System and Method for Manufacturing a Customized Orthopedic Support Pillow

The present invention relates to the field of sleep accessories and comfort products, and more particularly to a pillow device and method of manufacturing.

A pillow is a soft, cushioned support typically used to cradle the head, neck, or other parts of the body during sleep, rest, or relaxation. The cushions typically assume rectangular or square shapes and are typically constructed from materials such as feathers, down, cotton, or synthetic fibers. Pillows can vary in size, thickness, and firmness levels. Beyond the primary function of sleep enhancement, pillows serve as accessories for relaxation and comfort in various settings. For example, pillows can be used for lumbar support during extended periods of sitting or as makeshift cushions for leisurely activities.

3D modeling is the process of creating three-dimensional representations of objects or scenes using specialized software. 3D modeling involves the manipulation of geometric shapes, textures, and lighting to simulate real-world or imaginary environments. Artists and designers use 3D modeling for various purposes, including animation, visualization, prototyping, and game development. The process typically begins with the creation of a wireframe outline, which serves as the foundation for adding detail and complexity. Creators can craft complex shapes and textures by manipulating vertices, edges, and faces in a virtual 3D space.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

is a drawing illustrating a view of an orthopedic pillowwith customized support, in accordance with one or more implementations.

A wedgeconstitutes the main body of the orthopedic pillow. In some implementations, the wedgeis 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 surfaceof the orthopedic pillowis the side that comes into contact with the user's head and neck. On the other hand, the bottom surfaceof the orthopedic pillowrests on the mattress or sleep surface and provides stability and support. In some implementations, the bottom surfaceis 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).

The orthopedic pillowfurther has a width, which refers to the lateral dimension of the pillow, extending from one side to the other. In some implementations, the widthis tailored to accommodate the width of the user's head, to ensure adequate coverage and support across the entire head area. Likewise, the orthopedic pillowhas a length, which represents the longitudinal dimension of the pillow, measuring from the front to the back. The heightof the orthopedic pillowis the tallest point of the vertical dimension of the orthopedic pillow, measuring from the bottom surfaceto the top surface. In some implementations, the heightis 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.

A depressionof the orthopedic pillowis an indented area or cavity molded into the top surfaceof the orthopedic pillow. In some implementations, the depressionis custom-designed based on the user's specific head and neck dimensions, to ensure a proper fit and personalized support. The depressionhas a depression widththat represents the lateral span of the depression which closely matches the width of the user's head. Similarly, the depression lengthdenotes the longitudinal extent of the depressionthat accommodates the length of the user's head. Lastly, the depression heightrefers to the depth of the depression, measuring from the top surfaceof the pillow to the bottom of the indented area (e.g., of the depression). In some implementations, the material of the depression matches that of the rest of the wedge.

In some implementations, the orthopedic pillowfeatures additional elements to enhance the functionality and comfort. For instance, the wedgeincorporates adjustable layers or inserts that allow users to customize the firmness or height of the orthopedic pillowto 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.

In some implementations, the orthopedic pillowincludes an outer cover designed for easy removal and cleaning. Seefor further discussion. The outer cover, in some implementations, is made from breathable, moisture-wicking materials to regulate temperature and promote airflow, and ensure a comfortable sleeping environment throughout the night. Additionally, the outer cover, in some implementations, features antimicrobial properties to inhibit the growth of bacteria and allergens for hygiene purposes and user comfort.

In some implementations, the orthopedic pillowincorporates 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.

Furthermore, in some implementations, the orthopedic pillowincludes 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.

is a drawing illustrating a front view of an imagegenerated by a camera system of a user's head and a user's neck, in accordance with one or more implementations.is a drawing illustrating a side view of an imagegenerated by a camera system of a user's head and a user's neck, in accordance with one or more implementations.

The imageenables the customization of an orthopedic support pillow to the dimensions of a specific user. The imagecan contain various anatomical features of the user (e.g., head, neck, ears). Widthrepresents the width of the image, which, in some implementations, provides the lateral dimensions of the orthopedic pillow to fit the user. Similarly, lengthrepresents the length of the image, providing the longitudinal dimensions of the orthopedic pillow to fit the user. Depthrepresents the depth of the image, providing the thickness of the orthopedic pillow to fit the user. The image can include a user's headand a user's neck. Within the image, various features of the user's head and neck, including ears and other prominent anatomical features, are included in the image(e.g., ears).

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 imagecan 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.

is a drawing illustrating a wedgeof resilient material, in accordance with one or more implementations.

The wedgeincludes a taller endand a shorter end, and is connected by a surfacebridging the taller endand the shorter end. A width, extends from one side of the taller endand shorter endto the other side. In some implementations, the widthfor the taller endand the widthfor the shorter endare equal. Similarly, a lengthof the wedgedetermines the longitudinal span of the orthopedic pillow. The heightof the wedgerepresents the wedge'svertical dimensions, controlling the degree of elevation and support provided to the user's head and neck. In some implementations, wedgeof resilient material varies in shape and composition to cater to different user preferences. For example, whiledepicts a traditional triangular wedge design, alternative shapes such as rectangular or contoured wedges can also be employed. The alternative configurations can cater to individuals with specific sleeping postures or orthopedic concerns to ensure that the pillow supports a variety of preferences.

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 wedgefeatures 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.

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.

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.

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.

is a drawing illustrating a depressionof the orthopedic pillow, in accordance with one or more implementations.

The depressionincludes an exposed portion, where material from the wedgeof resilient material has been hallowed out. The depressioncontains a bottom portion, where the user can rest their head and/or neck. In some implementations, the depression has a covering, which is placed above the wedgeof resilient material.

Creating the depressionin the orthopedic pillow, in some implementations, is achieved by hollowing out the depressionfrom the top surfaceof the wedge. 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 surfaceto create the depression. The machine follows the programmed path dictated by the CAD software to ensure accuracy and consistency in the depression'sshape and size.

In some implementations, molding techniques are used to create the depression. 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 depressionin the pillow material.

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.

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.

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.

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.

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.

In some implementations, the depressionincorporates adjustable features, such as modular inserts or removable layers, within the depressionto allow users to customize the depth or firmness of the support. In some implementations, sensor technology can be integrated within the depression. For example, orthopedic pillows equipped with sensors monitor the user's sleeping position through the depression and provide real-time feedback or adjustments.

In some implementations tailored for therapeutic use, the depressionincorporates features such as heat or vibration therapy. Integrated heating elements or massage modules within the depressioncan provide targeted relief to alleviate muscle tension and promote relaxation.

is a drawing illustrating a 3D digital twin, in accordance with one or more implementations.

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. 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 portionincludes dimensions of different sides of the portion(e.g., a first side, a second side, a third side), which correspond to different measurements.

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.

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.

In some implementations, such as in, Delaunay triangulation is used, which creates a mesh of interconnected triangles that cover the surface of the user's anatomy (e.g., triangles including a first side, a second side, a third side). In some implementations, no triangle edges intersect, so that the mesh maintains a high degree of geometric fidelity.

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.

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.

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.