With Fireproof Material Patents (Class 5/698)
  • Patent number: 9756957
    Abstract: A mattress wherein a plurality of independent yarn based fire barrier fabrics encases a plurality of distinct and unattached interior core structures. The plurality of interior core structures include at least a detached and internally flippable upper comfort layer assembly with a plurality of non-homogeneous foams or filling materials encased in a yarn-based fire barrier fabric and a lower, interiorly disposed support core structure with resilient filling materials encased in a yarn-based fire barrier fabric and a fabric cover. The detachable and internally flippable upper comfort layer assembly may be contained in a user accessible compartment that is fashioned into an outer cover assembly.
    Type: Grant
    Filed: June 30, 2016
    Date of Patent: September 12, 2017
    Assignee: KICKBALL CONCEPTS, LLC
    Inventors: Harrison Robert Murphy, Juraj Michal Daniel Slavik, II
  • Patent number: 9538857
    Abstract: A mattress is disclosed that includes a sleeping side, a cushioning layer, an inner support compartment, and a fire-containing compartment disposed between the sleeping side and the inner support compartment. The fire-containing compartment includes first and second layers of fire-resistant material selected from the group consisting of a barrier sheet, a high loft batt, and a fire-resistant chemical. The cushioning layer is disposed between the first and second layers of fire-resistant material.
    Type: Grant
    Filed: January 4, 2013
    Date of Patent: January 10, 2017
    Assignee: SERTA, INC.
    Inventor: Alvin R. Klancnik
  • Patent number: 9006118
    Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.
    Type: Grant
    Filed: January 22, 2013
    Date of Patent: April 14, 2015
    Assignee: Precision Fabrics Group, Inc.
    Inventors: Melanie Pierce Jones, James Douglas Small, Jr., John H. Walton, Alfred Frank Baldwin, Jr., Zareh Mikaelian, William Scott Kinlaw
  • Publication number: 20150096125
    Abstract: Flame retardant panels and methods of manufacture generally include a batting material including a layer having a top surface and a bottom surface, the layer comprising a plurality of substantially vertically oriented flame retardant treated fibers extending from the top surface to the bottom surface; and a binder material.
    Type: Application
    Filed: October 4, 2013
    Publication date: April 9, 2015
    Applicant: DREAMWELL, LTD.
    Inventors: Michael S. DeFranks, Sheri L. McGuire
  • Patent number: 8935821
    Abstract: A bedding apparatus may include a frame, a fabric cover, and a liquid containment member. The frame may include first and second members coupled to a base for pivotable motion relative thereto between first and second positions. The base may define an opening surrounded by the first and second members when the first and second members are in the first position. The fabric cover may be coupled to the first and second members and may be maintained in a taught condition by the first and second members when the first and second members are in the first position. The liquid containment member may be disposed below the cover and includes sidewalls and a bottom wall attached to the sidewalls. The sidewalls are attached to the base and extend through the opening. The sidewalls may include a mesh material allowing fluid-flow therethrough. The bottom wall may include a liquid-impermeable material.
    Type: Grant
    Filed: March 15, 2013
    Date of Patent: January 20, 2015
    Assignee: Phoenix Design, LLC
    Inventor: Kelly M. Obriot
  • Patent number: 8893337
    Abstract: A removable top panel for a mattress assembly generally includes at least one layer having length and width dimensions sufficient to support a reclining body of the user; a mechanical fastener component disposed at about a perimeter edge of a bottom facing surface of the at least one layer, wherein the mechanical fastener is configured to provide releasable engagement to an underlying mattress body; and a layer of a fire resistant material extending inwardly from the perimeter edge. Also disclosed are mattress assemblies including the removable top panel.
    Type: Grant
    Filed: August 11, 2011
    Date of Patent: November 25, 2014
    Assignee: Dreamwell, Ltd.
    Inventor: Jeremy B. Lynn
  • Patent number: 8852131
    Abstract: A support surface system provides alternating pressure therapy and low air loss therapy simultaneously using a single pump. The system includes a plurality of cells. Each cell has a foam-filled lower chamber and an upper chamber. Fluid communication between the lower and upper chambers is controlled by a normally closed valve that opens if the pressure within the lower chamber exceeds a predetermined threshold pressure. Pressurized air is alternatingly supplied to the lower chambers of a first subset of cells and the lower chambers of a second subset of cells, thereby providing alternating pressure therapy. When the pressure in the lower chamber exceeds the threshold, the valve opens to allow air from the lower chamber to flow into the upper chamber. Air is expelled from the upper chamber through perforations therein, to remove moisture and humidity and possibly reducing the temperature of the micro-climate beneath a patient.
    Type: Grant
    Filed: September 15, 2010
    Date of Patent: October 7, 2014
    Assignee: Anodyne Medical Device, Inc.
    Inventor: Kenneth Scott Siegner
  • Patent number: 8745795
    Abstract: Components, such as bedding components including mattresses are disclosed herein. The components include a first layer, a fire-resistant layer affixed to the first layer or an optional additional layer, and a fire-resistant sock. The first layer, the optional additional layer, and fire-resistant layer are disposed within the fire-resistant sock.
    Type: Grant
    Filed: January 9, 2012
    Date of Patent: June 10, 2014
    Assignee: Serta, Inc.
    Inventor: Steve Klancnik
  • Publication number: 20140075678
    Abstract: A mattress wherein a plurality of independent yarn based fire barrier fabrics encases a plurality of distinct and unattached interior core structures. The plurality of interior core structures include at least a detached and internally flippable upper comfort layer assembly with a plurality of non-homogeneous foams or filling materials encased in a yarn-based fire barrier fabric and a lower, interiorly disposed support core structure with resilient filling materials encased in a yarn-based fire barrier fabric and a fabric cover. The detachable and internally flippable upper comfort layer assembly may be contained in a user accessible compartment that is fashioned into an outer cover assembly.
    Type: Application
    Filed: September 20, 2012
    Publication date: March 20, 2014
    Inventors: Harrison Robert MURPHY, Juraj Michal Daniel SLAVIK, II
  • Publication number: 20130283537
    Abstract: A quilted panel for a mattress having gel fibers incorporated therein so as to bring the gel material closer to the top of the mattress such that the benefits of the gel material are better realized by the user. In some embodiments, the gel fibers are incorporated into the FR fiber pad of the quilted panel. In other embodiments, a separate gel fiber pad is positioned within the quilted panel.
    Type: Application
    Filed: April 25, 2013
    Publication date: October 31, 2013
    Applicant: Advanced Sleep Concepts
    Inventor: Dominick Azevedo
  • Publication number: 20130174346
    Abstract: Components, such as bedding components including mattresses are disclosed herein. The components include a first layer, a fire-resistant layer affixed to the first layer or an optional additional layer, and a fire-resistant sock. The first layer, the optional additional layer, and fire-resistant layer are disposed within the fire-resistant sock.
    Type: Application
    Filed: January 9, 2012
    Publication date: July 11, 2013
    Inventor: Steve Klancnik
  • Publication number: 20130174344
    Abstract: Components are disclosed that include a first layer and a second layer affixed to the first layer or an optional third layer. At least one of the first layer and the second layer includes a gel foam.
    Type: Application
    Filed: January 9, 2012
    Publication date: July 11, 2013
    Inventors: Steve Klancnik, Leona Wightman
  • Publication number: 20130149518
    Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.
    Type: Application
    Filed: January 22, 2013
    Publication date: June 13, 2013
    Applicant: Precision Fabrics Group, Inc.
    Inventor: Precision Fabrics Group, Inc.
  • Publication number: 20130133139
    Abstract: A mattress is disclosed that includes a sleeping side, a cushioning layer, an inner support compartment, and a fire-containing compartment disposed between the sleeping side and the inner support compartment. The fire-containing compartment includes first and second layers of fire-resistant material selected from the group consisting of a barrier sheet, a high loft batt, and a fire-resistant chemical. The cushioning layer is disposed between the first and second layers of fire-resistant material.
    Type: Application
    Filed: January 4, 2013
    Publication date: May 30, 2013
    Applicant: Serta, Inc.
    Inventor: Serta, Inc.
  • Publication number: 20130117940
    Abstract: A composite upholstery panel includes a layer of ticking fabric, a layer of flame and heat-resistant backing fabric, and a layer of resilient flame and heat-resistant cushioning material sandwiched between the layer of ticking fabric and the layer of backing fabric. The composite upholstery panel maintains flame and heat resistant integrity when impinged at any location with a gas flame in accordance with testing protocol set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs (TB-603). However, individually, the ticking layer, backing layer and cushioning layer would fail to maintain flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocol set forth in TB-603.
    Type: Application
    Filed: January 2, 2013
    Publication date: May 16, 2013
    Applicant: Precision Fabrics Group, Inc.
    Inventor: Precision Fabrics Group, Inc.
  • Publication number: 20130111672
    Abstract: A mattress is constructed of a core comprising a matrix of foam pieces that are bonded together. The core has a thickness in the range from about 1.5 inches to about 10 inches, and more particularly from about 3 inches to about 8 inches, a density of about 4 pounds to 8 pounds per cubic foot, and an IFD of about 28 to 65. The core has a top surface and a bottom surface. A base layer is coupled to the bottom surface of the core, and a cushion layer is coupled to the top surface.
    Type: Application
    Filed: November 1, 2012
    Publication date: May 9, 2013
    Inventor: Bob Rensink
  • Patent number: 8429776
    Abstract: A fire-retardant mattress having at least one sleeping side is disclosed that has an inner support compartment with a generally parallelepiped shape with a top side opposite the sleeping side and a fire-containing compartment covering the top side of the inner support compartment and located between the sleeping side and the inner support compartment. The fire-containing compartment includes a first fire-resistant layer consisting essentially of natural fibers, the first fire-resistant layer being in direct contact with the top side of the inner support compartment, a second fire-resistant layer consisting essentially of natural fibers, the second fire-resistant layer located separate from the first self supporting layer of fire-resistant material, and a plurality of combustible cushioning layers positioned between the first and second fire-resistant layers.
    Type: Grant
    Filed: March 27, 2012
    Date of Patent: April 30, 2013
    Assignee: Serta, Inc.
    Inventors: Alvin R. Klancnik, Stephen E. Wolf, Kenneth R. Oliver
  • Patent number: 8414732
    Abstract: 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.
    Type: Grant
    Filed: November 23, 2010
    Date of Patent: April 9, 2013
    Assignee: Dreamwell, Ltd.
    Inventor: Michael S. DeFranks
  • Publication number: 20130022805
    Abstract: A mattress, foundation, or other upholstered sleep product or article includes a core and barrier material surrounding the core. The barrier material includes flame and heat-resistant material that is configured to prevent combustion of the core when the upholstered article is impinged with a gas flame according to California Technical Bulletin 603 of the State of California Department of Consumer Affairs. The barrier material may include an intumescent material that is configured to swell and char in the presence of a flame so as to form a barrier to the flame and to heat generated by the flame.
    Type: Application
    Filed: August 23, 2012
    Publication date: January 24, 2013
    Inventors: James Douglas Small, JR., John H. Walton, Samuel Mark Gillette, Ladson L. Fraser, JR., Zareh Mikaelian
  • Patent number: 8353072
    Abstract: A mattress is disclosed that includes a sleeping side, a cushioning layer, an inner support compartment, and a fire-containing compartment disposed between the sleeping side and the inner support compartment and including first and second layers of fire-resistant material. The cushioning layer is disposed between the first and second layers of fire-resistant material.
    Type: Grant
    Filed: March 27, 2012
    Date of Patent: January 15, 2013
    Assignee: Serta, Inc.
    Inventor: Alvin R. Klancnik
  • Publication number: 20120266384
    Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.
    Type: Application
    Filed: June 28, 2012
    Publication date: October 25, 2012
    Inventors: Melanie Pearce Jones, James Douglas Samll, JR., John H. Walton, Alfred Frank Baldwin, JR., Zarch Mikaelian
  • Publication number: 20120266385
    Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.
    Type: Application
    Filed: June 28, 2012
    Publication date: October 25, 2012
    Inventors: Melanie Pearce Jones, James Douglas Small, JR., John H. Walton, Alfred Frank Baldwin, JR., Zareh Mikaelian
  • Publication number: 20120258643
    Abstract: The present invention relates to flame-retardant Lyocell fibers which include incorporated inorganic additives which are particularly suited for use in flame barriers for articles of manufacture, such as mattresses and upholstered furniture applications.
    Type: Application
    Filed: October 12, 2010
    Publication date: October 11, 2012
    Applicant: LENZING AKTIENGESELLSCHAFT
    Inventors: Hartmut Rüf, Gert Kroner, Peter Dobson, Johann Männer, Christoph Schrempf
  • Publication number: 20120255128
    Abstract: An enhanced knit fabric fire barrier for mattresses and method for making same, the fabric barrier including a looped terry knitted fabric with a jersey side and a looped terry side; the jersey side including a fire retardant yarn and a melting yarn; the looped terry side including a fire retardant yarn; the loops in the jersey side are very high loops between about 4 mm and about 8 mm which char to provide a fire barrier for latex and highly volatile foams in mattresses. Also a double knit construction and method for making same, the fabric providing improved performance with the addition of a fire retardant yarn on the outside of the loops. Also, an enhanced fire-resistant full-foam mattress.
    Type: Application
    Filed: April 5, 2012
    Publication date: October 11, 2012
    Inventor: Ronald M. Sytz
  • Publication number: 20120246832
    Abstract: A filler cloth includes cellulosic fibers treated with a flame retardant chemistry such that the filler cloth has a char length of less than about nine inches when tested in accordance with NFPA 701, such that thermal shrinkage of the filler cloth at 400° F. is less than about 35% in any direction, and such that the filler cloth maintains flame and heat resistant integrity when impinged with a gas flame in accordance with testing protocols set forth in Technical Bulletin 603 of the State of California Department of Consumer Affairs. The filler cloth cellulosic fibers are treated with a flame retardant chemistry such that the filler cloth has a Frazier air permeability of less than about 400 cfm and a thermal resistance rating of at least about 3 when tested according to NFPA 2112.
    Type: Application
    Filed: May 30, 2012
    Publication date: October 4, 2012
    Inventors: Melanie Pearce Jones, James Douglas Small, JR., John H. Walton, Alfred Frank Baldwin, JR., Zareh Mikaelian
  • Publication number: 20120222220
    Abstract: A fire-retardant mattress having at least one sleeping side is disclosed that has an inner support compartment with a generally parallelepiped shape with a top side opposite the sleeping side and a fire-containing compartment covering the top side of the inner support compartment and located between the sleeping side and the inner support compartment. The fire-containing compartment includes a first fire-resistant layer consisting essentially of natural fibers, the first fire-resistant layer being in direct contact with the top side of the inner support compartment, a second fire-resistant layer consisting essentially of natural fibers, the second fire-resistant layer located separate from the first self supporting layer of fire-resistant material, and a plurality of combustible cushioning layers positioned between the first and second fire-resistant layers.
    Type: Application
    Filed: March 27, 2012
    Publication date: September 6, 2012
    Inventors: Alvin R. Klancnik, Stephen E. Wolf, Kenneth R. Oliver
  • Publication number: 20120219784
    Abstract: The invention relates to the use of a regenerated cellulose fiber, in which carboxymethylcellulose is incorporated, in a flame-retardant product.
    Type: Application
    Filed: July 9, 2010
    Publication date: August 30, 2012
    Applicant: Kelheim Fibres GmbH
    Inventor: Ingo Bernt
  • Publication number: 20120180223
    Abstract: A mattress is disclosed that includes a sleeping side, a cushioning layer, an inner support compartment, and a fire-containing compartment disposed between the sleeping side and the inner support compartment and including first and second layers of fire-resistant material. The cushioning layer is disposed between the first and second layers of fire-resistant material.
    Type: Application
    Filed: March 27, 2012
    Publication date: July 19, 2012
    Inventor: Alvin R. Klancnik
  • Patent number: 8181293
    Abstract: A mattress is constructed from a mattress body having an upper and a lower deck, which is preferably pervious to moisture and air. A removable panel, which includes a top layer of breathable fabric, a bottom layer of a fabric that forms a moisture barrier, and a batting layer, is placed on at least the upper deck of the mattress body. The removable panel is removably attached along the perimeter of the deck or decks by a fastener, such as a zipper. The panel can be removed from the deck for cleaning and folded and secured by the fastener in an inverted configuration, with the top layer facing outward.
    Type: Grant
    Filed: September 14, 2009
    Date of Patent: May 22, 2012
    Assignee: Dreamwell, Ltd.
    Inventors: Michael S. DeFranks, Kurtis A. Ling, Joyce A. Handley, James R. Peavyhouse, Ruben M. Ortiz
  • Publication number: 20120102657
    Abstract: A mattress construction having a resilient core incorporating deformable foam either alone or in combination with integrated springs with a complimentary flame barrier fabric disposed in overlying relation to the resilient core. The flame barrier fabric has a stitch-bonded construction with elastomeric yarns extending in stitched relation through a fleece substrate of substantially inelastic character incorporating a percentage of flame retardant fibers. In a relaxed condition, the fleece substrate is bunched between stitch lines formed by the elastomeric yarns. Upon the application of tension, the barrier fabric stretches by the extension of the elastomeric stitching yarns in combination with a flattening of the fleece substrate.
    Type: Application
    Filed: October 5, 2011
    Publication date: May 3, 2012
    Inventor: Martin Wildeman
  • Publication number: 20120102656
    Abstract: A fire-retardant mattress that compartmentalizes bedding material between layers of fire-resistant material. The mattress includes an inner support compartment, a first layer of fire-resistant material adjacent to at least one side of the inner support compartment, at least one layer of cushioning material adjacent to the first layer of fire-resistant material, and a second layer of fire-resistant material adjacent to the at least one cushioning layer, the second layer of fire-resistant material distal to the first layer of fire-resistant material.
    Type: Application
    Filed: August 4, 2011
    Publication date: May 3, 2012
    Inventor: Alvin R. Klancnik
  • Publication number: 20120036644
    Abstract: A removable top panel for a mattress assembly generally includes at least one layer having length and width dimensions sufficient to support a reclining body of the user; a mechanical fastener component disposed at about a perimeter edge of a bottom facing surface of the at least one layer, wherein the mechanical fastener is configured to provide releasable engagement to an underlying mattress body; and a layer of a fire resistant material extending inwardly from the perimeter edge. Also disclosed are mattress assemblies including the removable top panel.
    Type: Application
    Filed: August 11, 2011
    Publication date: February 16, 2012
    Applicant: DREAMWELL, LTD.
    Inventor: Jeremy B. Lynn
  • Publication number: 20120005836
    Abstract: The invention provides a corrugated mattress and method for making. The mattress comprises an corrugated foam core, a middle cushioning layer and outer cover layer. The corrugated foam core includes an upper substrate, a lower substrate and a fluted middle substrate the flutes fixed to the upper and lower substrates providing three-dimensional support for the user. The middle cushioning layer may comprise a second corrugated foam product, a cotton batting layer, densified polyester or foam including polyurethane, polyester, polypropylene or polylactic acid and the like. The outer cover layer may comprise cotton or laminated foam comprising, polyurethane, polyethylene, polyester, polypropylene, polylactic acid and the like, the laminate comprising a film independently selected from polyurethane, polyethylene, polyester, polypropylene or polylactic acid and the like. In various embodiments the polymers are food grade polymers such that the mattress is non-toxic.
    Type: Application
    Filed: July 6, 2011
    Publication date: January 12, 2012
    Inventor: Jason Cik
  • Publication number: 20110283458
    Abstract: A method of producing a ticking includes laminating a flame retardant backer to film material, wherein the backer releases flame retardant in the vapor phase that reduces the rate of flame propagation along the film material, when the ticking layer is exposed to flame. The backer is laminated in direct contact with the film material. In some embodiments, the laminated ticking is configured to release less than 15 MJ of heat in the first ten minutes when exposed to a flame in accordance with the testing protocol set forth in 16 CFR 1633. Upholstered articles, such as mattresses, mattress foundations, and articles of furniture, may incorporate the ticking layer.
    Type: Application
    Filed: May 18, 2010
    Publication date: November 24, 2011
    Inventors: Samuel Mark Gillette, Zareh Mikaelian, Ladson L. Fraser, JR., James Douglas Small, JR.
  • Publication number: 20110274869
    Abstract: The invention relates to a flame-retardant, modified hollow fiber with a silicone-free soft-touch finish feature, and also to a method for production thereof and the use thereof for fiberfill fiber products, in particular in the fiber filling of clothing, cushions, furniture, insulation, quilts, filters, upholstery (e.g., automobiles), sleeping bags, mattress covers and mattresses. In general, the hollow fibers used for these applications are those with flame-retardant, phosphorus-containing compounds. Polyester hollow fibers are used preferably as hollow fibers.
    Type: Application
    Filed: September 23, 2009
    Publication date: November 10, 2011
    Inventors: Kay Bernhard, Jörg Dahringer, Michael Klanert
  • Publication number: 20110173757
    Abstract: A cushion may be constructed of a spacer material having a top layer, a bottom layer and a plurality of loosely arranged spacer elements that extend between the top and bottom layers so as to maintain the top layer and the bottom layer spaced apart from each other. An elastomeric gel material is incorporated into the top layer and/or the bottom layer. The gel material may also extend into at least a portion of the spacer elements.
    Type: Application
    Filed: March 4, 2011
    Publication date: July 21, 2011
    Applicant: Denver Mattress Co. LLC
    Inventors: Bob Rensink, Jonathan Amendola
  • Publication number: 20110067182
    Abstract: A bed-bug proof mattress comprises an inner section including filler and springs and a continuous outer layer comprised of (i) a bed bug retardant layer made of light weight interlock knit polyester laminated to a hydrophilic breathable polyurethane film, (ii) a fire retardant layer; (iii) a foam layer, the bed bug retardant layer quilted to the fire retardant layer and to the foam layer and containing a seam. The bed bug retardant layer is integrally joined to the fire retardant layer and to the foam layer by being quilted together during the manufacturing of the mattress. The bed bug retardant layer may be approximately one mil thick. The interlock knit provides few places for dust accumulation and the film may act as a barrier for bed bugs. Although the film may be hydrophilic to increases the user's comfort, it may be without pores or even micropores so that it can act as an effective barrier.
    Type: Application
    Filed: September 22, 2009
    Publication date: March 24, 2011
    Inventor: ALEX KUSSOFF
  • Patent number: 7849542
    Abstract: 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.
    Type: Grant
    Filed: June 21, 2006
    Date of Patent: December 14, 2010
    Assignee: Dreamwell, Ltd.
    Inventor: Michael S. DeFranks
  • Patent number: 7832038
    Abstract: 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.
    Type: Grant
    Filed: April 19, 2007
    Date of Patent: November 16, 2010
    Assignee: Kickball Concepts, LLC
    Inventors: Harrison Robert Murphy, Juraj Michal Daniel Slavik, II
  • Patent number: 7827637
    Abstract: A flame resistant moisture barrier and a mattress having such a barrier and related methods of manufacture provide mattresses, furniture cushions and other products that provide resistance to flame and moisture.
    Type: Grant
    Filed: October 12, 2005
    Date of Patent: November 9, 2010
    Assignee: Dreamwell, Ltd.
    Inventor: Michael S. DeFranks
  • Publication number: 20100180383
    Abstract: A low-profile mattress comprises an inner spring core having a plurality of spring coils and having an upper and lower surface. The mattress further includes a padding layer disposed on the upper surface and a quilting layer disposed over the padding layer and having an exterior layer of a liquid resistant material, wherein the innerspring core padding layer and quilting layer are dimensionally adapted to be less than eight inches in height.
    Type: Application
    Filed: August 26, 2009
    Publication date: July 22, 2010
    Applicant: Dreamwell, Ltd.
    Inventors: Richard F. Gladney, Timothy Oakhill, Don Hofmann
  • Publication number: 20100170042
    Abstract: The present invention is directed toward an improved foam mattress. In one embodiment, the mattress has a base layer coupled to rectangular side sections each having a top surface. The top surfaces of the side sections extend above the top surface of the base layer and define a periphery of a space. The base layer and side sections are made of a material having a first resiliency. A central core layer is configured to fit entirely within the space defined by the side sections and is made of a material having a second resiliency, where the second resiliency is lower than said first resiliency. A top layer rests on the top surface of the central core layer and the top surface of the side sections. The top layer is made of a material of having a resiliency equal to or less than the second resiliency.
    Type: Application
    Filed: January 7, 2010
    Publication date: July 8, 2010
    Inventor: William H. Rose
  • Publication number: 20100017967
    Abstract: A mattress, mattress foundation, upholstered furniture article, filled furnishing article or other similar composite article for use in institutional (non-residential) occupancies made with a fluid proof outer cover, a fire barrier material and a mattress core, wherein all materials used are free of halogens are presented.
    Type: Application
    Filed: June 12, 2009
    Publication date: January 28, 2010
    Inventors: Harrison MURPHY, Juraj Michal Daniel Slavik, II
  • Publication number: 20100000019
    Abstract: A mattress is constructed from a mattress body having an upper and a lower deck, which is preferably pervious to moisture and air. A removable panel, which includes a top layer of breathable fabric, a bottom layer of a fabric that forms a moisture barrier, and a batting layer, is placed on at least the upper deck of the mattress body. The removable panel is removably attached along the perimeter of the deck or decks by a fastener, such as a zipper. The panel can be removed from the deck for cleaning and folded and secured by the fastener in an inverted configuration, with the top layer facing outward.
    Type: Application
    Filed: September 14, 2009
    Publication date: January 7, 2010
    Applicant: Dreamwell, Ltd.
    Inventors: Michael S. DeFranks, Kurtis A. Ling, Joyce A. Handley, James R. Peavyhouse, Ruben M. Ortiz
  • Patent number: 7587775
    Abstract: A mattress is constructed from a mattress body having an upper and a lower deck, which is preferably pervious to moisture and air. A removable panel, which includes a top layer of breathable fabric, a bottom layer of a fabric that forms a moisture barrier, and a batting layer, is placed on at least the upper deck of the mattress body. The removable panel is removably attached along the perimeter of the deck or decks by a fastener, such as a zipper. The panel can be removed from the deck for cleaning and folded and secured by the fastener in an inverted configuration, with the top layer facing outward.
    Type: Grant
    Filed: March 19, 2008
    Date of Patent: September 15, 2009
    Assignee: Dreamwell, Ltd.
    Inventors: Michael S. DeFranks, Kurtis A. Ling, Joyce A. Handley, James R. Peavyhouse, Ruben M. Ortiz
  • Publication number: 20090149101
    Abstract: A fire barrier fabric further comprising a multilayer fabric having at least two layers, including an outside layer and a fire barrier layer; wherein the fire barrier layer provides flame-retardant and/or flame-resistant properties to the entire fabric without requiring fabric coatings or treatments to provide any contribution to flame retardance or resistance, wherein additional layers may include a filler layer, and wherein the fabric is applied to articles, such as upholstered articles and mattresses.
    Type: Application
    Filed: November 25, 2008
    Publication date: June 11, 2009
    Inventor: Ronald M. Sytz
  • Publication number: 20090144907
    Abstract: The systems and methods described herein include, among other things, methods for manufacturing a fire-retardant mattress. In certain embodiments, the methods described herein employ an adhesive tape to secure a sock of fire resistant fabric to the exterior of a mattress core, rendering the mattress fire resistant. The mattress core may be a foam core, an innerspring core, or another type of core. The tape may be a two sided adhesive tape and the fire-retardant (FR) sock may be any suitable fire resistant material.
    Type: Application
    Filed: September 16, 2008
    Publication date: June 11, 2009
    Applicant: Dreamwell, Ltd.
    Inventors: Richard F. Gladney, Michael S. DeFranks
  • Publication number: 20090126119
    Abstract: A mattress or mattress foundation comprising a core and a ticking surrounding the core, the core comprising a spring assembly, a flammable core component positioned above the spring assembly, and a fire resistant (FR) insulator pad positioned between a spring assembly and the flammable core component, wherein the FR Insulator pads protects the flammable core component by delaying the penetration of the flammable core component by the spring assembly during a partial or complete consumption of the mattress or mattress foundation by a fire. The FR insulation pad may be a nonwoven fiber batt comprising a homogeneous blend of shoddy fibers and oxidized polyacrylonitrile fibers. If the mattress or mattress foundation further comprises a surface FR layer, the surface FR layer is the primary FR layer for the mattress or mattress foundation and the FR Insulator pad is the secondary FR layer for the mattress or mattress foundation.
    Type: Application
    Filed: April 11, 2008
    Publication date: May 21, 2009
    Applicant: L&P Property Management Company, a Delaware corporation
    Inventor: Steven E. OGLE
  • Publication number: 20090094754
    Abstract: A foam core article such as a mattress or pillow is covered on a surface with a flexible heat-resistant knitted fabric. Preferably a further sacrificial fabric also is used to allow passage of CPSC 16 CFR 1633 with a peak heat release of no more than 200 kilowatts in a 30 minute time period following ignition.
    Type: Application
    Filed: September 24, 2008
    Publication date: April 16, 2009
    Inventors: Walter Randall Hall, III, Warren Francis Knoff, Llewellyn Bentley Richardson, III
  • Publication number: 20090083910
    Abstract: Flame resistant fabrics useful as battings such as in mattresses and upholstery contain cellulose fibers (which retain at least 10 percent of their weight when heated in air to 700° C. at a rate of 20° C. per minute) and animal wool.
    Type: Application
    Filed: December 8, 2008
    Publication date: April 2, 2009
    Applicant: E. I. DU PONT DE NEMOURS AND COMPANY
    Inventors: Warren F. Knoff, Walter Randall Hall, III