CONSTRUCTIONAL ARRANGEMENT APPLIED TO A MATTRESS

Description

"Constructive arrangement applied to a mattress" FIELD OF THE INVENTION

[0001] The present invention relates to a mattress with flame-retardant properties, thermal insulation, non-toxic and non-proliferating fungi and bacteria, intended to increase fire safety in residential, commercial and hospital environments. More specifically, it is a mattress made of fire-resistant materials and with a structured design to minimize the spread of flames. STATE OF THE ART

[0002] In today's market, mattresses of various configurations utilize layers of foam, fabrics, and insulating materials for different purposes, including comfort, anatomical support, and thermal protection. However, known solutions often present limitations regarding flame safety and the efficiency of the materials used, making it necessary to have an optimized structure that combines comfort, safety, and greater durability.

[0003] Document BR202017018261-0 describes an arrangement applied to a mattress equipped with a built-in thermal heating system, in which a thermal sheet forms part of the mattress's intermediate layer. This solution aims to reduce the risks of electric shocks, short circuits, and burns. However, this technology presents some disadvantages regarding flame propagation, such as the dependence on a built-in electrical system, which can compromise the safety and longevity of the mattress, in addition to requiring more maintenance. Furthermore, the described structure does not efficiently address the prevention of fungal and bacterial growth, unlike our proposal.

[0004] Furthermore, this state-of-the-art document has several layers, making manufacturing and the final product costly.

[0005] The present invention seeks to solve deficiencies of conventional mattresses by offering a multi-layered composition. Petition 870250027502, dated 04 / 04 / 2025, page 9 / 26 2 / 13 innovative, integrating high-performance materials to enhance various aspects of the product. Fire safety is significantly increased due to the use of flame-retardant materials, which slow the spread of fire and reduce the risks associated with domestic accidents. Furthermore, the mattress's structural resistance is enhanced through the selection of high-density foams and strategically positioned layers to ensure greater durability and stability over time. Another essential benefit is the exceptional comfort provided to the user, achieved through a balanced distribution of layers that promote ergonomic adaptation to the body, minimizing pressure points and promoting more restful sleep.

[0006] Furthermore, the application of this technology is particularly relevant in demanding environments, such as prisons and naval platforms, which represent the main focus of our work. In these contexts, the adverse conditions and specific user needs require high-performance solutions in terms of safety, durability, and comfort. The innovation incorporated into these mattresses aims to meet these requirements, offering a product that not only improves sleep quality but also contributes to the safety and well-being of users in challenging environments.

[0007] Thus, the present invention represents a significant advance in mattress technology, offering a highly efficient, safe and comfortable product for the end consumer, especially in demanding contexts such as prisons and naval platforms. SUMMARY OF THE INVENTION

[0008] The present invention relates to a constructive arrangement applied to a mattress, designed to offer greater fire safety, structural strength and enhanced comfort.

[0009] The structure is composed of a multi-layered configuration, including a self-extinguishing polyurethane foam base, a flame-retardant polyester board such as a flame-retardant board. Petition 870250027502, dated 04 / 04 / 2025, page 10 / 26 3 / 13 Permanent Flame Retardant (PRF), a quilted blanket with flame-retardant PRF microfibers and a flame-retardant PRF fabric lining.

[00010] Unlike the prior art, this solution focuses on containing the spread of flames, making the mattress safer. The invention also reduces manufacturing costs and improves product durability, avoiding risks such as short circuits and overheating.

[00011] The combination of materials used provides better weight distribution, greater thermal insulation, and resistance to fungi and bacteria, resulting in a highly safe and comfortable mattress for users. BRIEF DESCRIPTION OF THE DRAWINGS

[00012] Examples of modalities will be described and explained with specificity and additional details through the use of the attached drawings in which:

[00013] Figure 1 is an example of the multilayer structure of the present invention;

[00014] Figure 2 shows the test specimen of the material tested (seamed face);

[00015] Figure 3 shows the test specimen of the material tested (smooth face);

[00016] Figures 4 and 5 show the test specimen in the cigarette test (Figure 4) and detail of the carbonization after the test (Figure 5).

[00017] The following detailed description, together with the attached figures, will provide a more comprehensive overview of the object, features, and advantages of the disclosed technology.

[00018] This description aims to present the aspects of the technology in a clearer and more detailed way, allowing for a complete and in-depth understanding of the benefits and features offered. Through this Petition 870250027502, dated 04 / 04 / 2025, page 11 / 26 4 / 13 For a more detailed explanation, readers will be able to more clearly perceive the contributions and innovations brought about by the technology described.

[00019] It should be understood that both the preceding general description and the following detailed description are examples and explanations and are not restrictive of the invention as claimed. It should be understood that the various embodiments are not limited to the arrangements and instrumentation illustrated in the drawings. It should also be understood that the embodiments may be combined or other embodiments may be used and that structural changes, unless claimed, may be made without departure from the scope of the various embodiments of the invention. The following detailed description should therefore not be taken in a limiting sense. DETAILED DESCRIPTION

[00020] All examples and conditional language described in this document are intended for pedagogical purposes to help the reader understand the invention and the concepts contributed by the inventor to advance the state of the art and should be interpreted as being without limitation to such examples and conditions specifically cited. Although embodiments of the present invention have been described in detail, it should be understood that various alterations, substitutions and changes may be made to this document without departing from the objective and scope of the invention.

[00021] In order for the invention to be better understood, it is described below with particular reference to the preferred features of specific elements of the invention.

[00022] In one embodiment, the present invention relates to a mattress with PRF flame retardant properties, with thermal insulation, non-toxic and non-proliferating fungi and bacteria, intended to increase fire safety in residential, commercial and hospital environments. More specifically, it is a mattress made of fire-resistant materials and with a structured design to minimize the spread of flames. Petition 870250027502, dated 04 / 04 / 2025, page 12 / 26 5 / 13

[00023] The present invention offers several advantages over conventional solutions, including: • Increased safety due to the use of flame-retardant PRF materials. • Improved thermal insulation, providing greater user comfort. • Greater durability, as the materials used resist wear and tear and deformation over time. • Prevention against the proliferation of fungi and bacteria due to the composition of the materials. • Absence of embedded electrical systems, reducing the risks of short circuits and failures. • Optimized structure with fewer layers, resulting in a more efficient and economical manufacturing process.

[00024] The proposed mattress arrangement comprises a multi-layered structure consisting of: • First layer of foam base (4): Made of self-extinguishing flexible polyurethane foam, with density D33 or D45, ensuring comfort and adequate support. • Second layer of polyester board (3): Made of flame retardant PRF polyester board with a weight of 160 g, white in color, providing thermal and structural insulation. • Third quilted layer (2): Consisting of a cover, blanket, padding or fabric with flame-retardant polypropylene microfibers, adding additional flame protection and contributing to the uniform distribution of weight. • Fourth layer of covering (1): Made of PFR flame retardant fabric, ensuring protection and durability for the mattress structure. Petition 870250027502, dated 04 / 04 / 2025, page 13 / 26 6 / 13

[00025] The mattress structure is designed to offer a balance between support and comfort, using carefully selected materials. The first foam base layer (4) serves as the main base of the mattress, offering stability and support to the user. On top of this layer, the second polyester board layer (3) acts as an insulator, ensuring better weight distribution and increased durability. The third quilted layer (2) contributes to greater softness and comfort, while the fourth cover layer (1) protects the entire structure and ensures flame resistance.

[00026] The inventiveness of the invention is directly associated with the unique interaction between the materials used and their specific thicknesses, resulting in performance not anticipated by the state of the art. While conventional mattresses already use layers of foam, polyester, and coverings, the innovative factor here is the way these layers are structured and their exact thicknesses, which provide highly efficient performance, especially in terms of fire safety, something that was not common or predictable in existing products.

[00027] The first unforeseen aspect lies in the precise combination of layer thicknesses: the foam base layer (4) with a thickness between 50 and 60 mm, the polyester board (3) and the quilted layer (2) with a thickness of 20 to 30 mm, and the cover (1) with a thickness of 0.1 to 1 mm. Although foam layers are frequently used, the combination of these specific thicknesses not only optimizes comfort and durability, but also results in flame propagation and smoke emission resistance far superior to that expected in traditional mattresses. The fact that these thicknesses have been carefully adjusted to ensure both comfort performance and fire safety is not something that could easily be anticipated, given the pre-existing knowledge about mattress composition. Petition 870250027502, dated 04 / 04 / 2025, p. 14 / 26 7 / 13

[00028] Another fundamental point that could not have been foreseen is related to the material's response in flammability tests. The mattress's behavior when exposed to flame revealed exceptional resistance, with charring restricted only to the area of ​​direct contact with the ignition source. This result is particularly important because, in many conventional mattresses, the flame can spread or cause significant damage beyond the ignition area. The invention, however, managed to prevent this type of spread, limiting the risk of fire and making the product much safer compared to other alternatives on the market.

[00029] The independent multi-layered structure offers several advantages for mattress construction, directly impacting its safety, comfort, and durability. One of the main advantages of this type of structure is the ability to distribute specific functions among the layers, ensuring that each material performs its role efficiently without compromising the overall performance of the mattress.

[00030] The order of the layers is a critical factor, as it directly influences ergonomics, structural strength, and fire safety. The planned arrangement of the layers allows support materials to be strategically positioned to provide stability, while upper layers focus on comfort and adaptability to the user's body. Furthermore, this organization reduces deformation over time, increasing the lifespan of the mattress.

[00031] Another essential aspect is the ability to contain the spread of flames. By correctly structuring the layers, the mattress prevents the fire from spreading rapidly, as the flame-retardant PRF materials are positioned to act as efficient barriers. This ensures greater safety for users, reducing risks in case of fire.

[00032] In addition, the separation between the layers improves the thermal insulation and ventilation of the mattress, preventing heat buildup. Petition 870250027502, dated 04 / 04 / 2025, page 15 / 26 8 / 13 excessive and contributing to a healthier environment by minimizing the proliferation of fungi and bacteria. In this way, the present invention stands out for its innovative approach, which combines safety, comfort and durability through a multi-layered structure organized in an optimized manner.

[00033] The average total thickness of the multilayer structure is 70.01 to 99 mm, composed of layers with specific thicknesses for each function. The first layer, a foam base (4), has a thickness between 50 and 60 mm, providing support and firmness. The second layer, a polyester board (3), together with the third quilted layer (2), have thicknesses ranging from 20 to 30 mm, offering a balance between comfort and resistance. Finally, the fourth cover layer (1), with a thickness between 0.1 and 1 mm, ensures finishing and protection, contributing to the overall performance of the mattress.

[00034] The arrangement of these layers ensures a high-quality product, combining technical characteristics that meet consumer needs.

[00035] Examples

[00036] A flammability test was performed on the material used in the composition of the mattress, as specified in the test method, with the test specimen being manufactured and identified as illustrated in Figures 2 and 3.

[00037] The test followed the parameters of the FTP Code / 2010 International Code for Application of Fire Test Procedures (MSC Resolution 88 / 26 / Add2, Annex 1, Part 9: Testing for bedding components) and the CETAC LSFEx-PE-123 test procedure - "Flammability test for bedding components".

[00038] The test specimens (Figures 2 and 3) were conditioned for 72 hours at a temperature of 23°C and a relative humidity of 50%. Due to the differences in the material faces, the test was performed on the fabric on both faces and on the seam on one face. Petition 870250027502, dated 04 / 04 / 2025, page 16 / 26 9 / 13

[00039] Table 1 presents the results obtained in the cigarette test. It was observed that the cigarettes were completely consumed, with the release of gray smoke and carbonization restricted to the area of ​​cigarette deposition. The coating was punctured, but there was no ignition of the test specimens. Further details of the test are illustrated in Figures 4 and 5.

[00040] Table 1: Test results Cigarette No. Cigarette Burning Time (min) Time to Ignite the Test Specimen Flame Sustaining Time (min) Average Carbonized Extension (mm) Length Width Depth 1 17 Did not ignite 0 74 21 25 2 17 Did not ignite 0 56 31 9 3 18 Did not ignite 0 62 29 7

[00041] The absence of ignition of the test specimens, as well as the non-propagation of flame to the edges or through the entire thickness of the mattress, demonstrates a level of safety that was not conventionally expected in mattresses, which, in turn, reflects the innovation of the invention. The fact that the material did not generate large amounts of smoke or heat, as often occurs with other flammable materials, is another clear example that the invention could not have been foreseen based on the state of the art.

[00042] Furthermore, conducting the tests following the rigorous criteria of the FTP Code / 2010 and complying with the safety requirements demanded by international standards, such as the absence of incandescence or flame propagation for more than 150 seconds after the removal of the pilot flame, further highlights the innovative nature of the material. The invention Petition 870250027502, dated 04 / 04 / 2025, page 17 / 26 10 / 13 manages to combine comfort, durability and fire resistance that meets global safety standards, a feature that could not have been anticipated from the technical knowledge available before its development.

[00043] The test was also performed to test the material under different conditions, with the application of a flame, following the acceptance criteria of the FTP Code / 2010, including the non-production of large detectable quantities of smoke, heat or incandescence after 1 hour of application of the ignition source, and the non-propagation of the flame or incandescence to the lateral edges or through the total thickness of the test specimen.

[00044] The results obtained indicate that the tested material met the criteria established by the FTP Code / 2010, showing no ignition, consumption exceeding 66%, nor flame propagation or incandescence beyond the permitted limits.

[00045] Based on the tests performed, several advantages can be highlighted regarding the performance of the material used in the mattress composition. Firstly, the material showed excellent resistance to ignition and flame propagation, meeting the rigorous safety criteria of the FTP Code / 2010. There was no ignition of the test specimens, which indicates that the mattress performs well against ignition sources, such as cigarettes or direct flames. Furthermore, carbonization was restricted to the area of ​​flame application, without spreading to other parts of the material, which reduces the risk of fire propagation.

[00046] Another positive point is the fact that the material did not generate large amounts of smoke, heat, or incandescence after the ignition source was removed, which indicates that the mattress has a low emission rate of substances potentially harmful to health in case of fire. Perforation of the coating was observed, but without this resulting in ignition or significant damage to the mattress structure. Petition 870250027502, dated 04 / 04 / 2025, page 18 / 26 11 / 13

[00047] These results indicate that the material not only meets the established safety requirements, but also offers greater protection to users in the event of unforeseen events, such as an accidental fire. Resistance to flame propagation and low smoke emission are characteristics that add value to the product, making it safer for residential use and in environments with fire safety requirements.

[00048] The unique combination of materials and the specific dimensions of the layers that make up the multilayer structure of the mattress, as well as its superior performance in flammability tests, could not have been predicted or anticipated by the existing state of the art.

[00049] While the state of the art features mattresses made of known materials, the proposed solution is innovative in that it optimizes the thickness and materials of the layers to not only ensure the comfort and durability of the product, but also to meet stringent fire safety criteria. The choice of specific thicknesses for each layer — 50 to 60 mm for the foam base, 20 to 30 mm for the polyester board and quilted layer, and 0.1 to 1 mm for the cover — is a combination that results in a material that efficiently resists fire, without ignition or flame propagation, which is not frequently observed in conventional mattresses.

[00050] Furthermore, the material's behavior during flammability tests, such as the absence of ignition, limited carbonization, and the absence of flame propagation, demonstrates that the invention was not only designed to be comfortable and functional, but also safe, an essential factor for innovation in the field of mattresses. The fact that the material has been tested and approved according to the demanding criteria of the FTP Code / 2010, which require resistance to fire and smoke propagation, reinforces the idea that the proposed solution goes beyond what was expected in the market, and this enhanced safety was not foreseen in the prior art. Petition 870250027502, dated 04 / 04 / 2025, page 19 / 26 12 / 13

[00051] Therefore, the invention is characterized by an innovative combination of technical factors — from the choice of materials to the exceptional performance in safety tests — that could not be easily predicted or replicated based on pre-existing knowledge in the field.

[00052] Furthermore, the material's performance in flammability tests—such as the absence of ignition, the restriction of charring to the flame deposition area, the non-propagation of fire to the edges or through the entire thickness of the test specimen, and the low smoke emission—is a result that could not have been anticipated without practical testing. The invention demonstrates fire resistance behavior that was not expected in the mattress market, making it a unique solution aligned with modern safety requirements, such as the criteria of the FTP Code / 2010.

[00053] The innovation lies in the integration of these factors in such a way that the mattress's performance, both in terms of comfort and fire safety, is optimized in an unprecedented manner. The combination of thicknesses and materials to guarantee both comfort and fire resistance is a solution that could not have been foreseen by previous knowledge in the field, as the invention goes beyond what was conventionally understood or applied in mattress design.

[00054] The precise and strategic combination of material layers, along with the specific thicknesses and their superior performance in flammability tests, could not have been foreseen by the prior art. Although the use of materials such as foam, polyester, and coatings was already known, the invention proposes a specific constructive arrangement, with thicknesses varying between 50 and 60 mm for the foam base, 20 and 30 mm for the polyester board and quilted layer, and 0.1 to 1 mm for the coating, resulting in an unusual balance between comfort, durability, and fire resistance. Petition 870250027502, dated 04 / 04 / 2025, p. 20 / 26 13 / 13

[00055] It should be understood that, although the present invention has been specifically disclosed for certain aspects, embodiments and optional features, modification, improvement and variation of such aspects, embodiments and optional features may be utilized by those skilled in the art, and that such modifications, improvements and variations are considered within the scope of this disclosure.

Claims

1. Constructive arrangement applied to a mattress characterized by the fact that it comprises: a multilayer structure comprising a first foam base layer (4), a second layer of polyester board (3), arranged over the first foam base layer (4), a third quilted layer (2), arranged over the second polyester board layer (3), and a fourth cover layer (1), enclosing the multilayer structure.

2. Constructive arrangement applied to a mattress, according to claim 1, characterized in that the fourth layer of covering (1) is made of flame retardant PRF fabric.

3. Constructive arrangement applied to a mattress, according to claim 1 or 2, characterized in that the third quilted layer (2) consists of a cover, blanket, padding or fabric with polypropylene composed of flame retardant PRF microfibers.

4. Constructive arrangement applied to a mattress, according to any one of claims 1 to 3, characterized in that the second layer of polyester board (3) is made of a board with a grammage of 160 g and white color.

5. Constructive arrangement applied to a mattress, according to any one of claims 1 to 4, characterized in that the first foam base layer (4) is made of self-extinguishing flexible polyurethane foam, with density D33 or D45.

6. Constructive arrangement applied to a mattress, according to any of claims 1 to 5, characterized in that the average total thickness of the multilayer structure is from 70.01 to 99 mm, the thickness of the first foam base layer (4) is between 50 and 60 mm; the thickness of the second polyester board layer (3) and the third quilted layer (2) is between 20 and 30 mm and the thickness of the fourth cover layer (1) is between 0.1 and 1 mm.

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