US2006048302A1PendingUtilityA1

Fire resistant fabric composite, process for fire-blocking a mattress and mattress set, and a mattress and mattress set fire-blocked thereby

49
Individually held — no corporate assignee on recordPriority: Jul 29, 2003Filed: Nov 4, 2005Published: Mar 9, 2006
Est. expiryJul 29, 2023(expired)· nominal 20-yr term from priority
Inventors:Herman Hans ForstenWarren Francis KnoffWilliam Younts
A47C 31/001Y10T442/647Y10T442/696Y10T442/698B32B 5/26B32B 5/18Y10T442/651B32B 2307/3065B32B 5/022B32B 5/024
49
PatentIndex Score
0
Cited by
0
References
0
Claims

Abstract

This invention relates to a fabric composite for use in fire-blocking a mattress, a fire-blocked mattress set, and a process for fire-blocking mattresses; the fabric composite comprising, in order, (a) sacrificial outer ticking, (b) sacrificial cushioning material, and (c) fire-blocking fabric, the fire-blocking fabric being a single layer of nonwoven fabric comprising at least 0.5 ounces per square yard (17 grams per square meter) of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air to 700 C at a rate of 20 degrees C. per minute, and at least 0.5 ounces per square yard (17 grams per square meter) of a heat-resistant fiber. Mattress sets fire-blocked with this fabric composite have a peak heat release rate of less than 150 kilowatts within 30 minutes, preferably less that 150 kilowatts within 60 minutes, and a total heat release of less than 25 megajoules within 10 minutes when tested according to Technical Bulletin 603 of the State of California.

Claims

exact text as granted — not AI-modified
1 - 16 . (canceled)  
   
   
       17 . A mattress resistant to an open flame comprising a fabric composite containing in order: 
 (a) sacrificial outer ticking,    (b) sacrificial cushioning material, and    (c) fire-blocking fabric,    the fire-blocking fabric being a single layer of nonwoven fabric comprising at least 0.5 ounces per square yard (17 grams per square meter) of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air to 700 C at a rate of 20 degrees C. per minute, and at least 0.5 ounces per square yarn (17 grams per square meter) of a heat-resistant fiber. 
 with the provisos: 
 (i) only a single layer is employed in the fireblocking fabric of (c) and  
 (ii) only a single layer of fabric is employed for fireblocking the mattress.  
 
   
   
   
       18 . The mattress of  claim 17  wherein the fabric composite is located in a panel of the mattress.  
   
   
       19 . The mattress of  claim 17  wherein the fabric composite is located in a border of the mattress.  
   
   
       20 . The mattress of  claim 17  wherein the fabric composite further comprises seams having fire resistant thread stitching.  
   
   
       21 . A mattress resistant to an open flame comprising the fabric composite of  claim 17  wherein the cellulose fiber retains at least 90 percent of its fiber weight.  
   
   
       22 . The mattress of  claim 21  wherein the fabric composite is located in a panel of the mattress.  
   
   
       23 . The mattress of  claim 21  wherein the fabric composite is located in a border of the mattress.  
   
   
       24 . The mattress of  claim 21  wherein the fabric composite further comprises seams having fire resistant thread stitching.  
   
   
       25 . A mattress resistant to open flame comprising the fabric composite of  claim 17 . 
 wherein the heat resistant fiber is a poly(paraphenylene terephthalamide) fiber and the cellulose fiber (X) and heat resistant fiber (Y) being present in the fire-blocking fabric in a weight ratio expressed by the equation:        Y>/=− 0.14 X+ 1.3.    
   
   
       26 . A mattress set resistance to an open flame comprising a mattress of  claim 17  and a mattress foundation.  
   
   
       27 . A mattress set resistance to an open flame comprising a mattress of  claim 21  and a mattress foundation.  
   
   
       28 . A mattress set resistance to an open flame comprising a mattress of  claim 25  and a mattress foundation.  
   
   
       29 . A mattress set resistant to an open flame comprising a mattress and a mattress foundation: 
 the mattress comprising a fabric composite and a mattress core, the fabric composite comprising in order: 
 (a) sacrificial outer ticking,  
 (b) sacrificial cushioning material, and  
 (c) a single layer nonwoven fire-blocking fabric,  
 the mattress foundation comprising a single layer nonwoven fire-blocking fabric and a support structure,  
   wherein the mattress set has a peak heat release rate of less than 150 kilowatts within 30 minutes and a total heat release of less than 25 megajoules in the first 10 minutes when tested according to Technical Bulletin 603 of the State of California. 
 with the provisos: 
 (iii) only a single layer is employed in the fireblocking fabric of (c) and  
 (iv) only a single layer of fabric is employed for fireblocking the mattress.  
 
   
   
   
       30 . The mattress set of  claim 26  wherein the single layer nonwoven fire-blocking fabric comprises at least 0.5 ounces per square yard (17 grams per square meter) of a heat resistant fiber, the nonwoven fabric having a basis weight of at least 2.5 ounces per square yard (85 grams per square meter).  
   
   
       31 . The mattress set of  claim 27  wherein the heat resistant fiber is an organic fiber that retains 90 percent of its fiber weight when heated in air to 500 C at a rate of 20 degrees C. per minute.  
   
   
       32 . The mattress set of  claim 27  wherein the heat resistant fiber comprises a polymer selected from the group of para-aramid, polybenzazole, polybenzimidazole, and polyimide.  
   
   
       33 . The mattress set of  claim 27  wherein the heat resistant fiber is a poly(paraphenylene terephthalamide) fiber and the nonwoven fire-blocking layer includes a viscose fiber containing silicic acid, the viscose fiber (X) and heat resistant fiber (Y) being present in the fire-blocking fabric in a weight ratio expressed by the equation  
         Y>/=− 0.14 X+ 1.3.  
   
   
       34 . The mattress set of  claim 18  wherein the mattress set has a peak heat release rate of less than 150 kilowatts within 60 minutes and a total heat release of less than 25 megajoules in the first 10 minutes when tested according to Technical Bulletin 603 of the State of California.  
   
   
       35 . The mattress set of  claim 31  wherein the single layer nonwoven fire-blocking fabric comprises at least 0.5 ounces per square yard (17 grams per square meter) of a heat resistant fiber, the nonwoven fabric having a basis weight of at least 2.5 ounces per square yard (85 grams per square meter).  
   
   
       36 . The mattress set of  claim 32  wherein the heat resistant fiber is an organic fiber that retains 90 percent of its fiber weight when heated in air to 500 C at a rate of 20 degrees C. per minute.  
   
   
       37 . The mattress set of  claim 32  wherein the heat resistant fiber comprises a polymer selected from the group of para-aramid, polybenzazole, polybenzimidazole, and polyimide.  
   
   
       38 . The mattress set of  claim 32  wherein the heat resistant fiber is a poly(paraphenylene terephthalamide) fiber and the nonwoven fire-blocking layer includes a viscose fiber containing silicic acid, the viscose fiber (X) and heat resistant fiber (Y) being present in the fire-blocking fabric in a weight ratio expressed by the equation  
         Y>/=− 0.14 X+ 1.4.  
   
   
       39 . A process for fire-blocking a mattress while retaining the aesthetics of the mattress cushioning material, the mattress having, in order, ticking, cushioning material, and a mattress core, the process comprising: 
 (a) incorporating into the mattress a fire-blocking fabric between the cushioning material and the mattress core,    (b) the fire-blocking fabric being a single layer of nonwoven fabric comprising at least 0.5 ounce per square yard (17 grams per square meter) of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air to 700 C at a rate of 20 degrees C. per minute and at least 0.5 ounces per square yard (17 grams per square meter) of a heat-resistant fiber. 
 with the provisos: 
 (v) only a single layer is employed in the fireblocking fabric set forth in (a) and (b) and  
 (vi) only a single layer of fabric is employed for fireblocking the mattress.  
 
   
   
   
       40 . The process of  claim 34  wherein the heat resistant fiber is an organic fiber that retains 90 percent of its fiber weight when heated in air to 500 C at a rate of 20 degrees C. per minute.  
   
   
       41 . The process of  claim 34  wherein the heat-resistant fiber comprises a polymer selected from the group of para-aramid, polybenzazole, polybenzimidazole, and polyimide.  
   
   
       42 . The process of  claim 36  wherein the para-aramid is poly(paraphenylene terephthalamide).  
   
   
       43 . The process of  claim 34  wherein the heat resistant fiber is a poly(paraphenylene terephthalamide) fiber and the cellulose fiber is a viscose fiber containing silicic acid, the viscose fiber (X) and poly(paraphenylene terephthalamide) fiber (Y) being present in the fire-blocking fabric in a weight ratio expressed by the equation  
         Y>/=− 0.14 X+ 1.4.  
   
   
       44 . The process of  claim 34  wherein the fire-blocking fabric further comprises an off gassing material that releases a flame suppressing gas when burned.

Join the waitlist — get patent alerts

Track US2006048302A1 — get alerts on status changes and closely related new filings.

We store only your email — no account needed. See our privacy policy.