Mattress with substantially uniform fire resistance characteristic

• US 20070006383A1
• Filed: 07/06/2005
• Published: 01/11/2007
• Est. Priority Date: 07/06/2005
• Status: Abandoned Application

• Current Assignee: Polyester Fibers, LLC
• Original Assignee: Polyester Fibers, LLC
• Inventors: Van Becelaere, Karl, Ogle, Steven
• Application Number:
  US11/175,423
• Publication Number:
  US 20070006383A1
• Time in Patent Office: Days
• US Class Current: 5/698
• CPC Class Codes: A47C 27/122 with special fibres, such as acrylic thread, coconut, horsehair
• CPC Class Codes: A47C 31/001 Fireproof means
• CPC Class Codes: D04H 1/02 Cotton wool; Wadding
• CPC Class Codes: D04H 1/42 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
• CPC Class Codes: D04H 1/43828 sheath-core
• CPC Class Codes: D04H 1/43835 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/54 by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485

Abstract

A fire resistant (FR) mattress comprising a core comprising a first densified nonwoven fiber batt, and a ticking comprising a first fabric, the ticking enclosing the core and the fill layer, wherein the core and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress. In another aspect, the invention includes a mattress comprising a core, a plurality of substantially adjacent similarly oriented spring coils arranged in a common plane within the core, and a ticking comprising a first fabric, the ticking enclosing the core and the fill layer, wherein the core and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.

Claims

1. A fire resistant (FR) mattress comprising:

a core comprising a first densified nonwoven fiber batt; and

a ticking comprising a first fabric, the ticking enclosing the core and the fill layer;

wherein the core and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.

2. The mattress of claim 1 further comprising:

a fill layer comprising a first high-loft nonwoven fiber batt, the fill layer positioned between the core and the ticking; and

wherein the core, the fill layer, and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.

3. The mattress of claim 2 wherein the common fiber composition consists essentially of synthetic fibers.

4. The mattress of claim 3 wherein the mattress further comprises a plurality of similarly oriented spring coils arranged in a common plane within the core.

5. The mattress of claim 4 wherein a coil spring path is adjacent to each of the spring coils in the core.

6. The mattress of claim 5 further comprising an insulator pad comprised of a second densified nonwoven fiber batt consisting essentially of the common fiber composition, the insulator pad positioned between the core and the fill layer such that the insulator pad separates the core from the fill layer.

7. The mattress of claim 6 further comprising:

a quilt panel positioned above the fill layer, the quilt panel comprising;

a quilt backing comprised a second fabric consisting essentially of the common fiber composition; and

a quilt layer comprised a second high-loft nonwoven fiber batt consisting essentially of the common fiber composition.

8. The mattress of claim 7 further comprising:

a tape comprised of a third fabric consisting essentially of the common fiber composition; and

a thread comprising at least one filament consisting essentially of the common fiber composition;

wherein the tape and the thread join the edges of the ticking together, thereby creating a seam.

9. The mattress of claim 8 wherein the core, the insulator pad, the fill layer, the ticking, the quilt panel, the tape, and the thread are fire resistant.

10. The mattress of claim 9 wherein the core, the insulator pad, the fill layer, the ticking, the quilt panel, the tape, and the thread are substantially free of fiberglass.

11. The mattress of claim 10 wherein the common fiber composition consists essentially of fibers selected from the group consisting of:

polyester and polypropylene.

12. A mattress comprising:

a core;

a plurality of substantially adjacent similarly oriented spring coils arranged in a common plane within the core; and

a ticking comprising a first fabric, the ticking enclosing the core and the fill layer;

wherein the core and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.

13. The mattress of claim 12 further comprising:

a fill layer comprising a first high-loft nonwoven fiber batt, the fill layer positioned between the core and the ticking; and

wherein the core, the fill layer, and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.

14. The mattress of claim 13 wherein the common fiber composition consists essentially of synthetic fibers.

15. The mattress of claim 14 wherein the core further comprises a first densified nonwoven fiber batt.

16. The mattress of claim 15 wherein a coil spring path is adjacent to each of the spring coils in the core.

17. The mattress of claim 16 further comprising an insulator pad comprised of a second densified nonwoven fiber batt consisting essentially of the common fiber composition, the insulator pad positioned between the core and the fill layer such that the insulator pad separates the core from the fill layer.

18. The mattress of claim 17 further comprising:

a quilt panel positioned above the fill layer, the quilt panel comprising;

a quilt backing comprised a second fabric consisting essentially of the common fiber composition; and

a quilt layer comprised a second high-loft nonwoven fiber batt consisting essentially of the common fiber composition.

19. The mattress of claim 18 further comprising:

a tape comprised of a third fabric consisting essentially of the common fiber composition; and

a thread comprising at least one filament consisting essentially of the common fiber composition;

wherein the tape and the thread join the edges of the ticking together, thereby creating a seam.

20. A mattress comprising:

a core;

a plurality of substantially adjacent similarly oriented spring coils arranged in a common plane within the core;

a fill layer comprising a first high-loft nonwoven fiber batt, the fill layer positioned above the core;

an insulator pad comprised of a first densified nonwoven fiber batt, the insulator pad positioned between the core and the fill layer such that the insulator pad separates the core from the fill layer;

a ticking comprising a first fabric, the ticking enclosing the core, the insulator pad, and the fill layer;

a quilt panel positioned above the fill layer, the quilt panel comprising;

a quilt backing comprised a second fabric; and

a quilt layer comprised a second high-loft nonwoven fiber batt;

a tape comprised of a third fabric consisting essentially of the common fiber composition; and

a thread comprising at least one filament consisting essentially of the common fiber composition;

wherein the tape and the thread join the edges of the ticking together, thereby creating a seam; and

wherein the core, the fill layer, the insulator pad, the quilt backing, the quilt layer, the tape, the thread, and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.