Flame barrier cushioning foams and upholstery layer construction incorporating such foams

• US 20050177950A1
• Filed: 02/17/2004
• Published: 08/18/2005
• Est. Priority Date: 02/17/2004
• Status: Abandoned Application

• Current Assignee: Foamex Innovations Operating Company
• Original Assignee: Foamex LP (FXI Holdings Incorporated)
• Inventors: Deery, William H., Tursi, Daniel V. Jr., Niederoest, Beat B., Chan, Chiu Y.
• Application Number:
  US10/780,545
• Publication Number:
  US 20050177950A1
• Time in Patent Office: Days
• US Class Current: 5/698
• CPC Class Codes: A47C 27/14 with foamed material inlays
• CPC Class Codes: A47C 31/001 Fireproof means
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 2421/00 Characterised by the use of unspecified rubbers
• CPC Class Codes: C08J 2427/00 Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
• CPC Class Codes: C08J 2431/00 Characterised by the use of copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, or carbonic acid, or of a haloformic acid
• CPC Class Codes: C08J 2475/00 Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
• CPC Class Codes: C08J 9/365 Coating
• CPC Class Codes: C08J 9/40 Impregnation

Abstract

An upholstery construction for a mattress or an article of furniture includes a flame barrier foam sheet proximate to the back face of a surface fabric layer. The flame barrier foam sheet is formed by coating or impregnating a polyurethane sheet with an aqueous solution of one or more binder(s), such as but not limited to a polyvinyl chloride copolymer or an acrylic latex binder, and one or more flame retardant(s), such as but not limited to aluminum trihydrate or melamine. The flame barrier foam sheet with dried binder(s) and flame retardant(s) not only resists flame ignition but also retains its cushioning properties.

Claims

1. An upholstery construction for a mattress or an article of furniture, comprising:

a fabric layer having a front surface and a back surface;

a flame barrier foam sheet proximate to the back surface of the fabric layer,

wherein said flame barrier foam sheet comprises a polyurethane foam sheet that is coated or impregnated with a coating of one or more binders and one or more flame retardants, and dried, further wherein said flame barrier foam sheet after it has been coated or impregnated and dried has a density of in the range of about 1.0 to 6.0 pcf and an compression force deflection (CFD₂₅) of in the range of about 0.1 to 0.4 psi.

2. The upholstery construction of claim 1, wherein the flame barrier foam sheet is adjacent to the back surface of the fabric layer.

3. The upholstery construction of claim 1, wherein the upholstery construction is quilted such as by stitching together the flame barrier foam sheet and fabric layer in combination with one or more other layers.

4. The upholstery construction of claim 1, wherein the binder in the coating has a glass transition temperature (Tg) of less than about 10°

C.

5. The upholstery construction of claim 1, wherein the binder in the coating has a glass transition temperature (Tg) of less than about 0°

C.

6. The upholstery construction of claim 1, wherein the coated or impregnated flame barrier foam sheet has a density of from about 2.0 to about 4.5 pcf.

7. The upholstery construction of claim 1, wherein the binder in the coating is selected from the group consisting of:

acrylic latex, natural rubber latex, polyvinyl chloride copolymers, ethylene vinyl chloride copolymers, vinyl acetate, vinylidene chloride copolymers, vinyl acetate ethylene copolymers, neoprene, acrylonitrile, polychloroprene, polyurethane, and mixtures thereof.

8. The upholstery construction of claim 1, wherein the binder in the coating has a chlorine content of at least about 20% on a dry weight basis.

9. The upholstery construction of claim 1, wherein the flame retardant in the coating is selected from the group consisting of:

melamine, a melamine derivative, aluminum trihydrate, polyvinyl chloride, antimony oxide, expandable graphite, magnesium hydroxide, urea, an amino phosphorous compound such as ammonium polyphosphate, and mixtures thereof.

10. The upholstery construction of claim 9, wherein the coating further comprises a liquid flame retardant.

11. The upholstery construction of claim 1, wherein the flame barrier foam sheet prior to being coated or impregnated has a density of less than about 1.5 pcf and an indentation force deflection (IFD₂₅) of about 15 lb-force or less.

12. The upholstery construction of claim 1, further comprising:

a second foam sheet installed proximate to the flame barrier foam sheet.

13. The upholstery construction of claim 12, wherein the second foam sheet is installed adjacent to the flame barrier foam sheet and between the flame barrier foam sheet and a backing sheet.

14. The upholstery construction of claim 1, wherein the flame barrier sheet resists yellowing when exposed to ultraviolet light.

15. The upholstery construction of claim 1, wherein the flame barrier sheet resists yellowing when exposed to one or more NO_x gases.

16. A mattress or article of upholstered furniture incorporating the upholstery construction of claim 1.

17. A mattress or article of upholstered furniture incorporating the upholstery construction of claim 13.