SYSTEM AND METHOD FOR MANUFACTURING A CUSTOMIZED ORTHOPEDIC SUPPORT PILLOW
20250338985 ยท 2025-11-06
Inventors
Cpc classification
International classification
Abstract
The technology discloses an orthopedic support pillow tailored to a user's anatomy. The method involves capturing multiple images of a user's head and neck from different angles using a camera system. A three-dimensional (3D) digital twin of the user's head and neck is then generated using computer-aided design (CAD). The manufacturing process includes providing a wedge of pillow material, which is then molded based on the generated 3D digital twin and results in a depression on the wedge's surface. The dimensions of the wedge correspond to that of the 3D digital twin.
Claims
1. A method for manufacturing an orthopedic support pillow, the method comprising: receiving multiple images of a user's head and the user's neck generated by a camera system, wherein the multiple images depict contours of the user's head and the user's neck, and wherein each of the multiple images is taken at a different angle to each other of the multiple images; performing computer-aided design (CAD) to generate a three-dimensional (3D) digital twin of the user's head and the user's neck, wherein a depth of the 3D digital twin corresponds to a depth of a depression in the orthopedic support pillow shaped and sized to support the user's head and the user's neck, wherein a width of the 3D digital twin corresponds to a lateral dimension of the user's head, and wherein a length of the 3D digital twin corresponds to a longitudinal dimension of the user's head, and wherein the generated 3D digital twin is configured to be used in molding a resilient material to manufacture the orthopedic support pillow; providing a wedge of the resilient material, wherein the wedge of the resilient material comprises a base, a top, and an inclined surface connecting the base and the top, wherein the base includes a first side, a second side, a third side, and a fourth side, wherein a first distance between the base and the top of the wedge forms a pillow height of the wedge of the resilient material, wherein a second distance between the first side and the third side of the base forms a pillow width of the wedge of the resilient material, and wherein a third distance between the second side and the fourth side of the base forms a pillow length of the wedge of the resilient material; and molding, based on the generated 3D digital twin, a depression into a surface of the wedge of the resilient material, wherein an angle formed by the inclined surface and the base is selected based on the 3D digital twin so that the pillow height is greater than the depth of the 3D digital twin, wherein the pillow height is greater than the width of the 3D digital twin, wherein the pillow length is greater than the length of the 3D digital twin; wherein the depression is positioned between the base and the top of the wedge for supporting the user's head and the user's neck, and wherein dimensions of the depression correspond to the dimensions of the 3D digital twin.
2. The method of claim 1, wherein the resilient material comprises soy-based foam.
3. The method of claim 1, wherein generating the 3D digital twin uses mesh reconstruction techniques to refine the 3D digital twin, wherein the mesh reconstruction techniques consider for surface irregularities.
4. The method of claim 1, wherein generating the 3D digital twin uses selective laser sintering and/or fused deposition modeling.
5. The method of claim 1, wherein the resilient material comprises memory foam, latex, polyurethane foam, gel-infused foam, bamboo foam, natural fibers, high-resilience foam, and/or natural latex foam.
6. The method of claim 1, wherein the wedge of the pillow material comprises an additional layer, wherein the additional layer comprises a different pillow material than the wedge.
7. The method of claim 1, wherein the wedge of the resilient material has a U-shape or circular shape.
8. A system for manufacturing an orthopedic support pillow, the system comprising: a camera system for capturing multiple images of a user's head and the user's neck, wherein the multiple images depict contours of the user's head and the user's neck, and wherein each of the multiple images is taken at a different angle to each other of the multiple images; a processing module for determining dimensions of a three-dimensional (3D) digital twin of the user's head and the user's neck; wherein a depth of the 3D digital twin corresponds to a depth of a depression in the orthopedic support pillow shaped and sized to support the user's head and the user's neck; a generation module for performing computer-aided design (CAD) to generate the 3D digital twin of the user's head and the user's neck, wherein the generated 3D digital twin is configured to be used in molding a pillow material to manufacture the orthopedic support pillow, a wedge of the pillow material, wherein the wedge of the pillow material comprises a base, a top, and an inclined surface connecting the base and the top; and a molding module for molding, based on the generated 3D digital twin, a depression into a surface of the wedge of the pillow material, wherein an angle formed by the inclined surface of the wedge is selected based on the 3D digital twin so that a pillow height of the wedge is greater than the depth of the 3D digital twin, and wherein dimensions of the depression correspond to the dimensions of the 3D digital twin.
9. The system of claim 8, comprising a user interface configured to receive user input associated with the 3D digital twin.
10. The system of claim 8, wherein the wedge of the pillow material is foldable and/or collapsible.
11. The system of claim 8, wherein the wedge of the pillow material includes an adjustable air chamber configured to be inflated and/or deflated to adjust dimensions of the wedge of the pillow material.
12. The system of claim 8, wherein the wedge of the pillow material comprises an additional layer, wherein the additional layer comprises a different pillow material than the wedge.
13. The system of claim 8, wherein said molding uses a vacuum-forming process, a rotational molding process, water-assisted injection molding process, extrusion molding process, and/or gas-assisted molding process.
14. The system of claim 8, comprising an integrated lumbar roll on one end of the wedge of the pillow material.
15. An orthopedic support pillow, comprising: a wedge of a pillow material; a depression molded into a surface of the wedge of the pillow material based on a 3D digital twin; wherein the 3D digital twin is generated by: capturing multiple images of a user's head and the user's neck with a camera system, wherein the multiple images depict contours of the user's head and the user's neck, and wherein each of the multiple images is taken at a different angle to each other of the multiple images; performing computer-aided design (CAD) to generate a three-dimensional (3D) digital twin of the user's head and the user's neck, wherein the generated 3D digital twin is configured to be used in molding the pillow material to manufacture the orthopedic support pillow, wherein dimensions of the 3D digital twin are based on the multiple images of the user's head and the user's neck, wherein an angle formed by the wedge is selected based on the 3D digital twin so that a height of the wedge is greater than a depression depth of the 3D digital twin, and wherein dimensions of the depression correspond to the dimensions of the 3D digital twin; and an outer cover, wherein the outer cover is comprised of a different material than the pillow material, wherein the outer cover is configured to envelop the wedge of the pillow material.
16. The orthopedic support pillow of claim 15, wherein the outer cover comprises a moisture-wicking material, preventing accumulation of moisture.
17. The orthopedic support pillow of claim 16, wherein the outer cover comprises a heating element to raise a temperature of the outer cover.
18. The orthopedic support pillow of claim 15, comprising an attachment system that is configured to attach cooling elements, heating elements, and/or massaging elements to the wedge of the pillow material.
19. The orthopedic support pillow of claim 15, the wedge of the pillow material comprises of individual sections to be replaced and/or adjusted independently for targeted support for the user's head and/or the user's neck.
20. The orthopedic support pillow of claim 15, wherein the wedge of the pillow material incorporates variable firmness zones, wherein the variable firmness zones include firm regions and soft regions for predetermined areas of the user's head and/or the user's neck.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Detailed descriptions of implementations of the present technology will be described and explained through the use of the accompanying drawings.
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[0019] The technologies described herein will become more apparent to those skilled in the art from studying the Detailed Description in conjunction with the drawings. Implementations describing aspects of the invention are illustrated by way of example, and the same references can indicate similar elements. While the drawings depict various implementations for the purpose of illustration, those skilled in the art will recognize that alternative implementations can be employed without departing from the principles of the present technologies. Accordingly, while specific implementations are shown in the drawings, the technology is amenable to various modifications.
DETAILED DESCRIPTION
[0020] Sleep quality and overall well-being are intricately linked, with pillows playing a pivotal role in ensuring a restful and comfortable night's sleep. Beyond their traditional association with nighttime rest, pillows play a crucial role in enhancing relaxation during leisure activities such as reading, watching TV, or engaging in various forms of recreation. Moreover, pillows have become indispensable in the realm of healthcare, offering therapeutic benefits by providing targeted support to individuals recovering from injuries or managing specific medical conditions.
[0021] Pillow manufacturing has predominantly featured conventional designs characterized by standardized shapes and fixed support structures. The production process relies on standardized designs, resulting in the same standardized pillows catered to a broad audience. Pillows are typically crafted through a systematic manufacturing process that involves the use of common materials and established sizing and patterns. The process typically begins with the selection of pillow fillings, which can include feathers, down, synthetic fibers, or other readily available materials. The chosen filling is then cut or shaped into uniform sizes to fit within standard pillowcases (e.g., twin, queen, king). Encasements or covers are often made from conventional fabrics such as cotton or polyester, with standardized dimensions to accommodate the filling. The filling is inserted into the cover, and the pillow is sealed through stitching or closures to maintain the shape.
[0022] However, such pillows typically offer limited customization options, which results in suboptimal support for users with distinct head and neck dimensions or specific orthopedic conditions. Moreover, existing pillows often lack the technological advancements seen in other medical and comfort devices. The absence of measurement and modeling techniques in the manufacturing process contributes to a lack of precision in accommodating individualized anatomical features. The limitation leads to discomfort and inadequate support, especially for individuals recovering from orthopedic surgery or experiencing neck-related issues.
[0023] In view of the foregoing, introduced here are methods, apparatuses, and systems for support pillows with orthopedic support are disclosed. According to methods described herein, images of a user's head and a user's neck are generated by a camera system. Then, a three-dimensional (3D) digital twin of the user's head and the user's neck is generated using computer-aided design (CAD). The 3D digital twin has dimensions corresponding to the dimensions of the user's head and the user's neck. A wedge of resilient material is then molded to reflect the dimensions of the 3D digital twin. Multiple images of a user's head and neck are generated by, in some implementations, a camera system. In some implementations, the multiple images depict contours of the user's head and neck taken at different angles. In some implementations, the camera system includes at least one scanner capturing user height, width, and length.
[0024] Computer-aided design (CAD), in some implementations, is performed to generate a three-dimensional (3D) digital twin of the user's head and neck. In some implementations, the dimensions of the 3D digital twin correspond to the depth, width, and length of the user's head. Mesh reconstruction techniques can be used for 3D digital twin generation that considers surface irregularities. In some implementations, selective laser sintering and/or fused deposition modeling are used in CAD modeling. In some implementations, the system includes a user interface that is designed to receive a 3D digital twin input.
[0025] A wedge of resilient material is provided, where, in some implementations, the wedge comprises a base, a top, and an inclined surface connecting the base and the top of the wedge. In some implementations, the wider base includes a first side, a second side, a third side, and a fourth side, which determines the pillow height, width, and length respectively. In some implementations, molding is performed based on the generated 3D digital twin to create a depression in the wedge's surface. In some implementations, the angle formed by the inclined surface and the wider base of the wedge is selected based on the 3D digital twin. In some implementations, the resilient material comprises soy-based foam. In some implementations, the resilient material comprises memory foam, latex, polyurethane foam, gel-infused foam, bamboo foam, natural fibers, high-resilience foam, and/or natural latex foam. In some implementations, the resilient material wedge has a U-shape or circular shape. In some implementations, the wedge is foldable and/or collapsible. In some implementations, an adjustable air chamber is included in the wedge for dimension adjustments. In some implementations, an integrated lumbar roll is present on one end of the wedge. In some implementations, the wedge incorporates variable firmness zones with firm and soft regions for specific areas. In some implementations, the pillow has individual replaceable sections for targeted support.
[0026] In some implementations, the support pillow includes an outer cover, which is comprised of a different material than the pillow. The outer cover, in some implementations, envelops the wedge. In some implementations, the outer cover is moisture-wicking, includes a heating element, and/or has an attachment system for additional elements.
[0027] While the present support pillow is described in detail for use with orthopedic support, the support pillow could be applied, with appropriate modifications, to improve various other applications and contexts beyond the explicitly mentioned orthopedic support pillow. These applications could span a wide range of uses, including but not limited to other types of cushions, seating arrangements, furniture components, or medical devices requiring support. The examples provided in this paragraph are intended as illustrative and are not limiting. Any application referenced in this document, and many others unmentioned are equally appropriate after appropriate modifications.
[0028] The invention is implemented in numerous ways, including as a process; an apparatus; a system; a composition of matter; a computer program product embodied on a computer-readable storage medium; and/or a processor, such as a processor configured to execute instructions stored on and/or provided by a memory coupled to the processor. In this specification, these implementations, or any other form that the invention may take, may be referred to as techniques. In general, the order of the steps of disclosed processes may be altered within the scope of the invention. Unless stated otherwise, a component such as a processor or a memory described as being configured to perform a task may be implemented as a general component that is temporarily configured to perform the task at a given time or a specific component that is manufactured to perform the task. As used herein, the term processor refers to one or more devices, circuits, and/or processing cores configured to process data, such as computer program instructions.
[0029] A detailed description that references the accompanying figures follows. The scope of the invention is limited only by the claims and the invention encompasses numerous alternatives, modifications, and equivalents. Numerous specific details are set forth in the following description in order to provide a thorough understanding of the disclosure. These details are provided for the purpose of example and the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.
[0030]
[0031] A wedge 102 constitutes the main body of the orthopedic pillow 100. In some implementations, the wedge 102 is made from resilient materials such as memory foam, latex, or other supportive foams. The wedge shape ensures proper elevation and support for the user's head and neck, which can thus promote spinal alignment during sleep. The top surface 104 of the orthopedic pillow 100 is the side that comes into contact with the user's head and neck. On the other hand, the bottom surface 106 of the orthopedic pillow 100 rests on the mattress or sleep surface and provides stability and support. In some implementations, the bottom surface 106 is designed to prevent slipping or shifting during use, thus ensuring the pillow remains in the desired position throughout the night. For example, the bottom surface can include a non-slip pad made of a non-slip material (e.g., rubber, silicone, PVC, neoprene).
[0032] The orthopedic pillow 100 further has a width 108, which refers to the lateral dimension of the pillow, extending from one side to the other. In some implementations, the width 108 is tailored to accommodate the width of the user's head, to ensure adequate coverage and support across the entire head area. Likewise, the orthopedic pillow 100 has a length 110, which represents the longitudinal dimension of the pillow, measuring from the front to the back. The height 112 of the orthopedic pillow 100 is the tallest point of the vertical dimension of the orthopedic pillow 100, measuring from the bottom surface 106 to the top surface 104. In some implementations, the height 112 is calibrated to offer a customizable elevation for the user's head to offer proper alignment with the spine and alleviate pressure on the neck muscles.
[0033] A depression 114 of the orthopedic pillow 100 is an indented area or cavity molded into the top surface 104 of the orthopedic pillow 100. In some implementations, the depression 114 is custom-designed based on the user's specific head and neck dimensions, to ensure a proper fit and personalized support. The depression 114 has a depression width 116 that represents the lateral span of the depression which closely matches the width of the user's head. Similarly, the depression length 118 denotes the longitudinal extent of the depression 114 that accommodates the length of the user's head. Lastly, the depression height 120 refers to the depth of the depression 114, measuring from the top surface 104 of the pillow to the bottom of the indented area (e.g., of the depression 114). In some implementations, the material of the depression matches that of the rest of the wedge.
[0034] In some implementations, the orthopedic pillow 100 features additional elements to enhance the functionality and comfort. For instance, the wedge 102 incorporates adjustable layers or inserts that allow users to customize the firmness or height of the orthopedic pillow 100 to suit the user's preferences. These adjustable components, in some implementations, are made from materials such as gel-infused foam or bamboo foam to provide cooling properties or hypoallergenic benefits to users with specific needs or sensitivities.
[0035] In some implementations, the orthopedic pillow 100 includes an outer cover designed for easy removal and cleaning. See
[0036] In some implementations, the orthopedic pillow 100 incorporates integrated sensors and/or actuators to monitor the user's sleep quality and patterns and provide insights for improving overall well-being. Actuators embedded within the pillow adjust the firmness or elevation in real time, responding to changes in the user's sleeping position or comfort level to optimize support and alignment.
[0037] Furthermore, in some implementations, the orthopedic pillow 100 includes specialized features for specific use cases or medical conditions. For example, pillows designed for individuals recovering from neck surgery feature additional neck support or cervical contouring to aid in rehabilitation and pain relief. Similarly, pillows intended for pregnant individuals incorporate a unique shape or design to accommodate the changing contours of the body during pregnancy.
[0038]
[0039] The image 200 enables the customization of an orthopedic support pillow to the dimensions of a specific user. The image 200 can contain various anatomical features of the user (e.g., head, neck, ears). Width 202 represents the width of the image 200, which, in some implementations, provides the lateral dimensions of the orthopedic pillow to fit the user. Similarly, length 204 represents the length of the image 200, providing the longitudinal dimensions of the orthopedic pillow to fit the user. Depth 206 represents the depth of the image 200, providing the thickness of the orthopedic pillow to fit the user. The image can include a user's head 208 and a user's neck 210. Within the image 200, various features of the user's head and neck, including ears and other prominent anatomical features, are included in the image 200 (e.g., ears 212).
[0040] By capturing images from multiple angles, the camera system ensures that a 3D digital model that closely reflects the user's unique anatomy can be created. In addition to the detailed depiction of the user's head and neck, the image 200 can incorporate supplementary elements such as the positioning of the user's shoulders and posture. The additional detail allows for further user customization and can promote proper spinal alignment and alleviate pressure points throughout the body.
[0041]
[0042] The wedge 300 includes a taller end 302 and a shorter end 304, and is connected by a surface 306 bridging the taller end 302 and the shorter end 304. A width 308, extends from one side of the taller end 302 and shorter end 304 to the other side. In some implementations, the width 308 for the taller end 302 and the width 308 for the shorter end 304 are equal. Similarly, a length 310 of the wedge 300 determines the longitudinal span of the orthopedic pillow. The height 312 of the wedge 300 represents the wedge's 300 vertical dimensions, controlling the degree of elevation and support provided to the user's head and neck. In some implementations, wedge 300 of resilient material varies in shape and composition to cater to different user preferences. For example, while
[0043] In some implementations, the resilient material used to construct the wedge can include any resilient material, such as memory foam, latex, polyurethane foam, gel-infused foam, bamboo foam, natural fibers, high-resilience foam, and/or natural latex foam. In some implementations, the resilient material used depends on the specific user preferences. For example, memory foam conforms to the contours of the user's head and neck and offers pressure-relieving properties. In another example, latex provides responsive support and durability. In another example, gel-infused foam offers additional cooling properties to regulate temperature and promote a restful sleep environment. In some implementations, the wedge 300 features adjustable components, allowing users to fine-tune the elevation and firmness according to their evolving needs and preferences. For example, the wedge can include removable inserts and/or inflatable chambers.
[0044] In some implementations, the resilient material used to construct the wedge is soy-based foam. Soy-based foam is biodegradable, reducing non-biodegradable waste in landfills. Additionally, the production of soy-based foam involves a process that emits fewer greenhouse gases. Unlike traditional petroleum-based foams, which contribute to the accumulation of non-biodegradable waste in landfills, soy-based foam decomposes naturally over time, reducing environmental impact and promoting a circular economy. By choosing soy-based foam products, the orthopedic pillow can actively contribute to the reduction of waste and the preservation of natural resources.
[0045] For example, soy-based foam is derived from renewable soybean oil, a natural and abundant resource that is cultivated through agricultural practices. Unlike petroleum-based foams, which rely on finite fossil fuel reserves, the cultivation of soybeans requires less energy and resources compared to the extraction and refinement of petroleum, resulting in a lower environmental footprint from the outset. Moreover, the production process of soy-based foam involves significantly fewer emissions of volatile organic compounds (VOCs) and greenhouse gases compared to conventional foam manufacturing methods. Soy-based foam production emits lower levels of toxic chemicals and pollutants, contributing to improved air quality and reducing environmental harm. The reduction in emissions is particularly significant in indoor environments, where VOCs can pose health risks and contribute to indoor air pollution.
[0046] Moreover, the production process of soy-based foam is inherently more environmentally friendly compared to conventional foam manufacturing methods. The cultivation of soybeans requires fewer resources and has a lower environmental footprint compared to the extraction and processing of petroleum. Additionally, soy-based foam production emits fewer greenhouse gases, contributing to reduced carbon emissions and mitigating the impacts of climate change. By opting for soy-based foam products, the claimed manufacturing method significantly reduces the carbon footprint. Furthermore, soy-based foam offers comparable performance characteristics to traditional petroleum-based foams and ensures that consumers do not have to compromise on quality or functionality when choosing sustainable materials.
[0047]
[0048] The depression 114 includes an exposed portion 402, where material from the wedge 300 of resilient material has been hallowed out. The depression 114 contains a bottom portion 404, where the user can rest their head and/or neck. In some implementations, the depression has a covering 406, which is placed above the wedge 300 of resilient material.
[0049] Creating the depression 114 in the orthopedic pillow, in some implementations, is achieved by hollowing out the depression 114 from the top surface 104 of the wedge 300. For example, computer-controlled machinery can be used to carve out the desired shape from the resilient material. Using CAD (Computer-Aided Design) software, the depression's dimensions and contours can take into account the specific requirements of the user's head and neck. In some implementations, the resilient material is securely held in place, while precision cutting tools remove material from the top surface 104 to create the depression 114. The machine follows the programmed path dictated by the CAD software to ensure accuracy and consistency in the depression's 114 shape and size.
[0050] In some implementations, molding techniques are used to create the depression 114. For example, a mold is created based on the desired depression shape, and the pillow material is poured or injected into the mold cavity. Once the material cures or solidifies, the mold is removed, leaving behind the depression 114 in the pillow material.
[0051] In some implementations, vacuum-forming molding is used. Also known as thermoforming, vacuum-forming heats a sheet of thermoplastic material until the material becomes pliable, and then drapes the material over a mold and uses a vacuum to draw the material tightly against the mold's contours. Once cooled, the material retains the shape of the mold, resulting in a precise and uniform product. Vacuum-forming can be used, for example, for orthopedic pillows with complex geometries and intricate details.
[0052] In some implementations, rotational molding is used. Rotational molding places a measured amount of powdered material into a hollow mold, which is then heated and rotated slowly in multiple axes. The centrifugal force generated by the rotation causes the material to evenly coat the interior of the mold, forming a seamless and durable product. Rotational molding can be used, for example, for creating large, hollow structures with uniform wall thickness.
[0053] In some implementations, water-assisted molding is used. Water-assisted injection molding utilizes water pressure to assist in the injection of molten material into a mold cavity. Water-assisted molding allows for faster cooling and solidification of the material, resulting in shorter cycle times and improved dimensional stability. Water-assisted injection can be used, for example, for manufacturing orthopedic pillows that use high precision and consistency in the orthopedic pillow's final dimensions.
[0054] In some implementations, extrusion molding is used. Extrusion molding forces molten material through a die to create a continuous profile of the desired shape. The method can be used, for example, to manufacture orthopedic pillows with consistent cross-sectional geometries, such as cylindrical or rectangular forms.
[0055] In some implementations, gas-assisted molding is used. Gas-assisted molding uses an inert gas to push molten material into a mold cavity to create hollow sections or intricate features within the final product. The process helps reduce material usage and cycle times while improving surface finish and part quality. Gas-assisted molding can be used, for example, to manufacture orthopedic pillows with lightweight, yet structurally sound designs.
[0056] In some implementations, the depression 114 incorporates adjustable features, such as modular inserts or removable layers, within the depression 114 to allow users to customize the depth or firmness of the support. In some implementations, sensor technology can be integrated within the depression 114. For example, orthopedic pillows equipped with sensors monitor the user's sleeping position through the depression and provide real-time feedback or adjustments.
[0057] In some implementations tailored for therapeutic use, the depression 114 incorporates features such as heat or vibration therapy. Integrated heating elements or massage modules within the depression 114 can provide targeted relief to alleviate muscle tension and promote relaxation.
[0058]
[0059] Once the images are captured, they are processed and stitched together to create a comprehensive 3D representation of the user's head and neck. Mesh reconstruction techniques are then applied to refine the 3D model to smooth out surface irregularities and interpolate missing data points. The 3D model is used for generating a final 3D digital twin, which replicates the user's anatomical features. The 3D digital twin, in some implementations, includes repeating portions 502. To create the CAD 3D model, design parameters such as height, width, and length are adjusted based on the user's specific dimensions to ensure a customized fit for the orthopedic pillow. Once the CAD 3D model is finalized, the CAD 3D model serves as a virtual blueprint for the molding process. In some implementations, each portion 502 includes dimensions of different sides of the portion 502 (e.g., a first side 504, a second side 506, a third side 508), which correspond to different measurements.
[0060] Mesh reconstruction, in some implementations, begins with aligning multiple images obtained from the camera system to ensure that the multiple images are properly registered and aligned with each other to correct for any discrepancies in perspective or orientation. Once alignment is achieved, the images serve as the basis for generating a mesh structure that accurately represents the surface geometry of the user's anatomy.
[0061] In some implementations, specialized software is employed to analyze the pixel intensity and texture information from the aligned images. The analysis enables the software to estimate the underlying geometry of the user's head and neck, providing an initial approximation of the surface contours. However, to achieve a more precise representation, the initial estimate undergoes refinement through iterative optimization algorithms. These algorithms adjust the mesh vertices iteratively to minimize discrepancies between the reconstructed surface and the captured data, thereby enhancing the fidelity and accuracy of the mesh model.
[0062] In some implementations, such as in
[0063] In some implementations, the system partitions the imaging volume into small cubic elements (e.g., voxels), which are then converted into a mesh representation through various interpolation techniques. For example, interpolation methods such as trilinear or tetrahedral interpolation are used to estimate the shape and position of the surface within each voxel and bridge the gaps between adjacent data points to create a continuous mesh representation. In some implementations, smoothing or subdivision eliminates artifacts and irregularities in the mesh, to result in a more visually appealing and anatomically accurate representation of the user's anatomy.
[0064] In some implementations, the process of generating the 3D digital twin for orthopedic pillow customization uses techniques such as selective laser sintering (SLS). Selective laser sintering, a form of additive manufacturing, involves using a high-powered laser to selectively fuse powdered materials, typically polymers or metals, layer by layer. In the context of orthopedic pillow production, SLS scans multiple images of the user's head and neck and translates the data into a digital representation, which is then converted into a physical prototype. A high-powered laser selectively fuses the powdered material, layer by layer, based on the digital model's specifications. The laser traces the cross-section of each layer, causing the powder to solidify and form the desired shape. The build platform descends by a predetermined distance, and a new layer of powder is evenly distributed across the surface. The laser then scans the layer, sintering the powder according to the digital model's specifications. Once a layer is completed, the build platform descends again, and the process repeats until the entire object is fabricated. A variety of materials, such as thermoplastics, nylon, and metals, can be used in the process.
[0065] Similarly, in some implementations, fused deposition modeling (FDM) is used. FDM heats thermoplastic filaments and extrudes the filaments through a nozzle onto a build platform in a layer-by-layer fashion, gradually forming the desired dimensions of the orthopedic pillow based on the digital model's specifications. The digital model serves as a blueprint for the FDM printer, guiding the printer's movements to create the physical prototype of the customized orthopedic pillow. As the printer operates, the printer heats the thermoplastic filament to a precise temperature. Once the filament is heated to the appropriate temperature, the filament is extruded through the printer's nozzle, which moves along the X, Y, and Z axes according to the digital model's instructions. The extruded filament is deposited onto the build platform in thin layers, gradually building up the final object with each pass. As each layer is deposited, each layer quickly cools and solidifies, bonding with the previous layers to form a cohesive structure.
[0066]
[0067] The U-shaped orthopedic pillow 600 encompasses a concave indentation that extends along the length of the pillow, forming a supportive cradle for the head and neck. By accommodating the curvature of the user's neck and providing support from multiple angles, the U-shape orthopedic pillow 600 alleviates pressure points and reduces strain on the cervical spine. Additionally, the U-shaped configuration facilitates airflow around the head and neck region, enhancing breathability and promoting a cooler sleep environment.
[0068] In some implementations, the U-shaped orthopedic pillow 600 incorporates customizable features to accommodate individual preferences and anatomical variations. For instance, the depth and width of the concave indentation can be adjusted to suit the user's head size and sleeping position. Furthermore, the material composition of the pillow, such as memory foam or latex, can be tailored to provide varying levels of firmness and support.
[0069]
[0070] The circular shape of the pillow provides a symmetrical and evenly distributed support surface to accommodate various sleeping positions and head movements throughout the night. The circular orthopedic pillow 700 has rounded edges and smooth contours that offer support to the user's head and neck, reducing strain on the cervical spine and enhancing overall comfort. By distributing weight evenly across the pillow surface, circular orthopedic pillow 700 minimizes the risk of neck pain, stiffness, and discomfort commonly associated with improper sleep posture.
[0071] In some implementations, the circular orthopedic pillow 700 incorporates customizable features to cater to individual preferences and sleeping habits. For instance, the diameter and thickness of the pillow can be adjusted to accommodate different head sizes and provide varying levels of firmness and support. Additionally, the material composition of the circular orthopedic pillow 700, such as memory foam or latex, can be tailored to suit the user's specific needs and preferences.
[0072]
[0073] The foldable design of the orthopedic pillow 800 is achieved through a series of placed hinges or articulation points that allow for controlled folding and unfolding. The hinges are engineered, in some implementations, to withstand repeated use without compromising the structural integrity of the pillow to ensure durability and long-term performance. In some implementations, the foldable orthopedic pillow 800 incorporates mechanisms to lock the folded configuration securely in place, preventing accidental unfolding during sleep.
[0074] In some implementations, the central section of the foldable orthopedic pillow 800 features a contour that cradles the head, while the side sections provide additional support for the neck and shoulders. In some implementations, the foldable orthopedic pillow 800 incorporates additional accessory features such as adjustable air chambers or modular inserts to allow users to fine-tune the firmness and height of the pillow to their preference. In some implementations, the accessory features are able to stay connected to the foldable orthopedic pillow 800 in the folded configuration. In some implementations, the foldable orthopedic pillow 800 can be compressed into a smaller form to provide easier transport or storage. In some implementations, the foldable orthopedic pillow 800 incorporates adjustable elevation features to accommodate post-surgery recovery or alleviate symptoms of conditions such as acid reflux and/or sleep apnea.
[0075]
[0076] The outer cover sits between the user and the orthopedic pillow, providing an additional layer of protection and functionality. In some implementations, the outer cover of the orthopedic pillow 900 is crafted from moisture-wicking fabrics such as bamboo-derived rayon or microfiber blends to absorb and dissipate moisture, keeping the surface of the pillow cool and dry throughout the night. Additionally, in some implementations, the outer cover includes perforations or mesh panels to promote airflow and ventilation to enhance breathability and comfort.
[0077] In some implementations, temperature-regulating features are included in the outer cover, such as using phase-change materials (PCMs) or cooling gel-infused fibers to absorb excess heat from the body and release the excess heat when temperatures drop, helping to maintain a comfortable sleep environment year-round. Additionally, the outer cover can be treated with antimicrobial agents or hypoallergenic coatings to inhibit the growth of bacteria and allergens to provide a more hygienic sleep surface. In some implementations, the outer cover of the orthopedic pillow 900 is removable and machine-washable components for easy care and maintenance. The cover can include zippered closures or Velcro fastenings to facilitate removal and reattachment.
[0078] In some implementations, the outer cover of the orthopedic pillow 900 incorporates customizable features to cater to individual preferences and needs. For example, the orthopedic pillow 900 has interchangeable covers with different materials or textures. Additionally, the orthopedic pillow 900 can feature adjustable straps or fastenings to ensure a secure fit around the pillow and prevent shifting or bunching during sleep.
[0079] In some implementations, smart functionalities can be integrated into the outer cover of the orthopedic pillow 900. For example, by incorporating sensors or connectivity capabilities, such as RFID tags or NFC technology, the outer cover can communicate with compatible sleep-tracking devices or smartphone apps. Then, users are able to monitor their sleep patterns, receive personalized recommendations for improving sleep quality, and/or control temperature or ventilation settings remotely.
[0080]
[0081] The modular orthopedic pillow 1000 includes individualized components (e.g., modules), where each module represents a removable portion of the module orthopedic pillow 1000.
[0082] In some implementations, each module within the orthopedic pillow 1000 is made of the same materials, such as high-density memory foam, responsive gel-infused polymers, or adaptive latex. In some implementations, two different modules within the orthopedic pillow 1000 contain different materials. For example, a first portion 1002 of the module contains memory foam, whereas a second portion 1004 of the module contains adaptive latex. Some modules can feature contoured surfaces or ergonomic shapes to cradle the head and neck in a comfortable position, while others can incorporate adjustable inserts or air chambers to fine-tune the level of support and firmness.
[0083] In some implementations, users can experiment with different module configurations to find the optimal combination for their individual needs, and they can easily replace or add modules as their preferences change or evolve. For instance, some modules can incorporate features such as adjustable inserts or air chambers, and users to fine-tune the level of support and firmness to their exact specifications. The versatility ensures that the orthopedic pillow 1000 remains adaptable to the user's evolving sleep habits and/or comfort preferences.
[0084]
[0085] The orthopedic pillow 1100 includes a dedicated lumbar portion 1102 within the wedge of resilient material to provide targeted support to the lumbar region of the spine. In some implementations, the lumbar portion 1102 is removable from the wedge of resilient material. In some implementations, the lumbar portion 1102 is molded into the wedge of resilient material.
[0086] The lumbar portion 1102 of the wedge is positioned to cradle the lower back, promoting proper spinal curvature and relieving pressure on the lumbar spine. In some implementations, the lumbar portion 1102 is made from resilient materials such as memory foam or adaptive latex. In some implementations, the lumbar portion 1102 follows the contours to the natural shape of the lumbar spine of the user, providing personalized support and cushioning where the support is needed most.
[0087] The orthopedic pillow 1100 includes a first side 1106 and a second side 1104. In some implementations, the first side 1106 and the second side 1104 have a width 1108 and a length 1110 respectively. In some implementations, the width 1108 is equivalent to the width 108 of the orthopedic pillow 1100, and the length 1110 is smaller than the length 110 of the orthopedic pillow. The elongated design of the orthopedic pillow 1100 accommodates various sleeping positions, allowing users to find their preferred orientation for maximum comfort and relaxation. Additionally, some implementations can incorporate therapeutic elements such as heating and/or massaging capabilities into the lumbar portion, and provide targeted relief to alleviate muscle tension and promote muscle relaxation in the lower back region.
[0088]
[0089] The orthopedic pillow 1200 includes a first strap portion 1202 and a second strap portion 1204, each equipped with corresponding attachment mechanisms. The first attaching portion 1206 corresponds to a second attaching portion 1208, where the first attaching portion 1206 is able to be attached to the second attaching portion 1208 (e.g., a buckle or belt mechanism).
[0090] The first strap portion 1202, along with the first attaching portion 1206, has a length 1210, while the second strap portion 1204, along with the second strap portion 1204, has a length 1212. In some implementations, users can manipulate the length 1210 and length 1212 to adjust the tension and positioning. For example, the user can place the orthopedic pillow 1200 on a vertical surface (e.g., a plane seat), and secure the orthopedic pillow 1200 in place.
[0091] In some implementations, a wide range of accessories can be attached to the orthopedic pillow 1200, such as cooling elements, heating pads, massaging devices, and/or aromatherapy inserts, to enhance the user's sleep environment according to personal preferences.
[0092]
[0093] The computer system 1300 can include one or more central processing units (processors) 1302, main memory 1306, non-volatile memory 1310, network adapters 1312 (e.g., network interface), video displays 1318, input/output devices 1320, control devices 1322 (e.g., keyboard and pointing devices), drive units 1324 including a storage medium 1326, and a signal generation device 1320 that are communicatively connected to a bus 1316. The bus 1316 is illustrated as an abstraction that represents one or more physical buses and/or point-to-point connections that are connected by appropriate bridges, adapters, or controllers. The bus 1316, therefore, can include a system bus, a Peripheral Component Interconnect (PCI) bus or PCI-Express bus, a HyperTransport or industry standard architecture (ISA) bus, a small computer system interface (SCSI) bus, a universal serial bus (USB), IIC (I2C) bus, or an Institute of Electrical and Electronics Engineers (IEEE) standard 1394 bus (also referred to as Firewire).
[0094] The computer system 1300 can share a similar computer processor architecture as that of a desktop computer, tablet computer, personal digital assistant (PDA), mobile phone, game console, music player, wearable electronic device (e.g., a watch or fitness tracker), network-connected (smart) device (e.g., a television or home assistant device), virtual/augmented reality systems (e.g., a head-mounted display), or another electronic device capable of executing a set of instructions (sequential or otherwise) that specify action(s) to be taken by the computer system 1300.
[0095] While the main memory 1306, non-volatile memory 1310, and storage medium 1326 (also called a machine-readable medium) are shown to be a single medium, the term machine-readable medium and storage medium should be taken to include a single medium or multiple media (e.g., a centralized/distributed database and/or associated caches and servers) that store one or more sets of instructions 1328. The term machine-readable medium and storage medium shall also be taken to include any medium that is capable of storing, encoding, or carrying a set of instructions for execution by the computer system 1300.
[0096] In general, the routines executed to implement the implementations of the disclosure can be implemented as part of an operating system or a specific application, component, program, object, module, or sequence of instructions (collectively referred to as computer programs). The computer programs typically include one or more instructions (e.g., instructions 1304, 1308, 1328) set at various times in various memory and storage devices in a computer device. When read and executed by the one or more processors 1302, the instruction(s) cause the computer system 1300 to perform operations to execute elements involving the various aspects of the disclosure.
[0097] Moreover, while implementations have been described in the context of fully functioning computer devices, those skilled in the art will appreciate that the various implementations are capable of being distributed as a program product in a variety of forms. The disclosure applies regardless of the particular type of machine or computer-readable media used to actually affect the distribution.
[0098] Further examples of machine-readable storage media, machine-readable media, or computer-readable media include recordable-type media such as volatile and non-volatile memory devices 1310, floppy and other removable disks, hard disk drives, optical discs (e.g., Compact Disc Read-Only Memory (CD-ROMS), Digital Versatile Discs (DVDs)), and transmission-type media such as digital and analog communication links.
[0099] The network adapter 1312 enables the computer system 1300 to mediate data in a network 1314 with an entity that is external to the computer system 1300 through any communication protocol supported by the computer system 1300 and the external entity. The network adapter 1312 can include a network adapter card, a wireless network interface card, a router, an access point, a wireless router, a switch, a multilayer switch, a protocol converter, a gateway, a bridge, a bridge router, a hub, a digital media receiver, and/or a repeater.
[0100] The network adapter 1312 can include a firewall that governs and/or manages permission to access proxy data in a computer network and tracks varying levels of trust between different machines and/or applications. The firewall can be any number of modules having any combination of hardware and/or software components able to enforce a predetermined set of access rights between a particular set of machines and applications, machines and machines, and/or applications and applications (e.g., to regulate the flow of traffic and resource sharing between these entities). The firewall can additionally manage and/or have access to an access control list that details permissions including the access and operation rights of an object by an individual, a machine, and/or an application, and the circumstances under which the permission rights stand.
[0101] The foregoing description of various implementations of the claimed subject matter has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the claimed subject matter to the precise forms disclosed. Many modifications and variations will be apparent to one skilled in the art. Implementations were chosen and described in order to best describe certain principles and practical applications, thereby enabling others skilled in the relevant art to understand the subject matter, the various implementations and the various modifications that are suited to the particular uses contemplated.
[0102] While implementations have been described in the context of fully functioning computers and computer systems, those skilled in the art will appreciate that the various implementations are capable of being distributed as a program product in a variety of forms and that the disclosure applies equally regardless of the particular type of machine- or computer-readable media used to actually effect the distribution.
[0103] Although the above Detailed Description describes certain implementations and the best mode contemplated, no matter how detailed the above appears in text, the implementations can be practiced in many ways. Details of the systems and methods may vary considerably in their implementation details while still being encompassed by the specification. As noted above, particular terminology used when describing certain features or aspects of various implementations should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the disclosed technique with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the disclosure to the specific implementations disclosed in the specification, unless those terms are explicitly defined herein. Accordingly, the actual scope of the technique encompasses not only the disclosed implementations but also all equivalent ways of practicing or implementing the implementations under the claims.
[0104] The language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the technique be limited not by this Detailed Description, but rather by any claims that issue on an application based hereon. Accordingly, the disclosure of various implementations is intended to be illustrative, but not limiting, of the scope of the implementations, which is set forth in the following claims.
[0105] From the foregoing, it will be appreciated that specific implementations of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the invention. Accordingly, the invention is not limited except as by the appended claims.