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.

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 including a pillow-liner having an upper liner, a lower liner, and at least one middle liner. The upper liner, lower liner, and at least one middle liner are sealed together adjacent peripheral edges thereof to define an open end and at least two internal compartments. The at least one middle liner is generally parallel with the upper and lower liners. The pillow also includes cushioning materials for filling the at least two internal compartments. Each of the at least two internal compartments are filled with different cushioning materials such that the internal compartments have different density and firmness when filled with the respective cushioning materials. At least one of the at least two internal compartments is filled with a plurality of loose pieces of a shredded foam material, and at least one of the at least two internal compartments is filled with a one-piece molded foam material.

A method of pillow customization includes analyzing shapes associated with people through the use of sensors to create analytical data; receiving photos from a subject user through a first computing device and a server; determining a firmness of a mattress of the subject user based on the photos; determining body measurements of the subject based on the photos through one or more algorithms and a second computing device; providing the subject user with a pillow diagram, the pillow diagram having one or more zones, each of the one or more zones being customizable in firmness; receiving one or more subject user inputted selections through the first computing device; and designing a pillow based on the firmness of the mattress, the body measurements, and the one or more subject user inputted characteristics, the pillow being customized to the subject user.

An adjustable pillow includes an inner cover defining a pocket and removable stuffing within the pocket. A related method of manufacture includes forming the inner cover having a pocket from a sheet and placing stuffing within the pocket.

The present invention relates to non-sewn down bedding including a partition wall provided with a unique non-sewn partition wall member and an edge portion finished to have a special structure, thereby greatly simplifying the bedding manufacturing process, reducing costs and improving productivity while inhibiting down from escaping through the edge portion. Therefore, the quality of a finished product may be very high. A non-sewn bedding item according to the present invention includes a bedding outer cover having an upper fabric and a lower fabric, the upper fabric and the lower fabric defining an inner space, a partition wall member configured to divide the inner space into a plurality of compartment spaces such that each of the compartment spaces is filled with down, the partition wall allowing air to flow between the compartment spaces and restricting movement of the down between the compartment spaces, and an edge finish portion formed at an edge of the bedding item to inhibit the down from escaping from each of the compartment spaces.

A filling system includes a first component having a fiber opener configured to open fibers. A second component is connected to the first component. The second component includes a fiber blower configured to blow opened fibers. A third component is connected to the second component. The third component includes a weighing system configured to weigh the opened fibers. A fourth component is connected to the third component. The fourth component includes a filler configured to dispose the opened fibers into a shell. Methods of use are disclosed.

In a first aspect there is disclosed a pillow (10) which including an envelope (12) enclosing pillow stuffing (14), wherein the pillow stuffing includes a plurality of elongate bodies (40). In one embodiment the elongate bodies are produced from memory foam.

A filling element (10) for filling fabric products comprising a longitudinally extending body portion (12) fabricated from a memory foam, wherein the cross-sectional shape of the filling element (10) is generally in the form of a regular hexagon. However, other cross-sectional profiles for the filling element (10) may be utilised such as stars, squares, rectangles, crosses, triangles, other polyhedrons (regular or irregular), squiggles or waves.

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.