A with the indicia 38 thereon is
`located over a portion of the gusset 20. The banner 36A is
`preferably attached along one of its faces so as to have one
`face 37 exposed with the indicia 38 thereon. This allows for
`easy visual recognition of information related to the pillow
`10, such as an intended purpose of the pillow, even with a
`plurality ofthe pillows 10 being stacked. The label 36 may be
`also in the form of tag 36B which may be in the form of one
`or more individual pieces of sheet material (e. g., paper and/or
`textile) which is affixed to the pillow 10 in any known tech-
`nique, such as by sewing, gluing, mechanically fastening, and
`so forth. The tag 36B may include printed, or otherwise
`provided thereon, information, such as care and/or allergy
`information. The tag 36B may be secured at a seam in the
`cover 12, such as along the connection between one ofthe first
`and second panels 16, 18 and the gusset 20. The tag 36B is
`preferably attached along one of its edges so as to have both
`faces viewable.
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`The indicia 38, without the banner 36A, may be directly
`affixed to the pillow 10, such as by embroidery, printing or
`other marking. For example, the indicia 38 may be directly
`affixed to the gusset 20, such as by embroidery. With direct
`application of the indicia 38 to the gusset 20, the ability to
`pass air through the gusset 20 is minimally impacted.
`Different fill materials 14 are possible for the pillow 10.
`The fill material may be blends of hypoallergenic polyester
`fibers to achieve different levels of support versus softness as
`described above. For example, with the pillow 10 being
`intended for a stomach sleeping position, the pillow 10 may
`be provided with a fill of microfiber, with the pillow 10 being
`intended for a back sleeping position, the pillow 10 may be
`provided with a fill of a blend of conjugate and hollow slick
`fiber, and, with the pillow 10 being intended for a side sleep-
`ing position, the pillow 10 may be provided with a fill of
`cluster/ball fiber. As will be appreciated by those skilled in the
`art, other fills are possible. Various down, memory foam
`(solid layer(s) and/or clusters) and/or latex (solid layer(s)
`and/or springs), in varying combinations, may be utilized
`with the pillow 10 herein. The indicia 38 may be provided to
`indicate the intended sleep position of the pillow 10 based on
`the fill material therein.
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`The pillow 10 may be of various configurations. In a pre-
`ferred embodiment, the pillow 10 is provided with increased
`height at central portions, as shown in FIGS. 1 and 2. The fill
`material 14 is configured to provide the desired shape. More
`preferably, the first and secondpanels 16, 18 may be arcuately
`bowed-out in opposing directions (e.g., being convexly arc-
`shaped in opposing directions). Preferably, top edges 40 of
`the first and second panels 16, 18 are generally straight and
`parallel as viewed in a direction perpendicular to the first and
`second panels 16, 18. The top edges 40 may be parallel to the
`longitudinal portions 22 of the gusset 20. An area 42 may be
`defined between and be bounded by the top edge 40 and the
`longitudinal portion 22 on opposing sides of each of the first
`and second panels 16, 18. The areas 42 are preferably flat and
`coplanar with the corresponding top edge 40 and longitudinal
`portion 22.
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`The first and second panels 16, 18 each preferably include
`bottom edges 44, each extending along the bottom of one of
`the areas 42, and end edges 46. The bottom edges 44 extend
`between the end edges 46 so as to define a generally rectan-
`gular profile. The gusset 20 is preferably attached to the first
`and second panels 16, 18 along the rectangular profiles ofthe
`bottom edges 44/end edges 46 of the first and second panels
`16, 18.
`The present invention provides the correct alignment to
`head and neck area for the specific position of the user (back,
`stomach or side) while at the same time creating an environ-
`ment of cooling and airflow, which allows the sleeper to
`maintain their body temperature, and spine alignment, which
`encourages a normal sleep cycle.
`To enhance the cooling effect, it is preferred that an inner
`cover 48 be provided, located inside the cover 12, in which the
`fill material 14 is disposed. Preferably, the inner cover 48 is
`relatively resistant to air flow therethrough, such as being
`formed by one or more layers of non-woven material (e.g.,
`100% polyester). The inner cover 48 may be formed of span-
`dex or a spandex blend, such as polyester/spandex; although
`less resistance to air flow therethrough is provided by spandex
`or a spandex blend as compared to non-woven material, the
`spandex or spandex blend provides greater elasticity than the
`non-woven material which may provide greater comfort to a
`user. The inner cover 48 acts as a barrier against air flow into
`the fill material 14. With the gusset 20 being of open cell
`construction, air exchange about the inner cover 48 is permit-
`ted. This allows for heat dissipation and minimal heat collec-
`tion within the pillow 10. In addition, because the inner cover
`48 acts as an air barrier during use, heat transfer by air flow
`into the fill material 14 may be reduced.
`The first panel 14 and/or the second panel 18 may be
`formed ofvarious materials particularly various textiles. Pref-
`erably, the first panel 14 and/or the second panel 18 is formed
`of a moisture-wicking fabric, such as 100% polyester fabric,
`rayon, nylon, or spandex-blend fabric for increased perfor-
`mance and stretch-ability, which allows for moisture disper-
`sion and, thus, heat management to cool the head and body. A
`cooling material, such as a gel, may be applied interiorly to
`the front panel 14 and/or the second panel 18. The cooling
`material may be silicon or polyether gel formed into layers
`and applied shapes, as well as, formed ceramics, neoprene
`and other material technology as developed and available for
`use to perform heat transfer and temperature regulation func-
`tion. Depending on the nature and stability of the cooling
`material, the cooling material may be applied internally and/
`or externally to the front panel 14 and/or the second panel 18.
`In an alternative embodiment, the first panel 14 and/or the
`second panel 18 may be partially or wholly formed with open
`cell construction. Any of the open cell constructions dis-
`cussed above may be utilized. The first panel 14, the second
`panel 18 and/or the gusset 20 may use the same or different
`open cell configurations in various combinations. The first
`panel 14, the second panel 18 and/or the gusset 20 may be
`provided with different visual appearances (e. g., different
`colors, patterns, etc.) in various combinations.
`To allow for washing of the cover 12, the cover 12 may be
`formed by at least two partially or wholly separable portions
`12A, 12B, as shown in FIG. 6. By separating the separable
`portions 12A, 12B, the cover 12 may be removed from the fill
`material 14, and the inner cover 48, if used. Preferably, the
`cover 12 is separated along at least one of the longitudinal
`portions 22 of the gusset 20 and possibly along portions of
`one orboth ofthe endportions 24 and/or along the other ofthe
`longitudinal portions 22. One or more fasteners 50 may be
`provided to selectively join the separable portions 12A, 12B.
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`material, said apertures being larger than any pores
`inherently defined in said base material; and
`compliant fill material disposed within said cover.
`12. A pillow as in claim 11, wherein said first and second
`panels each define a generally rectangular footprint common
`with said gusset.
`13. A pillow as in claim 11, further comprising an inner
`cover disposed inside of said cover, at least a portion of said
`compliant fill material being disposed within said inner cover.
`14. A pillow as in claim 13, wherein said compliant fill
`material includes first and second solid foam layers located
`on opposing sides of said inner cover within said cover.
`15. A pillow as in claim 13, wherein said inner cover is
`formed by one or more layers of a material selected from the
`group consisting of a non-woven, knit, woven materials and
`combinations thereof such that said inner cover is relatively
`resistant to air flow therethrough.
`16. A pillow as in claim 11, wherein the compliant fill
`material includes gel.
`17. A pillow comprising:
`a cover having opposing first and second panels, and a
`gusset perimetrically bounding, and joining, said first
`and second panels, said gusset being formed of an open
`cell construction and a base material, and said open cell
`construction is formed by porosity of said base material
`being substantially greater than porosity of material
`forming said first panel and substantially greater than
`porosity of material forming said second panel; and
`compliant fill material disposed within said cover.
`18. A pillow as in claim 17, further comprising an inner
`cover disposed inside of said cover, at least a portion of said
`compliant fill material being disposed within said inner cover.
`19. A pillow as in claim 13, wherein said compliant fill
`material includes first and second solid foam layers located
`on opposing sides of said inner cover within said cover.
`20. A pillow as in claim 13, wherein said inner cover is
`formed by one or more layers of material selected from the
`group selected from knit, woven, non-woven materials and
`combinations thereof such that said inner cover is relatively
`resistant to air flow therethrough.
`21. A pillow as in claim 17, wherein the compliant fill
`material includes gel.
`22. A pillow comprising:
`a cover having opposing first and second panels, and a
`gusset perimetrically bounding, and joining, said first
`and second panels, said gusset being formed of an open
`cell construction, said gusset including 3D spacer mate-
`rial; and
`compliant fill material disposed within said cover.
`23. A pillow as in claim 22, further comprising an inner
`cover disposed inside of said cover, at least a portion of said
`compliant fill material being disposed within said inner cover.
`24. A pillow as in claim 22, wherein the compliant fill
`material includes gel.
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`5
`The fastener(s) 50 is preferably a Zipper, but may also include
`buttons, snaps, hook-and-pile fasteners, and so forth.
`With the inner cover 48 being used, it is preferred that all of
`the fill material 14 be located therein. In an alternative
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`embodiment, as shown in FIG. 6, a portion of the fill material
`14 may be located outside of the inner cover 48 within the
`cover 12. If a portion of the fill material 14 is located outside
`of the inner cover 48, it is preferred that the fill material 14
`include one or more solid foam layers 52 located between the
`cover 12 and the inner cover 48. In a preferred arrangement,
`the same number of similarly configured (shape, material)
`solid foam layers 52 are located on both sides of the inner
`cover 48. As shown in FIG. 7, the solid foam layers 52 may be
`shaped to impart overall shape to the pillow 10. Preferably,
`the solid foam layers 52 have an arcuate profile to impart an
`outwardly-bowed shape to the first and second panels 16, 18.
`What is claimed is:
`
`1. A pillow comprising:
`a cover having opposing first and second panels, and a
`gusset perimetrically bounding, and joining, said first
`and second panels, said gusset being formed of an open
`cell construction, said open cell construction is formed
`by interlaced or spaced-apart strands; and,
`compliant fill material disposed within said cover.
`2. The pillow of claim 1, wherein said first and second
`panels each define a generally rectangular footprint common
`with said gusset.
`3. A pillow as in claim 1, wherein said first and second
`panels are arcuately bowed out in opposing directions.
`4. A pillow as in claim 1, wherein said first panel is formed
`with a moisture dispersing material.
`5. A pillow as in claim 1, wherein said cover is formed by
`at least two partially or wholly separable portions, with said
`separable portions being selectively joinable by a fastening
`means.
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`6. A pillow as in claim 1, further comprising an inner cover
`disposed inside of said cover, at least a portion of said com-
`pliant fill material being disposed within said inner cover.
`7. A pillow as in claim 6, wherein said compliant fill mate-
`rial includes first and second solid foam layers located on
`opposing sides of said inner cover within said cover.
`8. A pillow as in claim 1, further comprising an inner cover
`disposed inside of said cover, said compliant fill material
`being disposed within said inner cover.
`9. A pillow as in claim 8, wherein said inner cover is formed
`of one or more layers of nonwoven material.
`10. A pillow as in claim 1, wherein the compliant fill
`material includes gel.
`11. A pillow comprising:
`a cover having opposing first and second panels, and a
`gusset perimetrically bounding, and joining, said first
`and second panels, said gusset being formed of an open
`cell construction and a base material, and said open cell
`construction is formed by apertures defined in said base
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