In some embodiments, the inventive subject matter relates to a fiber construct suitable for use as a fill material for insulation or padding, comprising: a primary fiber structure comprising a predetermined length of fiber; a secondary fiber structure, the secondary fiber structure comprising a plurality of relatively short loops spaced along a length of the primary fiber. In some embodiments, the inventive subject matter relates to insulative fiber structures that mimic the structure and scale of natural down and thereby provide similar properties.

A pillow includes a first pillow cushion consisting essentially of a gelatinous elastomer that is sized and configured to support a head and neck of a person using the pillow cushion and a second pillow cushion coupled thereto. The pillow cushion has deformable wall members located and configured to define voids therebetween such that the deformable wall members may be displaced into adjacent voids upon deformation of the deformable wall members. The deformable wall members are configured to buckle when a pressure applied to a cushioning surface of the first pillow cushion, in a direction perpendicular to a first major surface, exceeds a threshold pressure level. A pillow cover covers the first pillow cushion and the second pillow cushion. A method of fabricating a pillow includes enclosing such first and second pillow cushions in a pillow cover.

A pillow includes a first pillow cushion consisting essentially of a gelatinous elastomer that is sized and configured to support a head and neck of a person using the pillow cushion and a second pillow cushion coupled thereto. The pillow cushion has deformable wall members located and configured to define voids therebetween such that the deformable wall members may be displaced into adjacent voids upon deformation of the deformable wall members. The deformable wall members are configured to buckle when a pressure applied to a cushioning surface of the first pillow cushion, in a direction perpendicular to a first major surface, exceeds a threshold pressure level. A pillow cover covers the first pillow cushion and the second pillow cushion. A method of fabricating a pillow includes enclosing such first and second pillow cushions in a pillow cover.

A filling for frameless furniture is provided that vastly increases the positional stability of the filling by being comprised of high aspect ratio particles that contact and interlock with many more nearby particles than can be accomplished by substantially mono-dimensional prior art particles. The invention further features a process and apparatus for the manufacture of the high aspect ratio particles that provide substantial advantages over the prior art. Included in the advantages are uniformity of support, minimizing voids without support, and lack of resiliency from clustering, clumping and dense packing, all of which result from size disparity of prior art filling that is made rather crudely by foam shredding machines. The invention further includes an apparatus for fabricating the filler.

The present disclosure provides an article and methods of its manufacture. The article may include a material configured to form an enclosure. The article may further include horsehair disposed within the enclosure. The article may also include a number of beneficial objects dispersed in the horsehair.

The present disclosure provides an article and methods of its manufacture. The article may include a material configured to form an enclosure. The article may further include horsehair disposed within the enclosure. The article may also include a number of beneficial objects dispersed in the horsehair.

A comfort item (200) has a first volume (202) delimited by an outer boundary, where the first volume (202) includes several foam pieces (100). The foam pieces have a body part (101); several foam arms (102) having a first end and a second end, where the first end is attached to the body part (101), and the second end protrudes away from the body part (101); and several contour recesses (103) between the foam arms (102), wherein the width of the foam arms is greater that the length of the foam arms. Several foam filling elements for such a comfort item are also described. As a result, a comfort item is obtained with a filling providing good filling properties and adding air to the comfort item.

A fiber-filled material composed of batting and ticking made of synthetic fibers, wherein the batting made of synthetic fibers includes a bulky yarn in which (1) a fineness ratio of a sheath yarn to a core yarn (sheath/core) is 0.5-2.0, (2) entanglement points of the core yarn with the sheath yarn in a fiber axis direction are present at 1-30/mm, and (3) a radius of curvature of the sheath yarn forming loops is 2.0-30.0 mm.

A fiber-filled material composed of batting and ticking made of synthetic fibers, wherein the batting made of synthetic fibers includes a bulky yarn in which (1) a fineness ratio of a sheath yarn to a core yarn (sheath/core) is 0.5-2.0, (2) entanglement points of the core yarn with the sheath yarn in a fiber axis direction are present at 1-30/mm, and (3) a radius of curvature of the sheath yarn forming loops is 2.0-30.0 mm.

The disclosure provides blowable insulation or filling material, and apparatus and methods for making same. The blowable insulation or filling material includes a plurality of discrete elongate floccules each formed of a plurality of fibers. The floccules include a relatively open enlarged medial portion. The floccules also include relatively condensed twisted tail portions extending from opposing ends of the medial portion. The floccules can be utilized by existing garment fill blowing machines without clogging thereof, and include a superior soft hand feel, thermal resistance and launderability. The floccules may be formed by forcing staple fibers through apertures of a rotating hollow drum to partially form the floccule structure within the drum. The partially formed floccules may be retained within the rotating drum for a dwell time to finalize the floccule structure.