Stretchable Flame Barrier Panel for Foam Mattress Core Deformation

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Solution Overview

Problem

Existing mattress flame barrier materials lack substantial stretch and recovery capabilities, which is problematic for mattresses with foam cores that require localized deformation during use.

Innovation Solution

A mattress incorporating a stitch-bonded stretchable fabric formed from a fibrous base layer with elastomeric yarns, providing an interior stretch zone with substantial stretch and recovery, while the selvedge zones offer dimensional stability through shrinkable yarns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If prior flame barrier materials (non-woven fleece construction with flame-retardant fibers) are used, then flame blocking and insulation characteristics are improved, but stretch and recovery capacity deteriorates

Engineering Contradiction:

Improveflame blockingVSAvoidstretch and recovery

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent combines flame-retardant fibers (rayon, para-aramid, meta-aramid, modacrylic, wool) with elastomeric fibers (spandex, Hytrel) to create a composite non-woven fabric that simultaneously provides flame blocking properties and stretch/recovery capability. This composite structure allows the material to meet both flame safety requirements and the deformation needs of foam mattress cores.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the physical and chemical parameters of the flame barrier material by incorporating elastomeric components that change the fabric's mechanical properties. The elastomeric fibers provide elastic modulus and recovery characteristics while the flame-retardant fibers maintain fire resistance, achieving a balance between rigidity for flame blocking and flexibility for stretch.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If circular knit sock structure with fiberglass core yarns is used, then stretch and recovery are improved, but manufacturing difficulty and weight increase

Engineering Contradiction:

Improvestretch and recoveryVSAvoidmanufacturing difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent employs a non-woven fabric construction with inherent porosity that allows the foam mattress core to be easily inserted and accommodated. The porous structure of the non-woven fabric eliminates the need for complex sock-like encasement while still providing stretch and recovery through the elastomeric fiber content.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent extracts the essential function of stretch and recovery from the complex circular knit sock structure and implements it through a simpler non-woven fabric construction. By removing the need for knitted encasement and using a flat non-woven panel with elastomeric fibers, the design achieves the same mechanical functionality with reduced manufacturing complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If flame barrier panel provides substantial stretch and recovery, then adaptability to foam core deformation is improved, but flame resistance may deteriorate

Engineering Contradiction:

Improvestretch and recoveryVSAvoidflame resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent creates a composite non-woven fabric where flame-retardant fibers (rayon, para-aramid, meta-aramid, modacrylic, wool) provide fire resistance while elastomeric fibers (spandex, Hytrel) provide stretch and recovery. The synergistic combination ensures that the flame barrier maintains its fire-blocking properties even when stretched, as the flame-retardant fibers retain their structural integrity and fire-resistant characteristics during deformation.

Inventive Principle:

Principle #40Composite materials

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 achieves continuous coverage and substantial stretch and recovery characteristics matching the mattress core, while maintaining edge stability and flame resistance, even under heat and moisture exposure.

Implementation Method 1

a plurality of elastomeric yarns such as covered spandex, Hytrel or the like engaging the fibrous base layer to form an interior stretch zone

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the selvedge zones offer dimensional stability through shrinkable yarns

Methodology Applied

Scientific EffectThermal shrinkage: Thermal Contraction

Data Source

PatentUS12201222B2Stretchable flame barrier panels

Publication Date: 2025.01.21 TIETEX INTERNATIONAL LTD

AI summary

A stretchable flame barrier panel including an interior stretch zone having elastomeric yarns extending across a fibrous base layer of textile fibers and optionally substantially stable lateral selvage zones outboard of the interior stretch zone. In a finished state, the interior stretch zone has substantial stretch and recovery in both the machine direction and the cross-machine direction.