Flame-Resistant Mattress Border Panel With Oxygen Barrier Layers
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Solution Overview
Problem
Adding flame resistance to mattresses is challenging due to the need for a high degree of resistance without stiffening the mattress or causing odor issues, and existing solutions are often expensive.
Innovation Solution
A mattress design featuring a quilted panel with a fire barrier layer made of batting material adjacent to a thermoplastic layer, which reduces oxygen transfer to the padding and can be manufactured using a thermoplastic film bonded to a fabric layer, providing a continuous flame-resistant barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame resistant materials are added to mattresses, then flame resistance is improved, but cost increases significantly
Solution Approach 1:
The patent combines a thermoplastic polymer layer with a fabric layer to create a composite fire barrier material. The thermoplastic polymer provides flame resistance while the fabric layer provides structural support and comfort. This composite approach allows the use of less expensive materials compared to traditional single-layer flame resistant fabrics, thereby reducing manufacturing costs while maintaining effective flame resistance.
Solution Approach 2:
The fire barrier material is applied selectively to specific regions of the mattress where flame resistance is most critical, such as the perimeter and areas near heat sources. This localized application reduces the overall amount of expensive flame resistant material needed, thereby reducing manufacturing costs while still providing adequate protection where it is most needed.
2Reliability
If thick flame resistant layers are used, then flame resistance is improved, but mattress softness deteriorates
Solution Approach 1:
The fire barrier is concentrated in specific strategic locations such as the mattress perimeter and areas near potential heat sources, rather than uniformly throughout the entire mattress. This localized placement provides adequate flame resistance while minimizing the impact on overall mattress softness and comfort in the sleeping areas.
Solution Approach 2:
The patent uses a thin film approach with the thermoplastic polymer layer that provides flame resistance without adding significant thickness. The thermoplastic layer forms a flexible barrier that maintains mattress softness while providing effective flame protection. The thin film nature of the barrier allows it to conform to the mattress structure without creating a stiff or uncomfortable surface.
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 reduces the transfer of oxygen to the padding, preventing combustion while maintaining mattress softness and reducing manufacturing costs by using a less expensive thermoplastic layer, meeting current flame resistance standards.
Implementation Method 1
The first and second fire barrier layers provide a fire barrier that reduces the transfer of oxygen to the padding material, thereby reducing the oxygen needed to support combustion of the padding material
Implementation Method 2
the flame resistant thermoplastic may be heated to its transition temperature so that it flows through a surface of the fabric layer and into the fibers
Implementation Method 3
the flame resistant thermoplastic may be pressure bonded, ultrasonically or adhesively bonded, or bonded or joined in any other suitable way to the other layer
Implementation Method 4
the flame resistant thermoplastic may be pressure bonded, ultrasonically or adhesively bonded, or bonded or joined in any other suitable way to the other layer
Data Source
AI summary
Mattresses and methods for manufacturing mattresses that have a flame resistant panel, such as a flame resistant border panel. The systems and methods include mattresses that have a flame resistant panel that, in certain embodiments, includes a fire barrier layer made of a batting material and being disposed over a thermoplastic fire barrier layer. The first and second fire barrier layers provide a fire barrier that reduces the transfer of oxygen to the mattress core, thereby reducing the presence of oxygen, which is needed to support combustion of the padding material. Additionally, the invention encompasses methods for manufacturing mattresses.