Mattress containing microencapsulated phase change material

Patent metadata

Field	Value
Publication number	US-10111534-B2
Application number	US-201615078395-A
Country	US
Kind code	B2
Filing date	Mar 23, 2016
Priority date	Apr 1, 2015
Publication date	Oct 30, 2018
Grant date	Oct 30, 2018

Abstract

A mattress containing a core section, a high loft non-woven layer at least partially covering a first side of the core section and containing a plurality of heat and flame resistant fibers, bulking fibers, and binder fibers, a ticking layer at least partially covering the high loft non-woven layer and containing a textile layer, a pattern coated layer. The pattern coated layer may be printed on the high loft non-woven layer, the ticking layer, or any layer between the high loft non-woven layer and the ticking layer. The pattern coated layer contains a blend of microencapsulated phase change material (PCM) and a binder, wherein the PCM is fully encapsulated by the binder.

First claim

What is claimed is:

1. A mattress comprising:
a core section, wherein the core section comprises a first side and an opposing second side connected by at least one side wall;
a high loft non-woven layer having an inner side, an outer side, a length, and a width, wherein the high loft non-woven layer at least partially covers the first side of the core section, wherein the high loft non-woven layer is oriented such that the inner side of the high loft non-woven layer faces the first side of the core section, and wherein the high loft non-woven layer comprises a plurality of heat and flame resistant fibers, bulking fibers, and binder fibers;
a pattern coated layer having a thickness and comprising a blend of microencapsulated phase change material (PCM) and a binder in a pattern, wherein the PCM is fully encapsulated by the binder and wherein the pattern coated layer overlays at least a portion of the outer side of the high loft non-woven layer, wherein the pattern is a regular, repeating pattern having a pattern density, wherein the pattern is continuous or discontinuous, and wherein at least one of the pattern coated layer thickness and pattern density vary over at least one of the length and width of the high loft non-woven layer; and,
a ticking layer having an inner side and an outer side, wherein the ticking layer at least partially covers the high loft non-woven layer, wherein the ticking layer is oriented such that the inner side of the ticking layer faces the outer side of the high loft non-woven layer, and wherein the ticking layer comprises a textile layer.

2. The mattress of claim 1 , wherein the outer side of the ticking layer forms the outermost surface of the mattress.

3. The mattress of claim 1 , wherein the pattern of the patterned coating is discontinuous.

4. The mattress of claim 1 , wherein the patterned coating covers between about 45 and 75% of the outer side of the high loft non-woven layer.

5. The mattress of claim 1 , wherein the patterned coating has an add-on weight of between about 50 and 200 g/m 2 .

6. The mattress of claim 1 , wherein the heat and flame resistant fibers comprise FR rayon.

7. The mattress of claim 1 , wherein the pattern of the patterned coating is a dot pattern.

8. The mattress of claim 1 , wherein the PCM particles have an acrylic shell.

9. The mattress of claim 1 , wherein the pattern of the patterned coating is continuous.

10. The mattress of claim 1 , wherein the layer thickness of the pattern coated layer varies over at least one of the length and width of the high loft non-woven layer.

11. The mattress of claim 1 , wherein the pattern density varies over at least one of the length and width of the high loft non-woven layer.

12. A mattress comprising:
a core section, wherein the core section comprises a first side and an opposing second side connected by at least one side wall;
a high loft non-woven layer having an inner side and an outer side, wherein the high loft non-woven layer at least partially covers the first side of the core section, wherein the high loft non-woven layer is oriented such that the inner side of the high loft non-woven layer faces the first side of the core section, and wherein the high loft non-woven layer comprises a plurality of heat and flame resistant fibers, bulking fibers, and binder fibers;
a ticking layer having an inner side and an outer side, wherein the ticking layer at least partially covers the high loft non-woven layer, wherein the ticking layer is oriented such that the inner side of the ticking layer faces the outer side of the high loft non-woven layer, and wherein the exterior ticking layer comprises a textile layer;
an additional layer having a length and a width; and,
a pattern coated layer comprising a blend of microencapsulated phase change material (PCM) and a binder in a pattern, wherein the PCM is fully encapsulated by the binder and wherein the pattern coated layer overlays a portion of the inner side of the additional layer, wherein the pattern is a regular, repeating pattern having a pattern density, wherein the pattern is continuous or discontinuous, and wherein at least one of the pattern coated layer thickness and pattern density vary over at least one of the length and width of the high loft non-woven layer.

13. The mattress of claim 12 , wherein the pattern of the patterned coating is a dot pattern.

14. The mattress of claim 12 , wherein the outer side of the ticking layer forms the outermost surface of the mattress.

15. The mattress of claim 12 , wherein the pattern of the patterned coating is discontinuous.

16. The mattress of claim 12 , wherein the patterned coating covers between about 45 and 75% of the inner side of the ticking layer.

17. The mattress of claim 12 , wherein the patterned coating has an add-on weight of between about 50 and 200 g/m 2 .

18. The mattress of claim 12 , wherein the pattern density varies over at least one of the length and width of the additional layer.

19. The mattress of claim 12 , wherein the microencapsulated PCM comprises PCM particles having an average size less than about 1000 μm.

20. The mattress of claim 12 , wherein the PCM particles have an acrylic shell.

21. The mattress of claim 12 , wherein the additional layer is a scrim.

22. The mattress of claim 12 , wherein the layer thickness of the pattern coated layer varies over at least one of the length and width of the additional layer.

23. The mattress of claim 12 , wherein the pattern of the patterned coating is continuous.

24. A mattress comprising:
a core section, wherein the core section comprises a first side and an opposing second side connected by at least one side wall;
a high loft non-woven layer having an inner side and an outer side, wherein the high loft non-woven layer at least partially covers the first side of the core section, wherein the high loft non-woven layer is oriented such that the inner side of the high loft non-woven layer faces the first side of the core section, and wherein the high loft non-woven layer comprises a plurality of heat and flame resistant fibers, bulking fibers, and binder fibers;
a ticking layer having an inner side, an outer side, a length, and a width, wherein the ticking layer at least partially covers the high loft non-woven layer, wherein the ticking layer is oriented such that the inner side of the ticking layer faces the outer side of the high loft non-woven layer, and wherein the exterior ticking layer comprises a textile layer; and,
a pattern coated layer having a thickness and comprising a blend of microencapsulated phase change material (PCM) and a binder in a pattern, wherein the PCM is fully encapsulated by the binder and wherein the pattern coated layer overlays at least a portion of the inner side of the ticking layer, wherein the pattern is a regular, repeating pattern having a pattern density, wherein the pattern is continuous or discontinuous, and wherein at least one of the pattern coated layer thickness and pattern density vary over at least one of the length and width of the high loft non-woven layer.

25. The mattress of claim 24 , wherein the outer side of the ticking layer forms the outermost surface of the mattress.

26. The mattress of claim 24 , wherein the layer thickness of the pattern coated layer varies over at least one of the length and width of the ticking layer.

27. The mattress of claim 25 , wherein t

Assignees

• Milliken & Co

Inventors

• Valenta Petr
• Carroll Patrick R
• Ringo Will
• Joyce Tripp

Classifications

• A47C31/001

  Fireproof means · CPC title

• A47C27/121 Primary

  with different inlays · CPC title

• A47C21/046

  without active means, e.g. with openings or heat conductors · CPC title

• A47C27/002

  Mattress or cushion tickings or covers · CPC title

• A47C27/122

  with special fibres, such as acrylic thread, coconut, horsehair · CPC title