Fire-resistant mattress and high strength fire-retardant composite

• US 4,504,991 A
• Filed: 06/07/1982
• Issued: 03/19/1985
• Est. Priority Date: 06/07/1982
• Status: Expired due to Fees

• Current Assignee: Ohio Mattress Company Licensing and Components Group (Tempur Sealy International, Inc.)
• Original Assignee: Sealy Incorporated (Tempur Sealy International, Inc.)
• Inventors: Klancnik, Alvin R.
• Primary Examiner(s): Van Balen, William J.
• Application Number:
  US06/386,101
• Time in Patent Office: 1,016 Days
• Field of Search: 428/251, 428/252, 428/268, 428/273, 428/285, 428/290, 428/304.4, 428/319.1, 428/71, 428/76, 428/228, 428/255, 428/316.6, 5/459, 5/483, 297/DIG. 5
• US Class Current: 5/698
• CPC Class Codes: A47C 31/001 Fireproof means
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 5/028 Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: Y10S 297/05 Fireproof
• CPC Class Codes: Y10T 428/233 Foamed or expanded material encased
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 442/136 Including a foam layer
• CPC Class Codes: Y10T 442/3325 Including a foamed layer or component
• CPC Class Codes: Y10T 442/647 Including a foamed layer or component

Abstract

An improved mattress includes a composite made of a layer of a fire retardant material capable of providing a heat barrier bonded to a layer of high tensile strength material, such as fiberglass fabric. The composite encloses at least most and generally practically all of the flammable ingredients of the mattress. When exposed to a fire, the fire retardant material chars, thereby creating a heat shield that protects the inside of the mattress while the high tensile strength material holds the mattress together and prevents the mattress from bursting open thereby exposing the flammable ingredients thereof to the fire.

The composite of the present invention is made by bonding a fire-retardant material capable of providing a heat barrier to a high tensile strength material.

Claims

1. In a mattress comprising a cover and a plurality of flammable components, a composite comprising a first layer of a fire-retardant composition bonded to a second layer of a material having a high tensile strength in the directions along its surface, the composite substantially enclosing the flammable components and oriented such that the material having a high tensile strength is disposed adjacent to at least one of the flammable components and the fire-retardant composition is disposed adjacent to the cover.

2. The composite claimed in claim 1 wherein said first layer comprises a fire-retardant neoprene foam and said second layer comprises a fiberglass fabric.

3. The composite claimed in claim 1 wherein said first layer comprises a fire-retardant neoprene foam and said second layer is made of fiberglass fabric comprising at least one retaining layer of material bonded to a mesh of fiberglass fibers so as to prevent said fiberglass fibers from breaking off.

4. The composite claimed in claims 1, 2 or 3 further comprising a third layer composed of a fire retardant composition, said third layer being bonded to said second layer on the opposite side from said first layer.

5. The composite claimed in claim 4 wherein said third layer is made of fire-retardant neoprene foam.

6. In a mattress, the improvement comprising:

a composite layer enclosing substantially all of the flammable components of said mattress, said composite layer comprising a first layer of a fire retardant composition bonded to a second layer of a material having high tensile strength in directions along its surface, said first layer of said composite layer charring upon being exposed to fire to protect the inside of said mattress from heat and fire and said second layer preventing the mattress from bursting open upon being exposed to fire.

7. The mattress of claim 6 wherein:

said first layer is made of fire-retardant neoprene foam and said second layer is made of a fiberglass fabric.

8. The mattress of claim 6 wherein said first layer is made of a fire-retardant neoprene foam and said second layer is made of a fiberglass fabric comprising a layer of material bonded to a mesh of fiberglass fibers so as to prevent said fiberglass fibers from breaking off.

9. The mattress of claims 6, 7 or 8 wherein said composite layer further comprises a third layer made of a fire retardant composition bonded to said second layer on the opposite side from said first layer.

10. The mattress of claim 9 wherein said third layer is made of fire-retardant neoprene foam.