DE2415162A1 - FIRE RESISTANT MATTRESS OR UPHOLSTERY-LIKE CONSTRUCTION - Google Patents

Description

Patent attorney March 28, 1974

Dr. Michael Hann HvK / D (620)

63 Giessen 2415 162

Ludwigstrasse 67

Rohm and Haas Company, Philadelphia, Pennsylvania, USA

FIRE-RESISTANT MATTRESS OR UPHOLSTERY-LIKE STRUCTURE

Priority: April 2, 1973 / US A / Serial iNo. 347 036

This invention relates to a fire retardant mattress or cushion structure. More specifically, the invention relates to fire or flame retardant structures for mattresses. _} Pillows, sleeping bags, cushions and armchair or sofa upholstery are directed.

Up until now it has been common practice in the manufacture of ironing board covers to use a coating of metal particles, e.g. made of aluminum, to be applied to the front or back of the cover in order to ensure rapid heat dissipation obtain. Mattress cover fabric materials are, however, iir. generally comparatively thin and have a printed Ornamental pattern on their front side. Accordingly, the application of a layer containing metal particles the decorative pattern indistinctly on the front

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and, if this layer is attached to the back or the inside of the mattress cover fabric, results in an undesirable appearance of the coated coating as the metal coating is visible to the viewer is visible when he looks at the outside of the covered article, for example a mattress. Usually this observed effect is called "flashing through". In addition, this is done with a metal layer provided cover fabric stiffened in a disadvantageous manner.

Usually, a polyurethane foam is used in layers between a mattress cover and the filling or padding is embedded in the mattress, used as a self-extinguishing, insulating layer between the The cover and the filling are used to prevent accidental ignition of the mattress. But it was found that in places where the polyurethane foam is reduced to a smaller part of its original thickness, for example from 12.7 or 15.9 mm to 3.2 or 1.6 mm, with the aid of fastening means, such as means for Tying means such as stitching or tufting, the insulating Properties of the polyurethane foam are reduced or lost, and a lit cigarette, which is deposited in this compressed area, often inflammation of the cotton or another filling, which serves as a base for the layer of polyurethane foam, causes a smoldering fire to ignite will.

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The mattress-like or cushion-like structure according to the invention helps to reduce these disadvantages or dangers or even to prevent it. The structure is characterized by a light or damask-like fabric »one associated resilient flexible layer made of a resilient, self-extinguishing, heat-insulating plastic upholstery foam with a thickness of 0.25 to 2.5 cm, a metal-containing coating on the resilient Foam layer, where the metal content of the coating serves to quickly dissipate heat from all points, where heat is applied, the metal-coated foam adjacent to a combustible Is upholstery or filler, which in turn rests on a fabric base, and all of the above Elements are connected by fasteners that locally compress the foam padding layer and thereby reducing their heat-insulating properties at the compressed areas, thereby removing heat a source of heat from the ignition temperature of the cushioning or filler material that compressed it Places is fed through the metal-containing coating is derived.

The. present invention compensates for that Defects outlined above by placing them in specially defined places, e.g. on edges or at bundled or tacked spots, a thermally conductive layer of metallic material, usually a powdered one or blocked metal, which is bound together by a binding agent

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is held, provides, whereby the heat at the points of the compressed foam with the help of the metal instead of being directed to the flammable material. The metallic coating can be either on the front side of the foam, adjacent to the cover or on the inside, adjacent to the filling, is preferred in the latter, to prevent the metal from "flashing" through the cover. The reference can be made of damask-like or loosely woven rayon fabric and can have a decorative pattern that is either printed on it or woven in.

The drawings further explain the invention

Figure 1 shows a damask-like or artificial silk fabric or a cover 1, which is attached to a plastic upholstery foam made of polyurethane 2, which in turn has a metal-containing coating 3 e.g. means for stapling or bundling, fastened or connected through the relevant layers, including a _{fabric underlay r} 5, such as muslin (muslin) _%

Figure 2 shows essentially the same structure, with the exception that the metal-containing coating 3a is on the Surface of the polyurethane-containing foam layer in the vicinity of the cover instead of on the surface, in the neighboring

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shaft to the filling is located. The plastic foam pad usually about 0.25 to about 2.5 cm thick,

3 with a density of approximately 0.113 kg to 4.54 kg per 0.02832 m (0.25 to 10 pounds per cubic foot).

The structure according to the invention prevents the burning fibrous fillings of upholstery, armchairs, sofas, Pillows and mattresses and the like when a lighted cigarette or match is in Contact with the covering fabric or cover, including fibrous filler material, is particularly important at the points where the plastic foam is locally secured by fastening means, such as means for stapling or for bundling, is compressed to a thickness smaller than its usual thickness, so that the self-extinguishing and insulating properties are turned into an opposite mode of action to that of inflammation of the fibrous filler in the absence of this metal. The lit object can smolder or burning a small spot that is in direct contact with the burning segment of a cigarette, one A match or something like that, but the burning of this small spot quickly brings the metal-containing one Coating becomes effective, and as a result, the heat in this small spot is quickly absorbed by the metal layer derived, quickly increasing the temperature of the burning or smoldering points or segments such be lowered so that they are self-extinguishing, and with the rise in temperature of the particularly easily combustible

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fibrous packing materials on the inflammation or combustion temperature is prevented.

The thickness of the metal-containing coating or layer can be about 0.013 to 0.53 mm, preferably 0.051 to 0.102 mm (about 0.5 to 6 mils, preferably 2 to 4 mils). The metal in the coating can be powdered be, the individual particles bonded to one another with an organic, preferably non-combustible binder or the metal can be deposited by chemical plating or electroplating " in which case no organic binder is used. On the other hand, the metal can be sputtered or a metal evaporation process can be applied under vacuum, using a small amount Metal is evaporated in a vacuum. Located in this vacuum the laminate consists of broken or compressed foam and cover material (crushed foam / ticking laminate), which is covered on the side of the upholstery fabric with a removable protective film, e.g. made of polyethylene, to prevent that it is coated with the metal. If desired, the protective film can be applied after the plating process removed. A large number of different metals, such as aluminum, nickel, silver, Bismuth, antimony, tin, gold and alloys such as stainless steel Steel, brass, bronze, tin solder with lead content, Wood's metal, etc. be used. Present is Aluminum preferred. >

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When the metal is deposited by applying a coating composition comprising metal particles in a polymeric binder, the amount of metal can be about 25% wt.% Of the binder, and preferably at least 40 to 50 wt. Or even more thereof.

The amount of metal-containing coating is approximately

2
14.2 g to 113.4 g per Oj836 ra and preferably 28.4 g

2
up to 56.7 g per 0.836 m (about 0.5 to 4 oz./sq. yard, preferably 1 to 2 oz./sq.yard).

The metal-containing layer may be continuous or in the form of a foamed or a pressed one Foam layer that is somewhat discontinuous is, however, has the advantage of being more or less permeable, which means that it is a special Has breathability that makes it more comfortable for people who lie on a pillow, cushion, mattress and like sitting or lying down, especially in hot weather.

If the metal-containing layer is made from a mixture of powdered metal and binder, the binder used should usually be made of a fire-resistant polymer such as polyvinyl chloride, Polyvinylidene chloride; or another halogen-containing vinyl monomer. Regardless of the choice of Polymer that is used, it should be a flexible rather than a rigid polymer.

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Preferred mixtures are those which are based on aqueous dispersions of emulsion copolymers of monoethylene unsaturated monomers with a ^ ^ = CH ₂ ^ ^est including vinyl monomers, especially vinyl chloride, vinylidene chloride or mixtures thereof. Since such monomers form hard and brittle homopolymers, they are interpolymerized with monomers which, when homopolymerized, yield polymers which are soft and pliable. Examples of such monomers of the latter type are ethylene, ethyl acrylate, ßutyl acrylate, 2-ethylhexyl acrylate, which are included in the general group of acrylic acid esters of alcohols having 1 to 18 or more carbon atoms, as well as amyl methacrylate, 2-ethylhexyl methacrylate and octadecyl methacrylate, which are included in the general class the methacrylic acid esters of alcohols having 5 to 18 carbon atoms are included. In addition, the copolymers can include substantial amounts of other hard monomers, such as styrene, vinyl toluene, acrylonitrile and vinyl acetate, provided that the particularly soft monomer in the amount used is able to give the particularly coated coating material the desired flexibility for its intended use without the need to reduce the halogen-containing monomer to such an extent that the binder in the metal-containing layer would be too easily combustible. The interpolymers may further contain small amounts, about 0.1 to 2% wt. Of an acid, such as, for example, include acrylic acid, methacrylic acid and itaconic acid, to provide improved stability of the emulsion polymers and slight thickening by adjusting the pH of the

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System. It may further contain small amounts, about 0.5 to 5 wt.% Of other reactive monomers be included in order to achieve 'in the mixing polymers and / or in the preferred reaction of the mixture of metal-containing coating plus binder with the _w intermediate synthetic foam layer self-crosslinking properties This creates a chemical bond and the advantages of this type of adhesive bond between the metal-containing layer and the intermediate plastic foam layer.

The amount of powdered metal in such mixtures should generally be at least about 20% by weight, based on the total solids weight of the mixture, and preferably 40 to 50% by weight or more of the total solids weight turn off.

The weight of the das

powdered metal-containing coating layer should

2 will typically be in the range of 14.2 g to 113.4 g per 0.836 ra (0.5 to 4 oz. Per sq. Yard), using a single or double coating. The metal particles can have a wide range of sizes. Metal particles in the range from 0.02 to 0.1 mm, and preferably from 0.03 to 0.05 mm, are particularly useful. The size selection is made to ensure effective contact between the metal particles so that rapid heat dissipation from one to another location in the coating layer is achieved.

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For the metal-containing coatings that are made by chemical plating or electroplating Sputtering or metal evaporation in a vacuum, it is only necessary to have an adequate Weight of deposited metal to obtain substantial continuity. Thicker thicknesses of the However, metal is allowed. Generally a metal deposit of about 2.84 grams or more, e.g., 14.2 grams

2
per 0.836 m (0.1 oz. or more, eg, to 0.5 oz. per square yard) adequate. Thus, the upper limit of the thickness or the weight of the metal is determined by the degree of flexibility required for the particular application. Although a metal foil can be used, is it preferable _? avoid this because the composite cover fabric will make a creaking sound when it is bent.

The present invention is able to offer a wide variety of materials that are capable of being used for upholstery, sleeping bags, To serve mattresses, pillows, upholstered pillows, padded chairs, beds, sofas and the like.

In the following examples the invention continues explain, the data on parts and percentages are based on weight and the temperatures are given in C, unless otherwise stated.

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example 1

a) 25 parts of powdered aluminum with metal particles in a size of about 0.02 to 0.04 mm are mixed with 100 parts of an aqueous dispersion with 46% solids content of an 80:20 weight ratio mixture 1.) an emulsion copolymer of about 66% vinylidene chloride , 29 % butyl acrylate, 0.5% itaconic acid, about 3% acrylamide and about 2% JN-methylolacrylamide and 2.) an emulsion copolymer of about 96% .butyl acrylate, 2% methacrylamide and 2% N-methylolacrylamide, 2 parts methylene-bis- diamylphenoxypoly (9) ethoxyethanol, 8 parts of a 25% strength aqueous solution of acidic diammonium phosphate, 15 parts of a 50% strength aqueous solution of a copolymer of about 60% ethyl acrylate, 39.5% methyl methacrylate and about 0.5% diallyl phthalate and 42.5 Share water mixed. The mixture is stirred vigorously to give a coating composition having a solids content of 40%.

b) The solution obtained according to a) with 40% solids content is applied to the free surface of a non-compressed, resilient polyurethane foam layered to create a layer thickness of 0.15 mm (6 mils) « The coated structure is then dried for 4 minutes at 138 ° C (280 F) to leave a deposit of about 56.7 grams / 0.836 ra (2 oz / sq. Yard).

c) A test mattress is made for test purposes by adding a piece of cotton wadding, as in a mattress filling is used, 38.1 cm in length,

15.24 cm wide and 10.2 cm thick in the center of one A09840 / 0866

Cotton cover fabric with a length of 38.1 cm and a width of 30.5 cm is arranged in such a way that the 38.1 cm
the wadding and the fabric face in the same direction. Then it becomes a 12 "by 15"
Place large piece of polyurethane foam liner on top of the pad with theirs
38.1 cm 30.5 cm dimensions that match the
corresponding dimensions of the floor fabric layer and
with their metal-containing layer in contact with
the padding match, followed by a damask cover overlay. These two fabrics are tacked together along the 38.1 cm edges of the batting to compress the batting and foam along their edges. In addition, the wadding and the foam are pressed together along a central line parallel to the edges that are tacked together by tacking the structure together along this same central line. The resulting test mattress or test cushion structure can then, if so desired, be stretched taut by stitching the protruding edges of one or both of the cotton fabrics to the opposite sides of a square panel with a square opening within the square portions thereof. The resulting pad has a trough formed by the central line stapled together between two parallel, flared beads , one on each side of the central line. To the

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Testing is preferred with a lit cigarette either on top of one of the bulges or on the pad in the hollow, placed between the two. You let the cigarette burn by itself. If the padding ignites, the cover has a defect. However, if the padding does not ignite, Before the cigarette is burned, the cover goes through the test.

d) The test mattress obtained as above runs through if it is as described under c) was tested, the test.

Example 2. .

The procedure of Example 1 is repeated with the exception that in part a) the metal-containing mixture by inclusion of a foam stabilizer or agent, specifically a mixture of about 4.3 parts of a 33 % aqueous solution of ammonium stearate and 1.4 parts of a 33% aqueous solution of sodium lauryl sulfate is modified. The mixture is whipped into foam which is sprayed onto the surface of the polyurethane foam to form a thickness of about 1.53 mm. Make drying for 2 minutes

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at 138 ° C (280 ⁰ F), the composition is passed through nip rolls of a textile pad, in order to break the foamed metal-containing layer or to press (crush), then ihr'.Aushärten through a drying time of 4 minutes at 138 ⁰ C (28O ⁰ F). A material is obtained in which the metal-containing coating is in

2
in an amount of 99.3 g / 0.836 m (3.5 oz / sq.yard).

This metal-coated, resilient polyurethane plastic foam runs through the test according to example Ic) when it is incorporated into a test mattress.

Example 3

Example 1 is repeated with the exception in part a) that the aqueous dispersion is a 90:10 weight ratio mixture

1.) an emulsion copolymer made from about 69 % vinyl chloride, 29% butyl acrylate, 1 % methylolacrylamide, 0.5% acrylamide and 0.5% itaconic acid and 2% of an emulsion copolymer made from about 96% butyl acrylate, 2% methacrylamide and 2% methylol methacryl · Is amide.

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Example 4

The procedure of Example 1 is followed except that in part a) the pulverized Aluminum is replaced by 23 parts of powdered stainless steel, the particles being a size im Range from 0.05 to 0.1 mm. The corresponding test mattress runs through the test according to Example Ic).

Example 5

The procedure of Example 1 is followed, with the exception that in part a) the aluminum is replaced by 23 Parts of powdered silver is replaced, the particles having a size in the range from 0.03 to 0.07 mm. The corresponding test mattress runs through the test according to Example Ic).

Example 6

The procedure of Example 1 is followed, with the exception that in part a) the aluminum is replaced by 23 Parts of powdered nickel is replaced, the particles having a size in the range of 0.03 to 0.06 mm. The corresponding mattress runs through the test according to Example 1 c> y

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Example 7

The procedure of Example 1 is followed, with the exception that in part a) the aluminum is replaced by 23 parts of powdered tin with particles ranging in size from 0.02 to 0.04 mm. The corresponding mattress runs through the test according to example Ic).

Example 8

The procedure of Example 1 is followed, with the exception that in part a) the aluminum is replaced by 23 parts of anodized, powdered aluminum, the particles having a size in the range from 0.02 to 0.04 mm. The corresponding mattress runs through the test according to example Ic).

Example 9

The procedure of Example 1 is followed, with the exception that in part a) the aluminum is replaced by 23 parts of powdered bronze, with the particles ranging in size from 0.03 to 0.7 mm own. The corresponding test mattress runs through the test according to Example Ic).

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While previously self-extinguishing polyurethane foams other foam plastics with the desired padding, thermal insulation and self-extinguishing properties serve as a convenient equivalent.

The term "self-extinguishing" foam-like Plastics include common polyurethane dyes, which because of their uncompressed nature State and its porosity, not by a lighted cigarette or a lighted match on fire. In addition, all chemically processed foams are included, which are do not ignite or feed a smoldering fire when exposed to the flame of a soldering tube or blowtorch (blowtorch flame).

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Claims (1)

Claims Fireproof mattress-like or upholstery-like structure, identified by a light or damask-like structure Fabric (1), a resilient flexible layer (2) connected to it made of a resilient, self-extinguishing, heat-insulating plastic upholstery foam with a Thickness of 0.25 to 2.5 cm, a metal-containing coating (3) on the resilient foam layer, the Metal content of the coating (3) serves to quickly dissipate heat from all points where heat is supplied the metal-coated foam adjacent to a combustible cushion or filler (4) is, which in turn rests on a fabric base (5) and wherein all the elements listed by fastening means (6) are connected, which locally compress the upholstery foam layer (2) and thereby their heat-insulating Properties at the compressed areas diminish, eliminating heat from a heat source the inflammation temperature of the upholstery or filler material, which is fed to these compressed areas, is discharged through the metal-containing coating. 2. Structure according to claim 1, characterized in that that the plastic upholstery foam (2) is a polyurethane foam. 409840/0866 3. Structure according to claim 1, characterized e ichnet that the metal-containing coating (3) contains broken foam. 4. Structure according to claim 1, characterized in that that the thickness of the metal-containing coating (3) is from 0.013 to 0.153 mm. 5. Structure according to claim 2, characterized in that that the metal in the metal-containing coating (3) is aluminum, nickel, silver, bismuth, antimony, tin, gold, stainless steel, brass, bronze or Wood's metal. 6. Structure according to claim 5, characterized in that the metal is aluminum with a Particle size is on the order of 0.02 to 0.1 mm in an organic binder. 7. Structure according to claim 6, characterized in that that the metal is anodized aluminum, 8. Structure according to claim 6, d a d ur c h characterized, that the metal is stainless steel with a particle size on the order of 0.02 to 0.1 mm in one! organic binder. 9. Structure according to claim 5, characterized in that that the metal-containing coating (3) adheres to the plastic upholstery foam (3) on the side, 409840/0866 which is adjacent to the filling or cushioning material (4), the latter material consisting of combustible fibers. 409840/0866