Fire-Resistant Mattress Barrier With Granular Flame Isolation

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Solution Overview

Problem

Current fire-resistant materials for mattresses and upholstered furniture face challenges such as chemical treatments with objectionable odors, potential toxicity, high costs, and environmental impact, while also failing to consistently impart sufficient flame-retardant characteristics across various styles and constructions.

Innovation Solution

A fire-resistant barrier comprising a textile structure with a plurality of chambers and a flame-resistant granular filling, which isolates fuel loads from ignition sources, providing inherent flame and heat resistance without the need for chemical treatments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If chemical flame retardants are used to reduce flammability, then flame resistance is improved, but objectionable odors and potential toxicity occur

Engineering Contradiction:

Improveflame resistanceVSAvoidodors and toxicity

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and eliminates toxic chemical flame retardants from the system by using inherently flame-resistant natural fibers (such as wool, cotton, and plant-based materials) that provide fire protection without releasing harmful odors or toxins when exposed to flame

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs inexpensive, naturally occurring flame-resistant fibers that can be easily replaced and do not require costly chemical treatments, providing an economical solution that avoids the environmental and health issues associated with persistent chemical flame retardants

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If inherently flame-resistant fibers are used, then flame resistance is improved, but high costs occur

Engineering Contradiction:

Improveflame resistanceVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the approach from using expensive specialized flame-resistant fibers to using common, inexpensive natural fibers (wool, cotton, hemp) that possess inherent flame resistance through their natural material properties, thereby reducing manufacturing costs while maintaining fire safety

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses homogeneous, naturally occurring fibers that are already widely available and inexpensive, eliminating the need for costly chemical treatments or specialized materials, thus reducing production costs while achieving the desired flame resistance

Inventive Principle:

Principle #33Homogeneity

3Reliability

If chemical flame retardants are applied, then flame resistance is improved, but environmental impact worsens

Engineering Contradiction:

Improveflame resistanceVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the natural flame-resistant properties of organic materials (which were previously overlooked or misunderstood) into a beneficial fire safety mechanism, eliminating the need for harmful chemical additives and their associated environmental pollution, waste, and processing hazards

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Reliability

If conventional flame retardant methods are used, then flame resistance is improved, but they fail to consistently impart sufficient flame-retardant characteristics across various styles and constructions

Engineering Contradiction:

Improveflame resistanceVSAvoidconsistency across styles

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent creates a universal flame protection system using natural fibers that inherently resist fire across all mattress constructions and styles, providing consistent flame resistance regardless of the specific design, configuration, or assembly method used

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively renders mattresses, mattress foundations, and upholstered furniture resistant to open flames and smoldering ignition sources, meeting stringent flammability standards while offering improved comfort, reduced costs, and a lower environmental footprint.

Implementation Method 1

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS7832038B2Fire resistant barrier and use with mattresses, mattress foundations, and upholstered articles therein

Publication Date: 2010.11.16 KICKBALL CONCEPTS

AI summary

The invention relates to a fire resistant barrier and open flame resistant mattresses, mattress foundations, and upholstered articles having the fire resistant barrier therein for protection. The open flame resistance of the mattresses, mattress foundations, and upholstered articles is determined under a full-scale fire test of a composite article.