Patent Application
20240023725
The present invention relates to a flame-retardant fabric used in bedding and/or a sleep product, such as a mattress, and, more specifically, to a flame-retardant cover for a mattress.
Each year in the United States, the ignition of mattresses in private residences and overnight accommodations results in hundreds of deaths as well as hundreds of millions of dollars in property losses. Heightened awareness of fire prevention has led to the development of standards and regulations directed to reducing the likelihood that such fires will occur. Using flame resistant fabrics as flame barriers in bedding and sleep products, including mattresses, reduces the likelihood of fires.
The Claims, rather than the Summary, define covered embodiments of the present invention. The Summary is a high-level overview of various aspects of the invention, and introduces some concepts that are further described in the Detailed Description below. The Summary is not intended to identify key or essential features of the claimed subject matter, and also is not intended to be used in isolation to determine the scope of the claimed subject matter. Instead, the claimed subject matter should be understood by reference to appropriate portions of the Specification and drawings, as well as to each claim.
In some embodiments, the present invention provides a flame-retardant mattress cover, comprising: a back layer; an inlay layer, wherein the inlay layer comprises an inherently flame-retardant material; and a face layer, wherein the back layer is configured to be closer to a mattress core covered by the flame-retardant mattress cover than the inlay layer and the face layer, wherein the inlay layer is between the back layer and the face layer.
In some embodiments, the inherently flame-retardant material comprises at least one of a cellulosic yarn or a rayon yarn.
In some embodiments, the inherently flame-retardant material comprises at least one of a continuous flame-retardant viscose staple fiber (FRVSF) or a micro-flame-retardant-viscose (micro-FRV) yarn.
In some embodiments, the inherently flame-retardant material has a limiting oxygen index (LOI) from 14 to 45.
In some embodiments, at least one of the face layer and the back layer comprises at least one of a knit fabric material or a woven fabric material.
In some embodiments, the inlay layer comprises a number of loose yarns.
In some embodiments, the inlay layer excludes a polyester yarn.
In some embodiments, the present invention provides a mattress assembly, comprising: a mattress core; and a flame-retardant mattress cover that covers the mattress core, the flame-retardant mattress cover comprising: a back layer; an inlay layer, wherein the inlay layer comprises an inherently flame-retardant material; and a face layer, wherein the back layer is closer to the mattress core than the inlay layer and the face layer, wherein the inlay layer is between the back layer and the face layer.
In some embodiments, the inherently flame-retardant material comprises at least one of a cellulosic yarn or a rayon yarn.
In some embodiments, the inherently flame-retardant material comprises at least one of a continuous flame-retardant viscose staple fiber (FRVSF) or a micro-flame-retardant-viscose (micro-FRV) yarn.
In some embodiments, the inherently flame-retardant material has a limiting oxygen index (LOI) from 14 to 45.
In some embodiments, at least one of the face layer and the back layer comprises at least one of a knit fabric material or a woven fabric material.
In some embodiments, the inlay layer comprises a number of loose yarns.
In some embodiments, the inlay layer excludes a polyester yarn.
In some embodiments, the mattress core comprises foam.
In some embodiments, the back layer contacts the mattress core.
In some embodiments, the present invention provides a method, comprising: obtaining an inherently flame-retardant material; processing the inherently flame-retardant material, thereby to form a inlay layer of a mattress cover; obtaining a back layer; obtaining a face layer; and disposing the inlay layer between the back layer and the face layer, thereby to form a flame-retardant mattress cover.
In some embodiments, the processing comprises processing the inherently flame-retardant material with at least one of heat, water, or air.
In some embodiments, the processing comprises processing the inherently flame-retardant material with at least two of heat, water, or air.
In some embodiments, the inherently flame-retardant material comprises at least one of a continuous flame-retardant viscose staple fiber (FRVSF), a viscose filament yarn (VFY), or a micro-flame-retardant-viscose (micro-FRV) yarn, and the processing comprises water texturing the inherently flame-retardant material.
For a more complete understanding of the present invention, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings, which are presented for the purpose of illustration rather than being drawn to scale, and in which:
In addition to the benefits and improvements that the Specification discloses, other objects and advantages that the Specification provides will become apparent from the following description taken in conjunction with the accompanying figures. Although the description discloses and describes detailed embodiments of the present disclosure, the disclosed embodiments are merely illustrative of the disclosure that may be embodied in various forms. In addition, each of the examples given regarding the various embodiments of the disclosure are intended to be illustrative, and not restrictive.
In an embodiment, a flame-retardant mattress cover includes a face layer, a back layer, and an inlay or inner layer disposed between the face layer and the back layer. In an embodiment, the inlay layer is a non-knit flame-retardant material.
In an embodiment, the inlay layer is an inherently flame-retardant material. In an embodiment, the inherently flame-retardant material is a cellulosic yarn. In an embodiment, the inherently flame-retardant material is a rayon yarn.
In an embodiment, the inlay layer includes a number of loose yarns. In an embodiment, the loose yarns are 2 inches in length. In an embodiment, the loose yarns are more than 2 inches in length. In an embodiment, the loose yarns are less than 2 inches in length.
In an embodiment, the loose yarns are 0.5 inches in length. In an embodiment, the loose yarns are 1 inch in length. In an embodiment, the loose yarns are 1.5 inches in length. In an embodiment, the loose yarns are 2 inches in length. In an embodiment, the loose yarns are 2.5 inches in length. In an embodiment, the loose yarns are 3 inches in length.
In an embodiment, the loose yarns are more than 0.5 inches in length. In an embodiment, the loose yarns are more than 1 inch in length. In an embodiment, the loose yarns are more than 1.5 inches in length. In an embodiment, the loose yarns are more than 2 inches in length. In an embodiment, the loose yarns are more than 2.5 inches in length. In an embodiment, the loose yarns are more than 3 inches in length.
In an embodiment, the loose yarns are less than 0.5 inches in length. In an embodiment, the loose yarns are less than 1 inch in length. In an embodiment, the loose yarns are less than 1.5 inches in length. In an embodiment, the loose yarns are less than 2 inches in length. In an embodiment, the loose yarns are less than 2.5 inches in length. In an embodiment, the loose yarns are less than 3 inches in length.
In an embodiment, the loose yarns are 0.5 inches in length to 3 inches in length. In an embodiment, the loose yarns are 1 inch in length to 3 inches in length. In an embodiment, the loose yarns are 1.5 inches in length to 3 inches in length. In an embodiment, the loose yarns are 2 inches in length to 3 inches in length. In an embodiment, the loose yarns are 2.5 inches in length to 3 inches in length.
In an embodiment, the loose yarns are 0.5 inches in length to 2.5 inches in length. In an embodiment, the loose yarns are 1 inch in length to 2.5 inches in length. In an embodiment, the loose yarns are 1.5 inches in length to 2.5 inches in length. In an embodiment, the loose yarns are 2 inches in length to 2.5 inches in length.
In an embodiment, the loose yarns are 0.5 inches in length to 2 inches in length. In an embodiment, the loose yarns are 1 inch in length to 2 inches in length. In an embodiment, the loose yarns are 1.5 inches in length to 2 inches in length. In an embodiment, the loose yarns are 0.5 inches in length to 1.5 inches in length.
In an embodiment, the loose yarns are 1 inch in length to 1.5 inches in length. In an embodiment, the loose yarns are 0.5 inches in length to 1 inch in length.
In an embodiment, processing of the inherently flame-retardant material provides bulk. In an embodiment, bulk includes imparting a three-dimensional aspect to a top surface. In an embodiment, processing of the inherently flame-retardant material provides elongation. In an embodiment, elongation includes assistance with stretch, recovery, or both stretch and recovery. In an embodiment, processing of the inherently flame-retardant material provides bulk and elongation.
In an embodiment, the material of the inlay layer is a continuous flame-retardant viscose staple fiber (FRVSF). In an embodiment, the material of the inlay layer undergoes application of one or more drawn textured yarn (DTY) techniques.
In an embodiment, the material of the inlay layer is a viscose filament yarn (VFY). In an embodiment, processing of the VFY includes adding a flame-retardant substance into a purified and/or liquid cellulose material, prior to the material going through a spinneret. In an embodiment, the material then undergoes application of DTY techniques.
In an embodiment, the material of the inlay layer is a micro-flame-retardant-viscose (micro-FRV) yarn.
In an embodiment, the material of the inlay layer undergoes processing with heat. In an embodiment, the material of the inlay layer undergoes processing with water. In an embodiment, the material of the inlay layer undergoes processing with air. In an embodiment, the material of the inlay layer undergoes processing with more than one of heat, water, and/or air. In an embodiment, the material of the inlay layer undergoes water texturing. In an embodiment, the water-textured material of the inlay layer includes one or more of FRVSF, VFY, and/or micro-FRV yarn.
In an embodiment, the material of the inlay layer is a 600 denier, 90 filament yarn. In an embodiment, texturing the 600 denier, 90 filament yarn creates a 2 ply, 600 denier, 90 filament yarn. In an embodiment, the texturing is air texturing. In an embodiment, the texturing is water texturing.
In an embodiment, the material of the inlay layer is a 400 denier yarn. In an embodiment, the material of the inlay layer is a 450 denier yarn. In an embodiment, the material of the inlay layer is a 500 denier yarn. In an embodiment, the material of the inlay layer is a 550 denier yarn. In an embodiment, the material of the inlay layer is a 600 denier yarn. In an embodiment, the material of the inlay layer is a 650 denier yarn. In an embodiment, the material of the inlay layer is a 700 denier yarn. In an embodiment, the material of the inlay layer is a 750 denier yarn. In an embodiment, the material of the inlay layer is an 800 denier yarn.
In an embodiment, the material of the inlay layer is a yarn with a denier value that is less than 400 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is less than 450 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is less than 500 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is less than 550 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is less than 600 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is less than 650 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is less than 700 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is less than 750 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is less than 800 denier.
In an embodiment, the material of the inlay layer is a yarn with a denier value that is more than 400 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is more than 450 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is more than 500 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is more than 550 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is more than 600 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is more than 650 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is more than 700 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is more than 750 denier. In an embodiment, the material of the inlay layer is a yarn with a denier value that is more than 800 denier.
In an embodiment, the material of the inlay layer is a 400 denier yarn to an 800 denier yarn. In an embodiment, the material of the inlay layer is a 450 denier yarn to an 800 denier yarn. In an embodiment, the material of the inlay layer is a 500 denier yarn to an 800 denier yarn. In an embodiment, the material of the inlay layer is a 550 denier yarn to an 800 denier yarn. In an embodiment, the material of the inlay layer is a 600 denier yarn to an 800 denier yarn. In an embodiment, the material of the inlay layer is a 650 denier yarn to an 800 denier yarn. In an embodiment, the material of the inlay layer is a 700 denier yarn to an 800 denier yarn. In an embodiment, the material of the inlay layer is a 750 denier yarn to an 800 denier yarn.
In an embodiment, the material of the inlay layer is a 400 denier yarn to an 750 denier yarn. In an embodiment, the material of the inlay layer is a 450 denier yarn to an 750 denier yarn. In an embodiment, the material of the inlay layer is a 500 denier yarn to an 750 denier yarn. In an embodiment, the material of the inlay layer is a 550 denier yarn to an 750 denier yarn. In an embodiment, the material of the inlay layer is a 600 denier yarn to an 750 denier yarn. In an embodiment, the material of the inlay layer is a 650 denier yarn to a 750 denier yarn. In an embodiment, the material of the inlay layer is a 700 denier yarn to a 750 denier yarn.
In an embodiment, the material of the inlay layer is a 400 denier yarn to a 700 denier yarn. In an embodiment, the material of the inlay layer is a 450 denier yarn to a 700 denier yarn. In an embodiment, the material of the inlay layer is a 500 denier yarn to a 700 denier yarn. In an embodiment, the material of the inlay layer is a 550 denier yarn to a 700 denier yarn. In an embodiment, the material of the inlay layer is a 600 denier yarn to a 700 denier yarn. In an embodiment, the material of the inlay layer is a 650 denier yarn to a 700 denier yarn.
In an embodiment, the material of the inlay layer is a 400 denier yarn to a 650 denier yarn. In an embodiment, the material of the inlay layer is a 450 denier yarn to a 650 denier yarn. In an embodiment, the material of the inlay layer is a 500 denier yarn to a 650 denier yarn. In an embodiment, the material of the inlay layer is a 550 denier yarn to a 650 denier yarn. In an embodiment, the material of the inlay layer is a 600 denier yarn to a 650 denier yarn.
In an embodiment, the material of the inlay layer is a 400 denier yarn to a 600 denier yarn. In an embodiment, the material of the inlay layer is a 450 denier yarn to a 600 denier yarn. In an embodiment, the material of the inlay layer is a 500 denier yarn to a 600 denier yarn. In an embodiment, the material of the inlay layer is a 550 denier yarn to a 600 denier yarn.
In an embodiment, the material of the inlay layer is a 400 denier yarn to a 550 denier yarn. In an embodiment, the material of the inlay layer is a 450 denier yarn to a 550 denier yarn. In an embodiment, the material of the inlay layer is a 500 denier yarn to a 550 denier yarn.
In an embodiment, the material of the inlay layer is a 400 denier yarn to a 500 denier yarn. In an embodiment, the material of the inlay layer is a 450 denier yarn to a 500 denier yarn. In an embodiment, the material of the inlay layer is a 400 denier yarn to a 450 denier yarn.
In an embodiment, the material of the inlay layer includes silicate as a flame-retardant agent.
In an embodiment, the material of the inlay has a limiting oxygen index (LOI) from 14 to 45. In an embodiment, the material of the inlay has an LOI from 28 to 30. In an embodiment, the material of the inlay has an LOI of at least 25. In an embodiment, the material of the inlay has an LOI of 25.
In an embodiment, the material of the inlay has an LOI of 14. In an embodiment, the material of the inlay has an LOI of 15. In an embodiment, the material of the inlay has an LOI of 20. In an embodiment, the material of the inlay has an LOI of 25. In an embodiment, the material of the inlay has an LOI of 30. In an embodiment, the material of the inlay has an LOI of 35. In an embodiment, the material of the inlay has an LOI of 40. In an embodiment, the material of the inlay has an LOI of 45. In an embodiment, the material of the inlay has an LOI of 50.
In an embodiment, the material of more than the inlay has an LOI of more than 14. In an embodiment, the material of more than the inlay has an LOI of more than 15. In an embodiment, the material of more than the inlay has an LOI of more than 20. In an embodiment, the material of more than the inlay has an LOI of more than 25. In an embodiment, the material of more than the inlay has an LOI of more than 30. In an embodiment, the material of more than the inlay has an LOI of more than 35. In an embodiment, the material of more than the inlay has an LOI of more than 40. In an embodiment, the material of more than the inlay has an LOI of more than 45. In an embodiment, the material of more than the inlay has an LOI of more than 50.
In an embodiment, the material of less than the inlay has an LOI of less than 14. In an embodiment, the material of less than the inlay has an LOI of less than 15. In an embodiment, the material of less than the inlay has an LOI of less than 20. In an embodiment, the material of less than the inlay has an LOI of less than 25. In an embodiment, the material of less than the inlay has an LOI of less than 30. In an embodiment, the material of less than the inlay has an LOI of less than 35. In an embodiment, the material of less than the inlay has an LOI of less than 40. In an embodiment, the material of less than the inlay has an LOI of less than 45. In an embodiment, the material of less than the inlay has an LOI of less than 50.
In an embodiment, the material of the inlay has an LOI of 14 to 50. In an embodiment, the material of the inlay has an LOI of 15 to 50. In an embodiment, the material of the inlay has an LOI of 20 to 50. In an embodiment, the material of the inlay has an LOI of 25 to 50. In an embodiment, the material of the inlay has an LOI of 30 to 50. In an embodiment, the material of the inlay has an LOI of 35 to 50. In an embodiment, the material of the inlay has an LOI of 40 to 50. In an embodiment, the material of the inlay has an LOI of 45 to 50.
In an embodiment, the material of the inlay has an LOI of 14 to 45. In an embodiment, the material of the inlay has an LOI of 15 to 45. In an embodiment, the material of the inlay has an LOI of 20 to 45. In an embodiment, the material of the inlay has an LOI of 25 to 45. In an embodiment, the material of the inlay has an LOI of 30 to 45. In an embodiment, the material of the inlay has an LOI of 35 to 45. In an embodiment, the material of the inlay has an LOI of 40 to 45.
In an embodiment, the material of the inlay has an LOI of 14 to 40. In an embodiment, the material of the inlay has an LOI of 15 to 40. In an embodiment, the material of the inlay has an LOI of 20 to 40. In an embodiment, the material of the inlay has an LOI of 25 to 40. In an embodiment, the material of the inlay has an LOI of 30 to 40. In an embodiment, the material of the inlay has an LOI of 35 to 40.
In an embodiment, the material of the inlay has an LOI of 14 to 35. In an embodiment, the material of the inlay has an LOI of 15 to 35. In an embodiment, the material of the inlay has an LOI of 20 to 35. In an embodiment, the material of the inlay has an LOI of 25 to 35. In an embodiment, the material of the inlay has an LOI of 30 to 35.
In an embodiment, the material of the inlay has an LOI of 14 to 30. In an embodiment, the material of the inlay has an LOI of 15 to 30. In an embodiment, the material of the inlay has an LOI of 20 to 30. In an embodiment, the material of the inlay has an LOI of 25 to 30.
In an embodiment, the material of the inlay has an LOI of 14 to 25. In an embodiment, the material of the inlay has an LOI of 15 to 25. In an embodiment, the material of the inlay has an LOI of 20 to 25.
In an embodiment, the material of the inlay has an LOI of 14 to 20. In an embodiment, the material of the inlay has an LOI of 15 to 20. In an embodiment, the material of the inlay has an LOI of 14 to 15.
In an embodiment, the inlay layer conforms to a flame-retardancy standard that does not exceed a maximum heat release rate of 200 kW with a total heat release of 15 Mj (megajoules), thereby meeting the requirements of CPSC 16 CFR 1633 testing methodology that is applied to mattresses.
In an embodiment, the inlay layer prevents ignition of the mattress exposed to an open flame for one minute or less. In an embodiment, the inlay layer prevents ignition of the mattress exposed to an open flame for more than one minute
In an embodiment, the inlay layer excludes a polyester yarn. In an embodiment, the inlay layer provides similar elongation and bulk as a polyester yarn.
In an embodiment, at least one of the face layer and the back layer is a knit fabric material. In an embodiment, both of the face layer and the back layer are knit fabrics. In an embodiment, both of the face layer and the back layer are knit together.
In an embodiment, at least one of the face layer and the back layer is a woven fabric material. In an embodiment, both of the face layer and the back layer are woven fabrics. In an embodiment, both of the face layer and the back layer are woven together.
In an embodiment, at least one of the face layer and the back layer are not formed from a flame-retardant and/or flame-resistant material. In an embodiment, both of the face layer and the back layer are not formed from a flame-retardant and/or flame-resistant material.
In an embodiment, the mattress cover covers a top portion of the mattress core. In an embodiment, the mattress cover covers the entire mattress core. In some embodiments, the core is composed of foam.
With reference to the figures,
As shown, the back layer 111 may be the layer that is most adjacent (e.g., closest) to the mattress core 150. At least a portion of the face layer 115 may be adjacent a person resting on the cover 110 covering the mattress core 150. The inlay layer 113 may be between the back layer 111 and the face layer 115.
In an embodiment, the back layer 111 may cover the mattress core 150 directly—that is, there may be no additional layer disposed of the cover 110 disposed between the back layer 111 and the mattress core 150. In an embodiment, the cover 110 may include one or more additional layers (not shown) between back the layer 111 and the mattress core 150.
In an embodiment, the face layer 115 may be the outermost layer of the cover 110—that is, there may be no additional layer of the cover 110 disposed on the face layer 115. In an embodiment, the cover 110 may include one or more additional layers (not shown) disposed on the face layer 115.
In an embodiment, the inlay layer 113 may directly contact either or both of back the layer 111 and the face layer 115—that is, without any additional layer disposed in the cover 110. In an embodiment, the cover 110 may include one or more additional layers (not shown) disposed between the inlay layer 113 and of the back layer 111, may include one or more additional layers (not shown) disposed between the inlay layer 113 and the face layer 115, and/or may include one or more additional layers (not shown) disposed between the inlay layer 113 and the back layer 111 as well as one or more additional layers (not shown) disposed between the inlay layer 113 and the face layer 115.
In some embodiments, the present invention provides obtaining one or more of the layers, and forming the mattress cover.
In an embodiment, the disclosure may be applied to another bedding and/or sleep product. In an embodiment, a bed topper, a blanket, a duvet, or a comforter, for example, may have the structure of the disclosed flame-retardant mattress cover 110, including one or more of the disclosed back layer, the disclosed inlay layer, and/or the disclosed face layer.
Variations, modifications, and alterations to embodiments of the present disclosure described above will make themselves apparent to those skilled in the art. All such variations, modifications, alterations and the like are intended to fall within the spirit and scope of the present disclosure, limited solely by the appended claims.
While several embodiments of the present disclosure have been described, it is understood that these embodiments are illustrative only, and not restrictive, and that many modifications may become apparent to those of ordinary skill in the art. For example, all dimensions discussed herein are provided as examples only, and are intended to be illustrative and not restrictive.
Any feature or element that is positively identified in this description may also be specifically excluded as a feature or element of an embodiment of the present as defined in the claims.
The disclosure described herein may be practiced in the absence of any element or elements, limitation or limitations, which is not specifically disclosed herein. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the disclosure.
The present application claims priority to U.S. Provisional Patent Application No. 63/388,369, filed on Jul. 12, 2022, the disclosure of which is incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63388369 | Jul 2022 | US |
