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Hello. I'm in charge of development. The "Brain Sleep Pillow" is a pillow born from brain and sleep research, and as the one and only pillow that consolidates the methods of "The Stanford Way to a Restful Sleep," it has become Brain Sleep's flagship product. This time, please allow me to tell you the story of how the "Brain Sleep Pillow" came to be.
Stanford University's Sleep Research, said to be "World-Class"
Dr. Seiji Nishino, founder and chief research advisor of Brain Sleep, is a professor at Stanford University School of Medicine, which is said to be "world-class" in sleep research, and also the director of the Stanford Neuroscience and Sleep Center (SNCL) at the same university. The development of the "Brain Sleep Pillow" began with our encounter with Dr. Nishino.
The Importance of the Golden 90 Minutes
There are two types of sleep: "non-REM sleep" (a state where both the brain and body are deeply asleep) and "REM sleep" (a state where the body is resting but the brain is awake).
These "non-REM sleep" and "REM sleep" cycles repeat 4 to 5 times a night, with more deep non-REM sleep occurring in the first 3 hours of sleep, and more REM sleep as morning approaches.
Among these, it is known that deeper non-REM sleep during the first 90 minutes after falling asleep not only helps relieve sleepiness but also promotes metabolic hormones, leading to a refreshing morning and quality sleep. Dr. Nishino calls these first 90 minutes after falling asleep the "Golden 90 Minutes."
Furthermore, to improve the quality of sleep during the golden 90 minutes, it is also important to control the core body temperature. Humans have "skin temperature" (the temperature of the body's surface, such as the skin) and "core body temperature" (the temperature of the body's interior, such as the brain and organs). When the difference between skin temperature and core body temperature decreases, we feel sleepy.
While awake, the core body temperature rises, and the difference with skin temperature increases, but when falling asleep, the core body temperature drops due to heat radiation from the hands and feet, and the difference with skin temperature narrows, switching the body into sleep mode.
It is also known that cooling the brain is effective for a pillow to facilitate this heat radiation. And the development of the "Brain Sleep Pillow" began with a remark Dr. Nishino made one day: "There is no pillow in Japan that makes sense."
"Breathability and Fit" to Improve Sleep Quality
The development project for a "pillow that cools the brain, focusing on the first 90 minutes of sleep" began this way, but even with various bedding manufacturers constantly developing products, it was said that such a pillow did not exist in Japan, so development was not straightforward.
First of all, what material should be used to cool the brain? It was at this time that we encountered the patented knitted resin and technology of "Eco World."
Encountering "Eco World" with Patented Technology
Through a certain connection, we encountered the special grade polyethylene resin of "Eco World" in Oita Prefecture and its patented technology, "knitted resin mesh structure," which melts the resin into strands and weaves them into a spring-like shape.
Breathability to Enhance the Quality of the Golden 90 Minutes
This structure has been continuously researched and developed by "Eco World" for over 20 years, representing a craftsman's skill excellent in breathability and durability.
At that time, I thought, "With this material and technology, we can create a pillow that cools the brain, focusing on the first 90 minutes of sleep." Regarding breathability, which is indispensable for lowering brain temperature to improve the quality of the golden 90 minutes, by knitting polyethylene resin, over 90% became an air layer, ensuring excellent breathability.
However, there was a challenge to make it a satisfactory pillow.
Over 100 Prototypes
We immediately produced the first prototype, but the feedback when testing it was, "The rebound is too strong, I can't turn over!" and "My head bounces like a trampoline!" The very first prototype was not a pillow that allowed for comfortable sleep. The next challenge was "fit."
While breathability is important, fit is also crucial for improving sleep quality. From here, it would take about 100 prototypes until we could create a pillow that everyone involved was satisfied with and could offer to customers.
Multi-layered Gradient Structure with Varying Densities Ensures the Best Fit and Comfort
Through repeated prototyping, we arrived at a multi-layered gradient structure created by adjusting the density through the thickness and weaving method of the resin strands.
As you can see in the image below, the three-layer structure on the top and bottom provides the best fit, while the hardness gradient on the left and right ensures ease of turning over.
However, it is easy to say but very difficult to achieve such a structure. There are two major challenges.
The first is the technical difficulty of manufacturing.
To make a pillow from resin, the resin is first melted, then formed into strands, and then knitted and hardened. The appropriate resin temperature changes depending on the ambient temperature and humidity of the day, and even a slight temperature difference can compromise the fit. Therefore, thorough temperature control is required every day.
The second is the balance between fit and durability.
Making it softer increases the fit, but if it's too soft, durability will suffer. Even if it feels good the moment you lay your head on it, very fine adjustments are needed to answer questions like, "What about sleeping until morning?" or "Will the fit be maintained after several days of use?"
In both cases, we received tremendous cooperation from everyone at "Eco World," and through exchanging ideas, we repeatedly made prototypes until we achieved a satisfactory feel. We made it, slept on it, made it, slept on it. There were no shortcuts for these two challenges; we overcame them through continuous, painstaking fine-tuning.
And finally, the "initial model of the Brain Sleep Pillow" was completed.
The Finally Completed "Initial Model of the Brain Sleep Pillow"
It was first sold on the crowdfunding platform "Makuake," and its structure at that time was "3 layers x 5 gradations."
Thanks to an overwhelming response, we also received various feedback from customers who used it, leading to many new insights.
Based on customer feedback, we discussed it again with everyone at "Eco World," made improvements, and subsequently, the "Brain Sleep Pillow" evolved to 7 gradations, then further improved to 9 gradations, leading to its current form.
And the Current "Brain Sleep Pillow" is Completed
Though it looks simple, this pillow was completed after encountering various people and much trial and error, as I've described so far.
Carefully Designed Three-Layer Structure
From the top, it has a complex structure of three different thicknesses of resin stacked: a "fluffy layer" that fits the size and weight of the head, a "support layer" that firmly supports the head and neck, and a "base layer" that supports the pillow while allowing air to escape from below.
The bottom "base layer" is the firmest, and the "support layer" sandwiched between the upper and lower layers maintains balance with just the right amount of softness, preventing excessive sinking and providing a feeling of being gently pushed back.
The neck area of the bottom "base layer" has a core-like part with increased density, and by creating an uneven surface with the middle "support layer," it maintains sleeping comfort while firmly supporting the neck to reduce strain on the body. Furthermore, it improved durability.
The "Brain Sleep Pillow" offers just the right amount of rebound and softness, giving a zero-gravity sensation as if your head is floating. Additionally, its excellent breathability lowers the head temperature during sleep, enhancing sleep quality.
9-Gradation Structure with Increased Elasticity from the Center Outwards
Although the pillow appears uniform, the current "Brain Sleep Pillow" has a 9-gradation structure where the center is the softest, and the elasticity increases towards the left and right sides.
It gently cradles the head when lying on your back and supports it without sinking when lying on your side, providing a comfortable fit regardless of your sleeping position. During sleep, it is said that turning over moderately reduces strain on the body and improves sleep quality.
The 9-gradation structure of the "Brain Sleep Pillow" supports smooth turning, ensuring a comfortable night's sleep until morning without interruption.
Finally
The "Brain Sleep Pillow," packed with so much dedication and care, has surpassed 200,000 units in cumulative sales, and we are very happy that so many customers are using it. To improve your sleep quality, please try it once.
