US20240023725A1

Movatterモバイル変換

Info

Publication number: US20240023725A1
Application number: US18/221,205
Authority: US
Inventors: Christopher Keith Martin; Garrett Graven
Original assignee: Precision Textiles LLC
Current assignee: Precision Textiles LLC
Priority date: 2022-07-12
Filing date: 2023-07-12
Publication date: 2024-01-25

Abstract

A flame-retardant mattress cover, including a back layer; an inlay layer, where the inlay layer has an inherently flame-retardant material; and a face layer, where 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, where the inlay layer is between the back layer and the face layer.

Description

CROSS-REFERENCE TO RELATED APPLICATION

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.

FIELD

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.

BACKGROUND

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.

SUMMARY

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 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.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

FIG.1 is an isometric view of an assembly, including a mattress cover covering a mattress; and

FIG.2 is a cross-sectional view, taken along line II-II ofFIG.1.

DETAILED DESCRIPTION

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 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 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,FIG.1 is an isometric view of a mattress-and-cover assembly100, including amattress cover110 covering amattress core150; andFIG.2 is a cross-sectional view, taken along line II-II, of theassembly100, thecover110, and themattress core150, ofFIG.1. Referring toFIGS.1 and2, themattress cover110 may include three layers: aback layer111; an inlay orinner layer113; and aface layer115. One, two, or three of theback layer111, theinlay layer113, and theface layer115 may be in accordance with the above description. In some embodiments, themattress cover110 is in accordance with the flame-retardant mattress cover described above.

As shown, theback layer111 may be the layer that is most adjacent (e.g., closest) to themattress core150. At least a portion of theface layer115 may be adjacent a person resting on thecover110 covering themattress core150. Theinlay layer113 may be between theback layer111 and theface layer115.

In an embodiment, theback layer111 may cover themattress core150 directly—that is, there may be no additional layer disposed of thecover110 disposed between theback layer111 and themattress core150. In an embodiment, thecover110 may include one or more additional layers (not shown) between back thelayer111 and themattress core150.

In an embodiment, theface layer115 may be the outermost layer of thecover110—that is, there may be no additional layer of thecover110 disposed on theface layer115. In an embodiment, thecover110 may include one or more additional layers (not shown) disposed on theface layer115.

In an embodiment, theinlay layer113 may directly contact either or both of back thelayer111 and theface layer115—that is, without any additional layer disposed in thecover110. In an embodiment, thecover110 may include one or more additional layers (not shown) disposed between theinlay layer113 and of theback layer111, may include one or more additional layers (not shown) disposed between theinlay layer113 and theface layer115, and/or may include one or more additional layers (not shown) disposed between theinlay layer113 and theback layer111 as well as one or more additional layers (not shown) disposed between theinlay layer113 and theface layer115.

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 cover110, 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.

Claims

1. 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.

2. The flame-retardant mattress cover ofclaim 1, wherein the inherently flame-retardant material comprises at least one of a cellulosic yarn or a rayon yarn.

3. The flame-retardant mattress cover ofclaim 1, wherein 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.

4. The flame-retardant mattress cover ofclaim 1, wherein the inherently flame-retardant material has a limiting oxygen index (LOI) from 14 to 45.

5. The flame-retardant mattress cover ofclaim 1, wherein 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.

6. The flame-retardant mattress cover ofclaim 1, wherein the inlay layer comprises a number of loose yarns.

7. The flame-retardant mattress cover ofclaim 1, wherein the inlay layer excludes a polyester yarn.

8. 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.

9. The mattress assembly ofclaim 8, wherein the inherently flame-retardant material comprises at least one of a cellulosic yarn or a rayon yarn.

10. The mattress assembly ofclaim 8, wherein 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.

11. The mattress assembly ofclaim 8, wherein the inherently flame-retardant material has a limiting oxygen index (LOI) from 14 to 45.

12. The mattress assembly ofclaim 8, wherein 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.

13. The mattress assembly ofclaim 8, wherein the inlay layer comprises a number of loose yarns.

14. The mattress assembly ofclaim 8, wherein the inlay layer excludes a polyester yarn.

15. The mattress assembly ofclaim 8, wherein the mattress core comprises foam.

16. The mattress assembly ofclaim 8, wherein the back layer contacts the mattress core.

17. 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; and

obtaining a face layer;

disposing the inlay layer between the back layer and the face layer, thereby to form a flame-retardant mattress cover.

18. The method ofclaim 17, wherein the processing comprises processing the inherently flame-retardant material with at least one of heat, water, or air.

19. The method ofclaim 17, wherein the processing comprises processing the inherently flame-retardant material with at least two of heat, water, or air.

20. The method ofclaim 17, wherein 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 wherein the processing comprises water texturing the inherently flame-retardant material.