US20080209638A1

US20080209638A1 - Method for the manufacture of pillows and cushions with spacer fabric, spacer woven fabric and spacer knitted fabric

Info

Publication number: US20080209638A1
Application number: US11/940,014
Authority: US
Inventors: Fried-Jan Unger
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-05-15
Filing date: 2007-11-14
Publication date: 2008-09-04
Also published as: CA2645673A1; WO2006122614A1; DE502006009113D1; DE102006002098A1; KR20080007614A; EP1901636A1; ATE501657T1; EP1901636B1; JP2008540001A; CN101203161A

Abstract

A method for the manufacture of pillows and cushions with spacer fabric, spacer woven fabric and spacer knitted fabric. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims. Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.

Description

This application is a Continuation-In-Part application of International Patent Application No. PCT/EP2006/003317, filed on Apr. 11, 2006, which claims priority from Federal Republic of Germany Patent Application No. 10 2006 002 098.7, filed on Jan. 14, 2006, Federal Republic of Germany Patent Application No. 10 2005 034 797.5, filed on Jul. 21, 2005, and Federal Republic of Germany Patent Application No. 10 2005 023 197.7, filed on May 15, 2005. International Patent Application No. PCT/EP2006/003317 was pending as of the filing date of this application. The United States was an elected state in International Patent Application No. PCT/EP2006/003317.

BACKGROUND

1. Technical Field
This application relates to pillows and cushions and a method for the manufacture of pillows and cushions with spacer fabric, spacer woven fabric and spacer knitted fabric.
2. Background Information
Pillow and cushions normally have a pronounced convex curvature. The same is true for cushions. Likewise, pillows and cushions generally have the same elasticity response in the center and on the edge. That results from the pillow filling, which is distributed uniformly in the enclosed volume. The same is true for cushions.
In earlier times, feathers were generally used to fill pillows, while horsehair was used for higher-quality cushions. In modern times, plastic has been used instead. Plastic particles are used in the pillows, and foamed plastic in the form of a molding is used in cushions. The plastic is customarily polyurethane.
In the vicinity of the plastic foam, viscoelastic polyurethane foam represents a major development. This foam has a glass transition temperature that is in the range of room temperature, preferably slightly below room temperature. The result is a modified elasticity response when the pillow is heated slightly by the reclining person. This heating causes the reclining person to sink deeper into the pillow. The concept is based on the finding that the greatest heating takes place at points where the body has the greatest mass.
In one suggestion of the prior art, the pillows and cushions are formed from a spacer fabric. Such spacer fabrics have two fabric layers or plies that are at some distance from each other which are kept apart by filaments or threads or fibers. In this realization of the prior art, a plurality of plies are laid one on top of another and hot formed into a pillow or cushion.
It has been shown, however, that the plies are very severely compressed in the peripheral areas of the pillows and cushions. A severe compression is equivalent to a deterioration of the elasticity response. The pillows and cushions become harder on the edges. Pillows of this type are significantly less comfortable than the original pillows.

OBJECT OR OBJECTS

The object of at least one embodiment is to improve comfort, in that the plies of fabric or woven fabric or knitted fabric that lie one on top of another are stepped toward the edge of the pillows and cushions. The steps are created by smaller dimensions of the plies of fabric/woven fabric/knitted fabric. Optionally, uniform steps are provided. In other words, the width and length of the pieces of fabric/woven fabric/knitted fabric that lie on top of one another are each reduced by the same dimension. The same is true for the diameter of the plies for round pillows and cushions. The same is also true for rounded portions of the plies for round pillows and cushions.
The fabric/woven fabric/knitted fabric layers, for their part, can be single-ply or multi-ply. In the single-ply form, the cuttings are cut from a strip of material. In the multi-ply form, the strip of material is pleated one or more times so that the material forms a plurality of plies, one on top of the other.
On one hand, the folded material can be used unchanged for the pillow structure or the cushion structure. That optionally includes a cutting of the strip of material to size before it is pleated. In this form, the location of the pleat or the edge of the fold becomes the step of the pillow or cushion.
On the other hand, the folded material can be cut to size before it is used as a pillow or cushion. In that case, the pleating point or pleated edge can also become the step of the pillow or cushion. On account of the cutting to size, however, the pleat point or pleated edge can also be omitted.
Preferably the steps are adapted to the pillow profile or the cushion profile. The adaptation can optionally be achieved by laying the desired pillow profile or cushion profile in a 1:1 scale over the fabric/woven fabric/knitted fabric plies lying on top of one another. The dimensions of the different plies then result at the points of contact of the cover layers of the fabric/woven fabric/knitted fabric layers with the pillow profile or cushion profile. Optionally, the points of contact of the center lines of the fabric/woven fabric/knitted fabric can be used for the determination of the dimensions of the steps. Optionally, other lines between the cover layers can also be used for the determination of the dimensions of the steps.
After the dimensions have been determined, the fabric/woven fabric/knitted fabric plies are brought to the desired dimensions. When all the cuttings are the same size, that can be done by trimming. Preferably the cuttings are manufactured directly with the dimensions that are desired according to at least one embodiment. The amount of waste is thereby significantly reduced.
The trimmed or manufactured plies are then placed one on top of another.

SUMMARY

At least one embodiment teaches that on pillows in one variant the smallest cutting is positioned centrally and the larger cuttings are laid over it or under it so that the steps are formed progressively toward the outside edge of the pillow and the largest cuttings form the top and bottom cover surfaces. In other variants, another type of structure is provided.
At least one embodiment teaches that in the construction of a cushion, in one variant the smallest cutting is positioned on the bottom and the larger cuttings are laid on top of it so that the steps are formed progressively toward the outside edge of the cushion and the largest cutting forms the top cover surface.
If necessary, pillows and cushions with a plurality of raised areas and/or depressions can also be formed. As explained above, on a pillow or cushion with an elevated portion, cuttings are fabricated so that they correspond to the contour of the pillow or cushion. The correct dimensions for the individual plies of the cushion or pillow are thereby achieved.
Optionally, the plies that are laid one on top of another to form pillows or cushions can be processed without a cover or with a cover. The cover generally improves the appearance of the pillow or cushion.
Preferably the cover is also fabricated from a fabric/woven fabric or knitted fabric. Preferably the cover will have a low thickness, which is advantageous for the edging of the pillow or cushion. High thicknesses of the cover once again present problems in terms of forming the edge. Thick plies can be combined into an edge only under significant compression. The compression produces a hardening.
The different material plies in a pillow or cushion can be fixed in position simply by means of a loose cover. Optionally, there can be a connection between the individual plies in the pillow or cushion. The connection can be achieved by sewing, knitting or other types of fastenings, which also include needle bonding. Gluing or welding can also be used for the connection. Gluing points or adhesive strips or spot welds or strip welds that are at some distance from one another are thereby advantageous, so that flow of gases or liquids is not blocked.
Spacer fabrics are already widely used in motor vehicles. Reference is made by way of example to U.S. Pat. No. 6,629,724. Spacer fabrics are designed to ventilate the seats, so that any moisture that is produced by perspiration is evaporated and the vapor can be exhausted. The spaces can thereby be up to 15 mm. Spacer fabrics made of textiles are also known. In those cases, they are designed to ventilate waterproof plies. Reference is made by way of example to U.S. Pat. No. 6,716,778.
Spacer fabrics have been known for some time. U.S. Pat. No. 6,687,937, U.S. Pat. No. 6,687,935, U.S. Pat. No. 668,408, U.S. Pat. No. 6,499,157, U.S. Pat. No. 6,460,209, U.S. Pat. No. 6,447,874 and U.S. Pat. No. 6,115,861 describe such spacer materials.
Some of the spacer fabrics thereby form channels, through which the water vapor that is produced by the perspiration of the reclining person is extracted. Some spacer fabrics are also in the form of continuous plies.
One suggestion of the prior art relates to single-ply pillows. The spacer fabrics are thereby prefabricated in the final form, which can be achieved by a modification of the weaving or knitting process. Theoretically, that can be accomplished by a modification of the programming of the corresponding manufacturing machines. For large quantities of fabric that represents an optimum as well as an economical solution.
For smaller quantities of fabric, however, the modification of the program is extremely time-consuming and expensive. As a result of the cutting process according to at least one embodiment, less effort, time and expense are also required even on small series.
In a further example of spacer fabrics of the prior art, spacer knitted fabrics are deformed for the manufacture of mattresses by placing them in contact with a solid thermal conductor and by exposing them to a liquid or solid thermal transfer medium. Pillows can also be brought into the desired shape using this method. The ply construction according to at least one embodiment can also be processed by hot forming.
For the hot forming, heating is necessary. The required heating of the fabric, woven fabric or knitted fabric can be accomplished in a number of different ways. Preferably radiant heat and/or contact heat of a gas or liquid thermal transfer medium is used. The gas thermal transfer media that can advantageously be used also include steam. Steam has a very good thermal transfer action. With steam, temperatures of more than 100 degrees Celsius can be reached. In this case, steam is used which is under elevated pressure. At higher pressure, the steam can easily be heated well above 100 degrees Celsius.
Hot gases can also be used as the thermal transfer medium. Using hot gases, all temperatures can be reached that are necessary for the thermoforming of the plastics in question. This is also true for the thermoforming of polyester, which has a high melting point. In the form of polyethylene terephthalate (PET), the melting point is 250 degrees Celsius and above.
The gas or liquid thermal transfer medium can advantageously also permeate the fabric, knitted fabric or woven fabric thoroughly and ensure uniform contact everywhere. That is equivalent to uniform heating.
Optionally, a non-uniform heating can also take place, for example to leave unchanged the parts of the fabric that are required to undergo no or only a slight permanent deformation.
After the hot forming, it may be appropriate to first temper the parts to preserve the shape that has been achieved. The tempering can be done in a furnace, either an intermittently operated furnace or a continuously operating furnace. Continuously operating furnaces include, for example, tunnel furnaces in which there is a continuous throughput of the products. In the furnace the temperature can be maintained, reduced or controlled as appropriate. The length of a continuous furnace is determined on the basis of the desired duration of the heat treatment and the speed of transport through the furnace.
After the heat treatment, or if no heat treatment is required, after the deformation a rapid cooling is advantageous. The cooling can be accelerated by the use of a suitable coolant. The coolant can be in the form of a gas or liquid. Cold air can also be used as the coolant. The cooling air can gently permeate the knitted fabric, woven fabric or fabric. Ambient air can thereby be used, although it is also possible to use air at a lower temperature which is produced by appropriate cooling.
The knitted fabric, fabric or woven fabric can also be cooled with a liquid coolant, in particular with water, because the water easily flows out of the spacer knitted fabric, fabric or woven fabric, and because the knitted fabric/fabric/woven fabric dries very rapidly afterward. The drying can be promoted with drying air or drying gas. Suitable drying gases include, for example, the exhaust gas from a heating of the knitted fabric, fabric or woven fabric when gas is used as the thermal transfer medium. In other words, it can be advantageous to first heat the fabric, knitted fabric or woven fabric with a gas thermal transfer medium for a hot forming, cooling it with water after the deformation, and then drying it using the exhaust gas from the first heating process.
Optionally it is also advantageous to bring the exhaust gas to a lower temperature by mixing it with ambient air for the drying of the fabric, woven fabric or knitted fabric.
The heating can also advantageously be controlled very accurately. That is true both for the duration of the heating as well as for the profile of the heating process and also for the level of the external temperature to which the filaments, fibers etc. are exposed. As a result of the heating, the parts of the fabric, woven fabric and knitted fabric that are affected by a subsequent deformation, as well as the filaments, fibers etc. are transformed from the purely elastic range into a range in which subsequent deformation after appropriate cooling in the deformed state produces a permanent deformation. Preferably, a temperature on the parts to be deformed is set which is at least 5%, preferably at least 10% and even more preferably up to 20% below the temperature of the melting point.
Preferably the gas or liquid thermal transfer medium is introduced between the spaced outer plies. The thermal transfer media thereby release the heat to the filaments, fibers and threads that connect the outer plies to one another. The heating can take place before the deformation or during the deformation or after the deformation.
A heating before the deformation is advantageous because the admission of the gas or liquid thermal transfer medium is thereby simplified and because the resistance to the deformation is then very low.
An admission of the gas or liquid thermal transfer medium after the deformation is also advantageous, because the amount of energy required is then particularly low. As a result of the heating, filaments, fibers and threads are relaxed and these parts remain in the deformed state after the subsequent cooling. In other words, the fabric, knitted fabric and woven fabric retain the desired form after relaxation.
The gas or liquid thermal transfer media are advantageously admitted discontinuously. As a result, the heating process is extended and the heating process can be effectively controlled on the basis of the number of pulses of the thermal transfer medium admitted.
It is advantageous to apply the gas or liquid thermal transfer medium to the fabric, woven fabric and knitted fabric at an overpressure with respect to the ambient pressure. The overpressure is preferably at least 1 bar, even more preferably 2 bar and particularly preferably at least 3 bar. The desired pressure can be created with a pump. Heat-resistant pumps are available for the purpose. It is also possible, however, to first increase the pressure and then heat the gas or liquid thermal transfer medium so that the pump is not exposed to any significant heat load.
The thermal transfer medium can be applied to the fabric, woven fabric and knitted fabric at any desired point. The thermal transfer medium can be applied both to the separated plies as well as to the lateral surfaces between the separated plies. The gas or liquid thermal transfer medium then flows through the fabric or woven fabric or knitted fabric and exits again at a predetermined location. The flow can be controlled by means of the outlet aperture and/or the input aperture.
The flow can also be controlled by applying a vacuum to the outlet opening and/or to the inlet opening.
It has been found that, surprisingly, an application to the separated plies from outside does not lead to any damage to the plies, if it can be ensured as described above that the thermal transfer medium penetrates the fabric, knitted fabric and woven fabric without stopping and causing an uncontrolled heating.
Independently, the gas or liquid thermal transfer medium can be introduced immediately into the space between the fabric plies. For the admission of the thermal transfer medium between the separated outer plies, a later admission between the separated plies of the fabric or woven fabric or knitted fabric is possible. Nozzles that are located laterally can be used for this purpose. Advantageously a plurality of feed lines, in particular nozzles, can be provided. The use of perforated plates is also advantageous. The perforated plates contain a wall with a plurality of apertures in the wall. The openings can not have any nozzle effect or can exert a slight or severe nozzle action. The openings can be distributed uniformly. In that case a grid structure is created. The openings can also be distributed unevenly to make the thermal transfer medium available in a high concentration in the areas to be deformed where there is a high concentration of fibers and filaments.
Optionally, lances can also be used for the introduction of the thermal transfer medium. The lances can deliver the thermal transfer medium in a targeted manner to the points where it is needed. The lances can have a small diameter and a tip so that the lances do not damage the fabric, woven fabric or knitted fabric when they penetrate into the fabric, woven fabric or knitted fabric. The lances can be provided with one or more apertures. When the lances have a small diameter and appropriate length, they are in the form of spikes.
The spike-shaped lances can also optionally be pressed through the separated plies into the space between the separated plies. In that manner, all areas of the fabric, woven fabric and knitted fabric can be reached with short lances. It is also possible to insulate the lances on the outside to prevent a heating of the spaced fabric, woven fabric or knitted fabric at undesired places.
Satisfactory insulation can be achieved simply by surrounding the lances at a slight distance by a protective tube.
The fabric, woven fabric or knitted fabric can be deformed in a mold. The mold can be completely or partly closed. If the mold is partly open and the operation is conducted with a gas thermal transfer medium, any contamination of the environment can be prevented by an exhaust device.
Surprisingly, not only small deformations but also large deformations can be made on the fabric, woven fabric or knitted fabric. Large deformations can be promoted in particular by mechanically positioning and securing the separated plies. This is easier in the areas in which a pressure is applied than in other areas. At least one embodiment therefore teaches that a tension is applied to some or all of the separated plies that face the pressure area. The tension can be applied mechanically by gripping the outer plies. The gripping force in question is applied with hooks and/or tongs. The hooks or tongs an be arranged so that they can move in the mold, and can be extended from the mold if necessary to grab onto the fabric, woven fabric or knitted fabric. Movable hooks that can be opened to release the deformed fabric, woven fabric or knitted fabric are thereby advantageous.
It is particularly advantageous if the fabric, woven fabric or knitted fabric is gripped by suction. For that purpose, it is economical to create suction surfaces on the fabric, woven fabric or knitted fabric that is to be deformed. These suction surfaces can optionally be created by attaching a film to the fabric, woven fabric or knitted fabric. The film is preferably removed again after the deformation of the fabric, woven fabric or knitted fabric to once again ensure the permeability of the fabric, woven fabric or knitted fabric. The removal of the film can be omitted in cases where the permeability of the fabric, woven fabric or knitted fabric is not necessary in the specific application. For example, the film can be pulled off if it is necessary to remove the film. That can optionally be done by heating the film, which facilitates the removal. Films can also be used that react to microwaves on the contact surface with the fabric, woven fabric or knitted fabric, so that microwaves can be used to prevent damage to the fabric, woven fabric or knitted fabric.
Instead of a single suction film, different patches of film can also be attached. If the film patches are sufficiently small and are a sufficient distance from one another, the film patches will cause no significant adverse effects on the permeability of the fabric, woven fabric or knitted fabric. Consequently such film patches can always be left on the fabric, woven fabric or knitted fabric.
The film patches are elastic. The elasticity is not necessary in various applications. In that case, instead of film patches, relatively inflexible plates or pieces of plates can also be used. These parts can be assigned additional functions, e.g. they can be used for the fastening to the seat frame or the sofa frame. Currently, such frames are made almost exclusively of wood, for reasons of price but also on account of the ease of assembly, because the cushion can then be fastened to the frame by means of nails or staples. The fabric, woven fabric or knitted fabric according to at least one embodiment can be nailed or stapled to the construction with the parts described above. At least when staples are used, the fabric, woven fabric or knitted fabric can also be fastened without the cushions described above.
On the edge of the pillow or cushion a clean closing can be achieved by a concealed seam or by piping. With a concealed seam, the upper plies on the cushion are grasped, pushed inward and welded to one another. With the piping solution, a string or twine or a similar object is attached to the seam on the edge or is inserted into the edge.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments are illustrated in the accompanying drawings.

FIG. 1 shows spacer fabric for a pillow or cushion;

FIG. 2 shows another embodiment of the spacer fabric for a pillow or cushion;

FIG. 3 shows yet another embodiment of the spacer fabric for a pillow or cushion;

FIGS. 4 and 5 show an embodiment having a top fabric ply from which filaments extend;

FIG. 6 shows a variant of the embodiment illustrated in FIGS. 4 and 5 which has a honeycomb structure;

FIGS. 7 to 9 show examples for a molding of the fabric;

FIG. 10 shows a schematic drawing of the hot deformation according to at least one embodiment;

FIGS. 11 and 12 molding arrangements according to at least one possible embodiment;

FIG. 13 show film patches on a blank;

FIG. 14 shows a pillow profile according to at least one possible embodiment;

FIG. 15 shows a pillow profile according to at least one possible embodiment;

FIG. 16 shows layering of fabrics according to at least one possible embodiment;

FIG. 17 shows a pillow filling of spacer fabric with a trimming of the edge and a pillowcase;

FIG. 18 shows a pleated spacer fabric; and

FIG. 19 shows a pillow filling comprising spacer fabrics with plies one on top of another and a surrounding outer ply.

DESCRIPTION OF EMBODIMENT OR EMBODIMENTS

FIG. 1 shows the spacer fabric for a pillow or cushion lying upside down. The two plies 1 and 2 are connected with each other by filaments 3. Moreover, starting from the ply 2, additional filaments 4 are provided, the length of which is less than the distance between plies 1 and 2. When the pillow or cushion is compressed, the filaments 3 immediately absorb a load. The filaments 4, however, participate in the absorption of the load only if they are in contact with the ply 1.
The exemplary embodiment illustrated in FIG. 2 differs from the exemplary embodiment illustrated in FIG. 1 in that, instead of the filament 4, wound filaments 5 are provided. The wound filaments are better supported on the ply 1.
The exemplary embodiment illustrated in FIG. 3 differs from the exemplary embodiment illustrated in FIG. 1 in that, instead of the filaments 4, other filaments 6 are provided which are connected with an intermediate ply 7. The intermediate ply 7 achieves an even better support.
The exemplary embodiment illustrated in FIGS. 4 and 5 is also shown upside down in FIG. 4. The exemplary embodiment has a top fabric ply 10, from which filaments 13 and 14 extend. The filaments 13 hold fabric strips 11 and the filaments 14 hold fabric strips 12. The filaments 14 are shorter than the filaments 13, so that the distance of the strips 12 from the ply 10 is less than the distance of the strips 11 from the play 10. The strips 11, together with the filaments 13, form webs, as do the strips 12 with the filaments 14.
If the spacer fabric is compressed, first the webs with the strips 11 absorb the load until their distance from the ply 10 is equal to the distance between the strips 12 and the ply 10. Then the webs participate in the absorption of the load with the strips 12.
The exemplary embodiment illustrated in FIG. 6 is a variant of the system of webs illustrated in FIGS. 4 and 5. The webs 21 run so that a honeycomb structure is formed. Each honeycomb 20 encloses a tuft 22. In the exemplary embodiment, the webs 21 have the function of the webs 11, and the tufts the function of the webs 12. Accordingly, the webs 11 comprise on the illustrated end fabric strips which are connected by filaments with a facing fabric ply of the spacer fabric. The tufts 22 also have a fabric ply which is connected by filaments with the facing fabric ply of the spacer fabric.
FIG. 10 shows a schematic drawing of the hot deformation according to at least one embodiment. In this case the spacer fabric formed is placed in a heating station, where it is brought by means of hot air to an outside temperature which is 5 to 10% below the temperature of the melting point. The heating takes place in the manner described below at a hot gas temperature which is 10 to 30% above the temperature of the melting point. At this external temperature, there is a temperature gradient toward the center of the filaments or fibers of the fabric. In the center, the filaments and fibers are still at a temperature which is characteristic of the elastic range of the plastic.
In this state, the fabrics are delivered to a deformation station 46, where they undergo the desired deformation. The tools used can be optionally dies. The deformed fabrics are cooled while they are still in the die until a temperature, e.g. room temperature, has been reached externally on the filaments and fibers at which the fabric has permanently assumed the desired form.
FIGS. 7 to 9 show examples for a molding of the fabric.
FIG. 7 shows that the fabric 30 has indented articulation points 31. At these indentations, the illustrations show schematically a compression of the filaments, fibers etc. For the indentation of the articulation points, the blanks made of spacer fabric supplied with a uniform cross section are heated by hot air at the specified articulation points. Then a board or similar item is pressed with its narrow side into the heated area of the blank. After reaching the desired depth of penetration, the blank is treated with cool air until the filaments, fibers etc. have returned to room temperature. Then the board is removed.
FIG. 8 shows a seat cushion 35 with a convex curvature 36 on the upper side. The seat cushion is formed from a blank made of spacer fabric supplied with a uniform cross section. As shown in FIG. 7, the blank is heated with hot air. In contrast to the method illustrated in FIG. 7, however, the hot air is blown in between the spaced fabrics. The blank heated in this manner is compressed between a bottom die and a top die until the shape illustrated in FIG. 8 is achieved.
FIG. 9 shows a U-shaped cushion 40 for an armrest with legs 41, which is designed to surround the armrests of an armchair on both sides. The heating, molding and cooling are carried out as illustrated in the exemplary embodiment illustrated in FIG. 8.
In an additional exemplary embodiment (not shown), a pillow instead of the cushion is manufactured in the same manner as the cushion.
In an additional exemplary embodiment not shown, the blank is immediately placed in a mold and heated in the mold. The mold then has, at the appropriate locations, nozzle surfaces through which the heating agent and cooling agent can be introduced into the mold cavity. So that a sufficient heating medium and coolant feed can thereby also take place, openings are provided at a facing point, through which used heating medium and used coolant can be extracted. When steam is used, the openings are optionally closable, to be able to set a desired pressure level in the mold.
FIG. 11 shows a blank 52 made of a spacer knitted fabric with two separated plies 53 and 54 which are connected to each other by filaments 55. The blank 52 lies between two molding plates 50 and 51. On the side that faces the plate 50, the blank is provided with a film 57. The film is glued or otherwise attached to the fabric. In the plate 50 are suction openings with suction channels 56. By means of the suction openings and suction channels a vacuum is applied to the film 57, so that the film 57 adheres to the contour of the plate 50. Then the current of hot gas is made to flow through the blank 52 from the direction 58, so that the filaments 55 are softened. The hot gas exits the blank again at 59. After sufficient softening, a cooling takes place. The cooling in the illustrated example is a quenching process involving a coolant. The blank then remains in the new shape.
The exemplary embodiment illustrated in FIG. 12 differs from the exemplary embodiment illustrated in FIG. 11 in the different type of feed of the hot gas. As illustrated in FIG. 12, a plate 60 is provided with hot gas feeds 61 which in the exemplary embodiment project out of the plate 60 in the form of spikes and penetrate into the blank. With this type of hot gas feed, there is a targeted feed of hot gas in the vicinity of the deformation. Only a small amount of hot gas is necessary. The blank is subject to less deterioration from the hot gas.
The exemplary embodiment illustrated in FIG. 13 differs from the exemplary embodiment illustrated in FIGS. 11 and 12 in that, instead of a film 57 on the blank 52, a plurality of uniformly distributed film patches 65 are provided. The patches are attached so that during the upcoming deformation of the blank they will lie exactly on the suction openings. The patches 65 and the suction openings, as in the exemplary embodiments illustrated in FIGS. 11 and 12, effect a conformance to the contour of the plate 50.
FIG. 14 shows a pillow profile 80. The pillow profile 80 stands for a pillowcase. In the exemplary embodiment the pillow case is square. When the pillow is filled there is a convex curvature of the pillow. The pillow edges, even with the pillow filling, still form an approximate square. The pillow filling is represented by layered spacer knitted fabrics 70, 71, 72, 73, 74, 75. The spacer knitted fabrics lie on top of one another in FIG. 14. The spacer knitted fabrics 70 to 75 form different squares. The center, square spacer knitted fabrics 70 and 71 are equal and are the largest. Above and below them are the smaller, square spacer knitted fabrics 72 and 73. On the outside are even smaller, square spacer knitted fabrics 74 and 75. The dimensions of the knitted fabrics 72 to 75 in the exemplary embodiment have been defined on the basis of the pillow contour. The pillow contour is plotted on a scale of 1:1 and the knitted fabrics are placed with a narrow side on the contour. Where the outer edges of the knitted fabrics 72 to 75 are in contact, the edge length for these knitted fabrics 72 to 75 is determined. The knitted fabrics 70 and 71 are sized differently. Their dimension is determined on the basis of the associated peripheral length of the pillow. The peripheral length is significantly greater than the edge length of the filled pillow. Therefore the fabrics 70 and 71 project beyond the pillow contour in FIG. 14.
The different knitted fabrics form steps which are at a different distance from the center of the pillow and run progressively from the center of the pillow outward or vice-versa. The different knitted fabrics are shaped by hot forming into a pillow filling by placing them into a contour that corresponds to the contour 80. For that purpose, the different knitted fabrics are layered differently, as illustrated in FIG. 16. In this layering, the small pieces of knitted fabrics 74 and 75 are in the center. The larger pieces of fabric 72 and 73 lie on top and the pieces of fabric 70 and 71 outside.
The hot forming is conducted in a mold, the cavity of which has the contour 80 of the pillow in the manner described above with hot gas. The hot forming results in the deformation of the knitted fabric illustrated in FIG. 15. The knitted fabrics 70 and 71 abut each other in the center. The knitted fabrics 70 and 71 enclose the knitted fabrics between them as illustrated in FIG. 15.
FIG. 18 shows a pleated spacer fabric. The individual plies of the pleating are designated 91, 92 and 93. The pleating is designed so that the ply 92 is smaller than the ply 91 and the ply 93 is smaller than the ply 92. With pleats of this type, a pillow filling can be created which is significantly thinner on the edge than in the center.
FIG. 19 shows a pillow filling comprising of spacer fabrics with plies 95, 96 and 98 one on top of another and a surrounding outer ply 97. As a result of the ply structure and the arrangement of the outermost plies 98, the pillow filling has the shape of a neck support with lateral convexly curved portions and a central depression. The lateral convexly curved portions are up to 15 cm thick. The depression that results between the convexly curved portions has a thickness reduction of up to 50% in the illustrated exemplary embodiment.
FIG. 17 shows a pillow filling of spacer fabric 85 with a trimming 87 of the edge and a pillowcase 86 which is provided with a side zipper for the removal and insertion of the pillow filling. The pillowcase encloses the pillow filling, so that the pillow filling can also have a large external surface area.
In other exemplary embodiments the pillow filling is provided with a finished outside. This is achieved by providing large plies on the outside which enclose the remaining portion of the pillow filling in the manner of a pillowcase. In contrast to a pillowcase, however, these plies cannot be removed.
In other exemplary embodiments which are not illustrated, different levels of hardness are provided in the plies, various thicknesses and various densities of the spacer fabrics.
The plies can have a wide variety of different constructions, whereby the threads and surface structure of the individual plies are used in terms of their elasticity, diameter, length, position, number and placement to produce pillows that have specific deformation characteristics. For example, in a pillow the top ply can be made softer or harder at a specified location. Or lower layers can be provided with a shear strength that prevents what is called the “floating” of the pillow. Using spacer fabrics, the desired shear strength can be achieved, for example, by the crosswise orientation of the webs that connect the spaced plies. Optionally the spacer fabrics can also be made of a viscoelastic plastic that changes its elasticity in response to body heat.
Optionally, different materials can also be used in one or more plies. That can be done directly during the manufacture of the spacer fabrics or also subsequently. the following properties can be varied in each spacer fabric:

- Number of the threads
- Strength of the threads
- Length of the threads
- Angle of the threads to the spaced plies
- Composition of materials for the threads
- stretching ability, mesh width
  The number of plies can be 5 or up to 10 or even higher. Suitable materials include, for example, polyester, polyamide, polybutylene terephthalate, polyethylene terephthalate, PPT. The ply thickness can range from a few millimeters up to 50 mm and more. The ply thickness is preferably up to 35 mm, and even more preferably up to 25 mm.

Optionally the outer plies of the pillow filling are connected with the other plies of the pillow filling in the same manner as the plies with one another or in a different manner. Optionally the outer ply of the pillow filling also forms the pillow cover. That is possible because the pillow filling according to at least one embodiment is easily washable. From a hygienic point of view, that is highly preferable to replacing the used pillow cover with a washed pillow cover and continuing to use an unwashed pillow filling. This feature is important in particular when the pillows are used for sick or injured people.
Optionally, however, the pillow cover is removable to meet the expectations of conventional customers, who want to wash the pillow case more often than the pillow filling.
In the exemplary embodiments, the pillow in its initial shape has width and length dimensions that vary from 30 cm to 100 cm as desired and can be combined with one another. Preferably, the dimensions of different pillows are at least 10 cm different from one another. the thickness of the pillows is preferably 10 to 25 cm.
In the exemplary embodiments, the pillows are composed of fabric plies that can have a grammage of 100 grams per square meter up to 600 grams per square meter. A higher gram weight of the fabric plies per square meter (grammage) is not necessarily the same thing as a greater thickness of the fabric plies. On the other hand, a lower grammage is not necessarily the same thing as a lower thickness. The grammage is a function of the material used for the plies and the respective detail construction, for example the number of fibers, threads and filaments per unit of surface area. The result is that the above relationship (higher grammage=greater thickness, lower grammage=lower thickness) can exist. However, there can also be an increase in the grammage without a change in the thickness, likewise an increase of the grammage with a reduction in the thickness or a reduction of the grammage with a greater thickness.
The pillows can also be shaped as support pillows for specific parts of the body. In that case, one of the pillow surfaces on the body side should preferably be adapted to the part of the body to be supported. Such pillows include neck pillows, back pillows, hip pillows and knee pillows.
In support pillows, the stress-strain compression and the thickness of the pillows is preferably selected so that a person to be supported with a body weight of 50 kg does not completely squash the pillow on the body part in question. Even more preferably, the pillow must not be squashed by persons with a body weight of at least 100 kg. Squashing means that the user feels a solid substrate underneath the pillow.
Pillows can have spacer fabric plies according to at least one embodiment with even significantly higher grammages than pillows. The specific grammage can be up to 1500 grams per square meter and higher. Above that level, cushions can have a compression hardness that is a multiple of that of a pillow. The thickness of cushions is generally less than the thickness of pillows. On cushions, squashing is accordingly defined based on sitting. In other words, the cushion should support persons with a body weight of at least 50 kg, and preferably at least 100 kg, without the person feeling the solid substrate beneath the pillow.
Various of the features of the pillows and cushions described above can also be used even without the ply structure and/or hot forming.
One feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method for the manufacture of pillows and cushions of spacer fabrics, spacer woven fabrics or spacer knitted fabrics or similar material made of thermoplastic synthetic, whereby in each fabric, woven fabric or knitted fabric or similar material, two spaced plies are provided which are connected to each other by elements such as filaments, fibers or threads, characterized in that plies of the material are laid on top of one another in a stepped fashion and/or are heated and deformed to the extent that a permanent deformation is achieved in which all or part of the contour of a pillow or cushion results.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of plies, which form the steps by different dimensions in length and/or width and/or diameter and/or rounding.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of plies with steps, which viewed in the cross section of the pillow of cushion run progressively on the contour from the center outward.
Still another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of plies, of which the ply that has the largest dimensions lies in the middle and the smaller plies lie on it, or the ply that has the largest dimensions lies on the outside and forms all or part of the pillow contour or cushion contour, whereby the plies with smaller dimensions are surrounded by the largest ply.
A further feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of single-ply or multiple-ply layers and/or by the use of layers, all or some of which have a different elasticity.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the plies are pleated from strips of material that are previously or subsequently cut to size.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the threads, fibers and filaments differ from one another in number and/or in length and/or in diameter and/or in position and/or in their material properties from one another.
Still another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the heating for the hot forming of the material comprising fabric, woven fabric or knitted fabric or similar materials is done with a gas and/or liquid and/or solid thermal transfer medium.
A further feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the fabric, woven fabric or knitted fabric or similar material is permeated by the gas and/or liquid thermal transfer medium and/or is brought into contact with a solid object that acts as the thermal transfer medium, preferably in a mold.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that a heating of the plastic takes place to a temperature that is at last 5%, preferably at least 10% and particularly preferably up to 20% below the temperature of the melting point.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the temperature of the hot gas used as the thermal transfer medium is at least 10%, preferably at least 20%, and particularly preferably up to 30% higher than the temperature of the melting point.
One feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the gas and/or liquid thermal transfer medium is introduced between spacer fabrics, spacer woven fabrics or spacer knitted fabrics between the spaced layers and/or from outside.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of gas and/or liquid thermal transfer media at an overpressure of 1 bar, preferably of at least 2 bar and even more preferably of at least 3 bar with respect to the ambient pressure.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the used gas and/or liquid thermal transfer medium is evacuated with a vacuum.
Still another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by a tempering after the hot forming.
A further feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of a continuous furnace for the tempering.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by a cooling of the hot-formed and/or tempered plastic.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by treatment with a gas or liquid coolant.
Still another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the coolant flows through the fabric, knitted fabric or spacer fabric.
A further feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by a drying of the fabric, woven fabric or knitted fabric after cooling with a liquid coolant.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of evacuated gas from the previous heating with a gas thermal transfer medium for the drying.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of a mold which can be heated and/or cooled by a heating medium and/or coolant respectively.
One feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method as recited in one of the claims 1 to 22, characterized in that the heating medium and/or coolant is guided between the spaced plies by means of lances.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the lances are in the form of spikes and penetrate through the spaced plies into the area in between.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of plates and mold parts that are provided with spike-shaped lances for the introduction of heating medium and/or coolant.
Still another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of a mold with feed openings for gas and/or liquid thermal transfer media and drain openings for gas and/or liquid thermal transfer media.
A further feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of a mold with a plurality of openings located next to one another.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by a grid structure or structure of a plate with apertures for the feed or discharge.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of a mold with closable apertures.
Still another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the shaping of pillows from outside and/or from inside.
A further feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the shaping of pleats.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the molding and/or shaping of rounded edges and/or edges.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of fabric, woven fabric or knitted fabric as blanks which are provided at least on one side, on both sides or in places with a suction surface to which a vacuum is applied to bring the blank into contact with a shaping contour.
One feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the attachment of films as the suction surface.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of pasted-on films and by the location of suction apertures at the corresponding surfaces in the mold.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of film patches or film pieces which on account of their size and/or shape and/or distance have no adverse effect on the permeability of the fabric, woven fabric or knitted fabric, and by the placement of suction apertures on the corresponding surfaces in the mold.
Still another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of layers with a grammage of up to 600 grams per square meter for pillows and/or a grammage of up to 1500 grams per square meter for cushions.
A further feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of layers of fabric, woven fabric or knitted fabric with a thickness up to 50 mm, preferably up to 35 mm and even more preferably up too 25 mm.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of layers with different thicknesses and/or different compression hardness characteristics.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the pillows are not squashed flat when used as a support pillow for persons with a body weight of at least 50 kg, preferably a body weight of at least 100 kg, and that the cushions are not squashed flat when sat on by persons with a body weight of at least 50 kg, preferably a body weight of at least 100 kg.
Still another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized by the use of a pillow filling and a pillowcase, whereby the pillow filling has, on the outside, plies with a large surface area which enclose the rest of the pillow filling in the manner of a pillowcase.
A further feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the plies of a pillow or cushion are connected with one another by sewing and/or needle bonding and/or welding and/or adhesive.
Another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that pillows are used, whereby the outside layer of the pillow filling also forms the pillow cover.
Yet another feature or aspect of an embodiment is believed at the time of the filing of this patent application to possibly reside broadly in a method, characterized in that the pillow filling can be washed simultaneously with the pillow cover.
The components disclosed in the various publications, disclosed or incorporated by reference herein, may possibly be used in possible embodiments of the present invention, as well as equivalents thereof.
The purpose of the statements about the technical field is generally to enable the Patent and Trademark Office and the public to determine quickly, from a cursory inspection, the nature of this patent application. The description of the technical field is believed, at the time of the filing of this patent application, to adequately describe the technical field of this patent application. However, the description of the technical field may not be completely applicable to the claims as originally filed in this patent application, as amended during prosecution of this patent application, and as ultimately allowed in any patent issuing from this patent application. Therefore, any statements made relating to the technical field are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.
The appended drawings in their entirety, including all dimensions, proportions and/or shapes in at least one embodiment of the invention, are accurate and are hereby included by reference into this specification.
The background information is believed, at the time of the filing of this patent application, to adequately provide background information for this patent application. However, the background information may not be completely applicable to the claims as originally filed in this patent application, as amended during prosecution of this patent application, and as ultimately allowed in any patent issuing from this patent application. Therefore, any statements made relating to the background information are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.
All, or substantially all, of the components and methods of the various embodiments may be used with at least one embodiment or all of the embodiments, if more than one embodiment is described herein.
The purpose of the statements about the object or objects is generally to enable the Patent and Trademark Office and the public to determine quickly, from a cursory inspection, the nature of this patent application. The description of the object or objects is believed, at the time of the filing of this patent application, to adequately describe the object or objects of this patent application. However, the description of the object or objects may not be completely applicable to the claims as originally filed in this patent application, as amended during prosecution of this patent application, and as ultimately allowed in any patent issuing from this patent application. Therefore, any statements made relating to the object or objects are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.
All of the patents, patent applications and publications recited herein, and in the Declaration attached hereto, are hereby incorporated by reference as if set forth in their entirety herein.
The summary is believed, at the time of the filing of this patent application, to adequately summarize this patent application. However, portions or all of the information contained in the summary may not be completely applicable to the claims as originally filed in this patent application, as amended during prosecution of this patent application, and as ultimately allowed in any patent issuing from this patent application. Therefore, any statements made relating to the summary are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.
It will be understood that the examples of patents, published patent applications, and other documents which are included in this application and which are referred to in paragraphs which state “Some examples of . . . which may possibly be used in at least one possible embodiment of the present application . . . ” may possibly not be used or useable in any one or more embodiments of the application.
The sentence immediately above relates to patents, published patent applications and other documents either incorporated by reference or not incorporated by reference.
All of the patents, patent applications or patent publications, which were cited in the International Search Report dated Jul. 28, 2006, and/or cited elsewhere are hereby incorporated by reference as if set forth in their entirety herein as follows: U.S. Pat. No. 4,896,388; DE 27 50 511; DE 68 01 884; DE 197 36 951; EP 0 697 478; DE 202 01 919.
The corresponding foreign and international patent publication applications, namely, Federal Republic of Germany Patent Application No. 10 2006 002 098.7, filed on Jan. 14, 2006, having inventor Fried-Jan UNGER, and DE-OS 10 2006 002 098.7 and DE-PS 10 2006 002 098.7; Federal Republic of Germany Patent Application No. 10 2005 034 797.5, filed on Jul. 21, 2005, having inventor Fried-Jan UNGER, and DE-OS 10 2005 034 797.5 and DE-PS 10 2005 034 797.5; Federal Republic of Germany Patent Application No. 10 2005 023 197.7, filed on May 15, 2005, having inventor Fried-Jan UNGER, and DE-OS 10 2005 023 197.7 and DE-PS 10 2005 023 197.7, and International Application No. PCT/EP2006/003317, filed on Apr. 11, 2006, having WIPO Publication No. WO2006/122614 and inventor Fried-Jan UNGER, are hereby incorporated by reference as if set forth in their entirety herein for the purpose of correcting and explaining any possible misinterpretations of the English translation thereof. In addition, the published equivalents of the above corresponding foreign and international patent publication applications, and other equivalents or corresponding applications, if any, in corresponding cases in the Federal Republic of Germany and elsewhere, and the references and documents cited in any of the documents cited herein, such as the patents, patent applications and publications, are hereby incorporated by reference as if set forth in their entirety herein.
All of the references and documents, cited in any of the documents cited herein, are hereby incorporated by reference as if set forth in their entirety herein. All of the documents cited herein, referred to in the immediately preceding sentence, include all of the patents, patent applications and publications cited anywhere in the present application.
The description of the embodiment or embodiments is believed, at the time of the filing of this patent application, to adequately describe the embodiment or embodiments of this patent application. However, portions of the description of the embodiment or embodiments may not be completely applicable to the claims as originally filed in this patent application, as amended during prosecution of this patent application, and as ultimately allowed in any patent issuing from this patent application. Therefore, any statements made relating to the embodiment or embodiments are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.
The details in the patents, patent applications and publications may be considered to be incorporable, at applicant's option, into the claims during prosecution as further limitations in the claims to patentably distinguish any amended claims from any applied prior art.
The purpose of the title of this patent application is generally to enable the Patent and Trademark Office and the public to determine quickly, from a cursory inspection, the nature of this patent application. The title is believed, at the time of the filing of this patent application, to adequately reflect the general nature of this patent application. However, the title may not be completely applicable to the technical field, the object or objects, the summary, the description of the embodiment or embodiments, and the claims as originally filed in this patent application, as amended during prosecution of this patent application, and as ultimately allowed in any patent issuing from this patent application. Therefore, the title is not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.
The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b):

- A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims.
  Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.

The embodiments of the invention described herein above in the context of the preferred embodiments are not to be taken as limiting the embodiments of the invention to all of the provided details thereof, since modifications and variations thereof may be made without departing from the spirit and scope of the embodiments of the invention.

Claims

1. Method for the manufacture of pillows and cushions of spacer fabrics, spacer woven fabrics or spacer knitted fabrics or similar material made of thermoplastic synthetic, whereby in each fabric, woven fabric or knitted fabric or similar material, two spaced plies are provided which are connected to each other by elements such as filaments, fibers or threads, wherein plies of the material are laid on top of one another in a stepped fashion and/or are heated and deformed to the extent that a permanent deformation is achieved in which all or part of the contour of a pillow or cushion results.

2. Method according to claim 1, including the use of plies, which form the steps by different dimensions in length and/or width and/or diameter and/or rounding.

3. Method according to claim 2, including the use of plies with steps, which viewed in the cross section of the pillow of cushion run progressively on the contour from the center outward.

4. Method according to claim 3, including at least one of the following:

a) the ply that has the largest dimensions lies in the middle and the smaller plies lie on it; and

b) the ply that has the largest dimensions lies on the outside and forms all or part of the pillow contour or cushion contour, whereby the plies with smaller dimensions are surrounded by the largest ply.

5. Method according to claim 4, including the use of single-ply or multiple-ply layers and/or by the use of layers, all or some of which have a different elasticity.

6. Method according to claim 5, wherein at least one of:

the plies are pleated from strips of material that are previously or subsequently cut to size; and

the threads, fibers and filaments differ from one another in number and/or in length and/or in diameter and/or in position and/or in their material properties from one another.

7. (canceled)

8. Method according to claim 6, wherein the heating for the hot forming of the material comprising fabric, woven fabric or knitted fabric or similar materials is done with a gas and/or liquid and/or solid thermal transfer medium.

9. Method according to claim 8, wherein the fabric, woven fabric or knitted fabric or similar material is permeated by the gas and/or liquid thermal transfer medium and/or is brought into contact with a solid object that acts as the thermal transfer medium, preferably in a mold.

10. Method according to claim 9, wherein a heating of the plastic takes place to a temperature that is at last 5%, preferably at least 10% and particularly preferably up to 20% below the temperature of the melting point.

11. Method according to claim 10, wherein the temperature of the hot gas used as the thermal transfer medium is at least 10%, preferably at least 20%, and particularly preferably up to 30% higher than the temperature of the melting point.

12. Method according to claim 11, wherein the gas and/or liquid thermal transfer medium is introduced between spacer fabrics, spacer woven fabrics or spacer knitted fabrics between the spaced layers and/or from outside.

13. Method according to claim 12, including the use of gas and/or liquid thermal transfer media at an overpressure of 1 bar, preferably of at least 2 bar and even more preferably of at least 3 bar with respect to the ambient pressure.

14. Method according to claim 13, wherein the used gas and/or liquid thermal transfer medium is evacuated with a vacuum.

15. Method according to claim 14, including a tempering after the hot forming.

16. Method according to claim 15, including the use of a continuous furnace for the tempering.

17. Method according to claim 16, including a cooling of the hot-formed and/or tempered plastic.

18. Method according to claim 17, including treatment with a gas or liquid coolant.

19. Method according to claim 18, wherein the coolant flows through the fabric, knitted fabric or spacer fabric.

20-44. (canceled)

45. Method according to claim 19, including at least one of (A) to (Y), wherein (A) to (Y) comprise the following:

(A) a drying of the fabric, woven fabric or knitted fabric after cooling with a liquid coolant;

(B) the use of evacuated gas from the previous heating with a gas thermal transfer medium for the drying;

(C) the use of a mold which can be heated and/or cooled by a heating medium and/or coolant respectively;

(D) the heating medium and/or coolant is guided between the spaced plies by means of lances;

(E) the lances are in the form of spikes and penetrate through the spaced plies into the area in between;

(F) the use of plates and mold parts that are provided with spike-shaped lances for the introduction of heating medium and/or coolant;

(F) the use of a mold with feed openings for gas and/or liquid thermal transfer media and drain openings for gas and/or liquid thermal transfer media;

(H) the use of a mold with a plurality of openings located next to one another;

(I) a grid structure or structure of a plate with apertures for the feed or discharge;

(J) the use of a mold with closable apertures;

(K) the shaping of pillows from outside and/or from inside;

(L) the shaping of pleats;

(M) the molding and/or shaping of rounded edges and/or edges;

(N) the use of fabric, woven fabric or knitted fabric as blanks which are provided at least on one side, on both sides or in places with a suction surface to which a vacuum is applied to bring the blank into contact with a shaping contour;

(O) the attachment of films as the suction surface;

(P) the use of pasted-on films and by the location of suction apertures at the corresponding surfaces in the mold;

(Q) the use of film patches or film pieces which on account of their size and/or shape and/or distance have no adverse effect on the permeability of the fabric, woven fabric or knitted fabric, and by the placement of suction apertures on the corresponding surfaces in the mold;

(R) the use of layers with a grammage of up to 600 grams per square meter for pillows and/or a grammage of up to 1500 grams per square meter for cushions;

(S) the use of layers of fabric, woven fabric or knitted fabric with a thickness up to 50 mm, preferably up to 35 mm and even more preferably up too 25 mm;

(T) the use of layers with different thicknesses and/or different compression hardness characteristics;

(U) the pillows are not squashed flat when used as a support pillow for persons with a body weight of at least 50 kg, preferably a body weight of at least 100 kg, and that the cushions are not squashed flat when sat on by persons with a body weight of at least 50 kg, preferably a body weight of at least 100 kg;

(V) the use of a pillow filling and a pillowcase, whereby the pillow filling has, on the outside, plies with a large surface area which enclose the rest of the pillow filling in the manner of a pillowcase;

(W) the plies of a pillow or cushion are connected with one another by sewing and/or needle bonding and/or welding and/or adhesive;

(X) pillows are used, whereby the outside layer of the pillow filling also forms the pillow cover; and

(Y) the pillow filling can be washed simultaneously with the pillow cover.

46. Method according to claim 19, including all of (A) to (Y), wherein (A) to (Y) comprise the following: