AU2012101035A4 - Multi-layer pillow - Google Patents

Abstract

A pillow is described including a first layer of foam material and a second 5 layer of foam material, wherein resistance to resilient deformation of the first layer is less than that of the second layer. Preferably, the first layer is made of visco elastic polyurethane foam and the second layer is made of polyurethane foam. 10 z +o F G E 2. 50 3 2

Description

1 MULTI-LAYER PILLOW FIELD OF THE INVENTION The present invention relates to a pillow and particularly but not exclusively to a pillow that is used as a support for a head or other part of a body. 5 BACKGROUND TO THE INVENTION Cushions, or pillows, may be used as a support for a head or any other part of a body to provide comfort. Pillows are known to be made from polyurethane foam material, such as 'Denton'sTM SoftecTM polyurethane foam'. A pillow made of polyurethane foam 10 material provides support to its users as it can be moulded to conform to the contours of the head and neck. The resistance to resilient deformation of polyurethane foam is such that the shape of a moulded pillow is retained to a certain extent. Also, polyurethane foam pillows are hypoallergenic because the likelihood of accumulation of dust and other allergens in the pillow is less in 15 comparison with other filling materials. A pillow is also known to be made of visco-elastic polyurethane foam, also known as 'memory foam', such as 'Denton'sTM Impressions T M visco-elastic foam'. Memory foam includes a particular cell structure in the polyurethane cells that depresses as pressure is applied to its surface, allowing the material to mould to 20 contours of the pressure applying means more efficiently than regular polyurethane. Memory foam efficiently conforms to the contours of the pressure applying means as well as allowing the memory foam to regain its original shape once pressure is removed. Memory foam reacts and responds to the weight of a body by moulding itself to match the contours of the body. Therefore, support is 25 provided to a body in contact with the memory foam. A pillow made of memory foam, therefore, supports a user by moulding itself to match the contours of the user's neck and head, or other body part. However, there are particular disadvantages to a pillow made solely of memory foam. Firstly, because of its deforming and reforming characteristic (as 30 explained earlier) it lacks sufficient support to a user. Secondly, it lacks sufficient resistance to resilient deformation and therefore is unable to retain its original shape when pressure is applied.

2 SUMMARY OF THE INVENTION According to an aspect of the present invention there is provided a pillow including a first layer of foam material and a second layer of foam material, wherein resistance to resilient deformation of the first layer is less than that of the 5 second layer. Preferably, the hardness of the foam material of the first layer is less than that of the second layer. Preferably, the first layer is arranged on at least one side of the second layer and, further preferably, the first layer is bonded with the second layer. 10 Preferably, the first layer is made of visco-elastic polyurethane foam and the second layer is made of polyurethane foam. Preferably, at least one of the first or second layers varies in thickness. Optionally, the pillow includes a first layer of foam material on each side of the second layer and, further optionally, the second layer is encompassed by the first 15 layer. Preferably, the density of the first layer ranges from 20kg/m 3 to 100kg/M 3 , and the density of the second layer ranges from 19kg/M 3 to 60kg/m 3 . Preferably, the hardness of the first layer ranges from 20N to 80N and the hardness of the second layer ranges from 30N to 1OON. 20 A second aspect of the present invention provides a method of manufacturing a pillow, the method including: forming a first layer of foam having a first resistance to resilient deformation, forming a second layer of foam having a second resistance to resilient deformation greater than the first resistance, such that said layers are arranged contiguously to each other. 25 Preferably, the first layer and/or second layer of foam is cut or moulded into a desired shape. Preferably, the first layer is moulded onto the second layer. Advantageously, a pillow including multiple layers according to the present invention provides sufficient support, durability and shape retention whilst also providing a high level of comfort. 30 BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 illustrates an isometric sectional view of a pillow according to an aspect of the present invention.

3 Figure 2 illustrates a cross-sectional view of a pillow according to an aspect of the present invention. Figure 3 illustrates an exploded isometric sectional view of a pillow according to an aspect of the present invention. 5 DESCRIPTION OF PREFERRED EMBODIMENT Referring to figure 1, a pillow 10 includes a first layer 20 of foam material and a second layer 30 of foam material attached to each other. The first layer 20 is made of visco-elastic polyurethane foam, whereas the second layer 30 is made of polyurethane foam. Visco-elastic polyurethane foam is also known as 'memory 10 foam'. The first layer 20 has a, relatively, lower resistance to resilient deformation than the second layer 30. This variance in resistance to resilient deformation is attained by selecting the hardness of the material of the first layer to be relatively lower than the second layer. In this example, the first layer 20 is made of a visco-elastic foam material, 15 such as 'Denton'sTM Impressions T M visco-elastic foam', whereas the second layer 30 is made of polyurethane foam material, such as 'Denton'sTM SoftecTM polyurethane foam'. The density of the first layer 20 ranges from 20kg/M 3 to 100kg/m 3 , whereas the density of the second layer 30 ranges from 19kg/m 3 to 60kg/m 3 . The hardness of the first layer 20 ranges from 20N to 80N, whereas the 20 hardness of the second layer 30 ranges from 30N to 100N. The first layer and the second layer are manufactured to comply with Australian Standards AS 2281 & AS 2282 1993. Referring to figure 2, the pillow 10 is arranged such that the first layer 20 and the second layer 30 are attached to each other at a joining surface 40. The 25 first layer 20 includes a substantially flat surface 32, being a surface of the pillow 10. The second layer 20 includes a contoured surface 22, being another surface of the pillow 10. The contoured surface 22 provides a gentle massage to a user's neck with every sleep movement. Optionally, the contoured surface 22 can include dimpled contours, as depicted in the figures. Alternatively, the surface 22 30 can include a flat contour. Either the flat surface 32 or the contoured surface 22 may be used as a top surface of the pillow 10, being the surface on which a user can rest their neck and/or head.

4 Advantageously, a pillow 10 including multiple layers, as described, provides sufficient support, durability and shape retention, whilst also providing a high level of comfort. The second layer 30, being made of polyurethane foam, provides sufficient support, durability and shape retention. Whereas the first layer 5 being made of visco-elastic polyurethane foam provides comfort due to its efficient deforming and reforming characteristic. Referring to figure 3, a method of manufacturing a pillow 10 including: forming, such as by moulding or cutting into shape, a second layer 30 made of polyurethane foam, forming, such as by moulding or cutting, a first layer 20 made 10 of visco-elastic polyurethane foam on at least one side of the second layer 30 such that the first layer 20 and second layer 30 are arranged one on top of the other. Preferably, the first layer 20 and second layer 30 are fused or bonded to each other, but they also may simple be placed together and held in place by, for example, friction or by external means. Most preferably, the first layer 20 and 15 second layer 30 are "co-moulded". For example, the first layer 20 is moulded to a desired shape and then the second layer 30 is moulded on to the first layer 20, or alternatively these steps are performed in reverse. The moulding process fuses the first and second layers together. Furthermore, the thickness of the first layer 20 and/or the second layer 30 may be constant and/or varying across the length 20 or the breadth of the pillow 10. It is envisaged that the pillow 10 including multiple layers of foam material is of any shape that provides desired additional support or lack of support, for example neck support, head support or a wedged depression for anti-snoring. While not depicted, it is envisaged that the first layer 20 could be attached 25 to both sides of the second layer 30, such that the second layer 30 is between two first layers 20. In addition, the second layer 30 can be completely encompassed by the first layer 20. In another embodiment, a pillow 10 may include a plurality of the first layer 20 and a plurality of the second layer 30 attached to each other such that the 30 pillow includes alternating first and second layers. Further modifications and improvements may be made without departing from the scope of the present invention. For example, one or more gels can be included in the construction of a pillow.

Claims (5)

1. A pillow including a first layer of foam material and a second layer of foam material, wherein resistance to resilient deformation of the first layer is less than that of the second layer. 5

2. A pillow according to claim 1, wherein the first layer is made of visco elastic polyurethane foam and the second layer is made of polyurethane foam.

3. A pillow according to either one of claims 1 or 2, wherein the density of the first layer ranges from 20kg/M 3 to 100kg/M 3 , and the density of the second layer ranges from 19kg/M 3 to 60kg/m 3 and the hardness of the first layer ranges from 10 20N to 80N and the hardness of the second layer ranges from 30N to 100N.

4. A method of manufacturing a pillow, the method including: forming a first layer of foam having a first resistance to resilient deformation, forming a second layer of foam having a second resistance to resilient deformation greater than the first resistance, such that said layers are arranged contiguously to each other. 15

5. A method of manufacturing a pillow according to claim 4, wherein the first layer is moulded onto the second layer. CAMATIC PTY LTD WATERMARK PATENT & TRADE MARK ATTORNEYS UIP1340AU00