Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
  • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/026—Knitted fabric
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
  • B32B2262/0261—Polyamide fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/724—Permeability to gases, adsorption
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/726—Permeability to liquids, absorption
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/726—Permeability to liquids, absorption
  • B32B2307/7265—Non-permeable
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2375/00—Polyureas; Polyurethanes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2601/00—Upholstery
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2403/00—Details of fabric structure established in the fabric forming process
  • D10B2403/01—Surface features
  • D10B2403/011—Dissimilar front and back faces
  • D10B2403/0112—One smooth surface, e.g. laminated or coated
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2403/00—Details of fabric structure established in the fabric forming process
  • D10B2403/02—Cross-sectional features
  • D10B2403/021—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
  • D10B2403/0213—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics with apertures, e.g. with one or more mesh fabric plies
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2503/00—Domestic or personal
  • D10B2503/06—Bed linen
  • D10B2503/062—Fitted bedsheets

Definitions

• This invention relates to spacer materials and more particularly to a novel spacer material and a novel mattress cover and composite mattress construction produced therefrom.
• a typical ventilated mattress construction comprises a core, consisting of a resilient layer of foamed plastics material having relatively large holes or perforations therethrough, covered by a fabric layer.
• the relatively large holes in the foam core have been considered necessary because of the hitherto recommended practice of laying babies on their stomachs on the cot mattress and the concern that the baby must be able to breathe comfortably when in this position.
• Ventilated cot mattresses are not easy to wash, and as a result vomit and other bodily excretions tend to become trapped in the perforations or holes in the foamed plastics core. These mattresses are therefore rather insanitary, and are capable of spreading diseases.
• a spacer fabric comprises a warp knitted double face construction in which the fabric faces are interconnected by a spacer yarn.
• Spacer fabrics have been suggested for many applications, and, for example, typical spacer fabrics and their potential uses are disclosed in DE3004444, DE4239068, DE-U-9016062.2, DE-U-9309374.8 and DE3139402, the entire disclosures of which are incorporated herein by reference.
• brochure "Spacer Fabrics - Manufacturing Methods and Applications” published in 1994 by Karl Mayer Textilmaschinenfabrik GmbH, a spacer fabric for a mattress cover is disclosed, the fabric having one dense and one open structure surface and a height of 4 to 12mm.
• the spacer fabric disclosed is to be used with anything other than a traditional sprung mattress, or a ventilated foam mattress body or core.
• the spacer fabric proposed is still a knitted, permeable structure and would not completely prevent body fluids from penetrating into the core or body of the mattress.
• the brochure does not address the problems of baby breathability, heat dissipation and fire retardance previously discussed in connection with cot mattresses. The entire disclosure of the brochure is incorporated herein by reference for all purposes.
• the present invention provides a novel spacer material which substantially obviates at least some of the problems set out above, and which comprises in combination a permeable heat and liquid dissipating fabric and a liquid impermeable layer.
• a novel spacer material comprises a fabric providing a liquid permeable and breathable upper surface and a heat and liquid dissipating spacer layer, and a liquid impermeable lower surface layer.
• the invention provides a mattress cover material which comprises a spacer material comprising a fabric providing a liquid permeable and breathable upper surface and a heat and liquid dissipating spacer layer, and a liquid impermeable lower surface layer.
• the invention provides a cot mattress comprising a foam plastics core and a cover comprising a spacer material comprising a fabric providing a liquid permeable and breathable upper surface and a heat and liquid dissipating spacer layer, and a liquid impermeable lower surface layer.
• the mattress achieves a pass under BS Standard 7177 for resistance to ignition of mattresses, divans and bed bases and BS Standard 1877 fire retardancy test for mattresses and bumpers for childrens' cots, perambulators and similar domestic articles and is devoid of fire retardant additives comprising antimony, phosphorus or arsenic.
• the fabric is a spacer fabric, which may have an upper surface in the form of a warp knitted mesh.
• the mesh hole size is preferably as large as possible for drainage and ventilation purposes, but should not be so large as to cause discomfort when placed next to the skin.
• the upper surface of the spacer fabric is preferably such that liquids and air can easily pass therethrough and into the spacer layer and the spacer fabric is preferably such that it has an enhanced ability to conduct liquid away from the surface and dissipate it through the fabric structure, and such that it permits passage of air through the structure.
• the upper surface of the spacer fabric is such that liquids of viscosity of at least 20 dynes/cm and more preferably of at least 30 dynes/cm can pass through the upper surface and into the spacer layer without lying on the surface.
• the upper surface of the spacer fabric has a grade of less than 1 when tested in accordance with the Oil Repellency Rating AATCC method.
• the spacer fabric preferably also has a high wickability, which is defined as the ability of the fabric to conduct liquid away from the area of initial contact and form a relatively thin liquid film within the fabric structure. Wickability can be measured in accordance with BS 3424 Part 18 by suspending test specimens vertically over a tray of water containing a suitable dye and measuring the height to which the liquid rises in a given time.
• the spacer fabric is such that the wicked liquid rises to a height of at least 100mm, and more preferably at least 125mm, when tested in both the warp and weft directions, in a time of 40 minutes.
• a further measure of the ability of the spacer fabric to take liquid away from its surface and dissipate it through the fabric structure is a water dispersion test in which a solution containing a suitable dye is used to measure the spread of liquid into and through the fabric. In this test, a measured amount of liquid (0.5ml) is applied to the fabric upper surface. The dimensions of the area stained due to the spread of liquid are measured over time. In a preferred spacer fabric in accordance with the invention the dimensions of the spread of water containing dye are at least 5.5cm x 2.5cm and the spread of liquid reaches near equilibrium in about 15 minutes.
• the breathability of the upper surface is preferably such that, when placed face down upon the fabric, a baby can continue to breathe relatively normally.
• a suitable air permeability test providing a measure of the breathability of a fabric, i.e. the ease with which air passes through the fabric structure, is BS 4578:1970 Measurement of Restriction of Airflow.
• the spacer fabric has a value of less than 5, more preferably less than 2, when tested in accordance with BS 4578:1970.
• the fabric preferably has good heat dissipation, such that it can dissipate heat rapidly away from a hot body.
• the fabric is such that the temperature of the fabric when placed under a hot plate with an initial temperature of 34°C does not exceed 25"C and more preferably 22"C after 10 minutes, and preferably does not exceed 48*C and more preferably 47°C after one hour.
• the preferred embodiments of the present invention achieve breathability and heat dissipation through the use of a combination of a permeable mesh upper surface and a spacer layer which is largely an open structure permitting relatively unimpeded circulation of air and which is relatively crush resistant, such that a baby's weight, when distributed across the spacer material, does not completely crush the spacer layer in use, allowing continued air circulation.
• the linking threads of the central spacer layer preferably comprise a monofilament yarn which traverses back and forth between the upper and lower surfaces.
• linking threads Whilst the linking threads can be perpendicularly arranged, they are preferably arranged such that each pair, or group, of threads is in the form of a V-shape, when the fabric is viewed in cross-section, with the angle of the V preferably being from 5° to 55°, for example, about 30° to about 35°.
• the V-shaped pairs or groups of threads can form a zig-zag pattern.
• linking threads need to have a sufficient stiffness to resist complete crushing of the fabric by the distributed weight of the baby, and yet have sufficient resilience to impart a springiness or "give" to the fabric for comfort.
• Preferred yarns for use as linking threads have a dTex of from 33 to 108, and are made, for example, from a polyamide such as Nylon, or a polypropylene.
• the spacer fabric is such that the spacer layer requires a work of compression, as measured by BS4098:1975 of at least 60J/m 2 , preferably at least
• the lower surface of the spacer fabric is preferably a multifilament or spun filament warp knitted fabric.
• the lower surface is sufficiently tightly knitted to provide a suitable substrate for good adhesion to a non-permeable backing layer.
• Liquid impermeability can be imparted to the lower surface of the spacer material by a number of methods, for example, by direct coating of the lower surface of the fabric with a liquid-impermeable polymeric material, by impregnation of a liquid-impermeable polymeric material, or by transfer coating, or laminating, a film of liquid-impermeable polymeric material thereto, to provide a tightly adherent, liquid impermeable, backing layer or impregnated layer.
• the liquid- impermeable layer is provided by laminating a flexible backing layer of a suitable polymeric material, for example, a polyurethane film, to the lower surface of the fabric by means of an adhesive.
• the layer of polymeric material is preferably from 10 to 30 microns in thickness, and good results and with good spacer material flexibility have been achieved using a 25 micron thick polyurethane layer.
• Other polymeric film materials such as, for example, polyethylene and polyvinylchloride may also be used in appropriate circumstances.
• an adhesive used for laminating
• this may be solvent or heat activated, or cold-cured, but the amount of heat and pressure used in the lamination process must neither be sufficient to compress the resultant spacer material unduly, nor to cause permanent damage thereto.
• the adhesive when set, forms a flexible film in order to permit crumpling and flexing of the material without cracking of the film.
• the backing layer achieves a pass as waterproof when tested in accordance with BS EB 20811:1992.
• the backing layer is preferably such that it can be repeatedly machine washed and dried in a tumble dryer without shrinkage or permanent damage thereto.
• the foam plastics core or body of the mattress preferably comprises an open cell polymeric foam material, for example, a foam polyurethane, and very good results have been obtained using Vitafoam, a polyurethane foam comprising melamine as a fire retardant additive.
• the foam plastics core or body is permeable to air, although with certain spacer materials of high breathability this may not be essential. Perforation of the foam plastics core is not usually required.
• the spacer material is used as a cover material or mattress protector, it is preferably removable from the mattress core or body for washing purposes, and for example, the cover material or mattress protector may be a loose cover, or provided with a zip at one or more edge regions to permit such removal.
• the spacer material as the top surface layer only of the mattress, the sides and lower surfaces being made of cheaper standard mattress cover fabric material.
• the yarns used for knitting the upper and lower surfaces of the spacer fabric are preferably non- allergenic, and preferably contain no animal fibres.
• Synthetic yarns and threads such as, for example, polyamides or polyesters are preferred, and, especially for the upper surface, they are preferably treated to provide a soft handle. Good results have been obtained with spun or textured Nylon, and the use of brush-effect Nylon is also possible.
• Natural yarns such as cotton may also be used for all, or a percentage, of the upper surface yarn, in order to give a natural feel to the upper surface, provided however that the composite cot mattress can still achieve a pass under BS Standard 7177 for resistance to ignition of mattresses, divans and bed bases and BS Standard 1877 fire retardancy test for mattresses and bumpers for childrens cots, perambulators and similar domestic articles.
• Spacer fabrics can be knitted, for example, on Raschelmachines with two needle bars. Depending upon the nature of the spacer fabric and its physical requirements, a minimum of four guide bars, and normally 4 to 6 guide bars, are used. In addition to the requirements set out hitherto, the thickness of the yarn used for the spacer threads also depends on the distance between the upper and lower surfaces, the desired softness of the upper surface, and whether the central layer is knitted with one guide bar or with two guide bars knitting in opposition to each other. The manufacturing methods for spacer fabrics are discussed in the aforementioned Karl Mayer brochure. In the spacer materials of the present invention, the distance between the upper and lower surfaces, that is, the width of the spacer layer, is preferably from 3 to 6mm, more preferably about 5mm.
• a spacer fabric for a material in accordance with the invention is knitted on an RD6N machine using two needle bars and five guide bars.
• the sequence of operation is as follows:
• GUIDE BAR 5 2-2-2-0/0-0-2-4// Guide bars 1 and 2 form the top mesh surface.
• the guide bar movement to form the mesh may be varied to make an oval, hexagonal, diamond, square, round, rectangular etc type mesh as desired.
• Guide bars 3 and 4 could have different movements for the linking threads, which could in an alternative manufacturing method use only one instead of two guide bars.
• Guide bar 5 could again have different movements for the production of different fabric backing types, and/or one or two guide bars could be used.
• Eg. 0-2 is a movement over one needle.
• 0-4 is a movement over two needles.
• the numbers between the / marks represent the movement with respect to a needle bar or bars.
• Eg. 2-0/2-4// will mean the guide bar knitting over both needle bars (to use the linking threads).
• 2-0-2-2/ will mean the guide bar knitting only on one needle bed, as there is no movement (2-2) on the second needle bar.
• the yarn dTex (thickness) is as follows:
• the resultant spacer fabric has a thickness of 5mm, and upper surface mesh hole average diameter of 2mm.
• a 25 micron thick liquid-impermeable polyurethane layer is laminated to the lower surface of the spacer fabric produced as described above using a solvent-based adhesive.
• the resultant spacer material can be slit to 60cm wide and made up into a zip-off cover for a cot mattress.
• the foam core of the cot mattress is a 10cm thick polyurethane foam material of grade 35M.
• Liquid dissipation test to demonstrate the ability of the fabric to take liquid away from the surface and dissipate it through the fabric structure
• the test consists of three parts as follows:
• Grade less than 1 indicates that liquids of all tested viscosities soaked into the fabric structure and proves liquid would not sit on the fabric surface.
• Test specimens are suspended over a tray of water containing dye, which leaves a visible stain to indicate the height to which the liquid rises.
• the fabric is tested, and compared to a control sample of a woven cotton mattress fabric, in both directions of the fabric.
• the spacer fabric wicks liquid to a height of 209mm in the warp and 150mm in the weft following 40 mins exposure.
• the woven fabric wicks liquid to a height of less than 5mm in both directions following 40 mins exposure.
• the spacer fabric is a superior fabric in terms of wicking liquid through the fabric structure, i.e. the liquid will spread into a relatively thin film within the fabric. Washing removes the liquid.
• a solution containing dye is used to measure the spread of liquid into and through the spacer fabric.
• a measured amount (0.5ml) is applied to the fabric surface.
• the dimensions of the area stained due to the spread of liquid are measured over time.
• the fabric is compared with control samples of a woven cotton mattress fabric and p.v.c. It is found that the spread of liquid in the spacer fabric reaches near equilibrium, i.e. maximum spread, after 15 minutes. The dimensions of the area covered are on average, 11cm x 5cm.
• Both the cotton woven fabric and p.v.c. are found to have zero spread, and water therefore sits on the surface of the fabrics.
• the spacer fabric is superior in taking liquid away from the surface of the fabric and dissipating it through the fabric structure.
• Air permeability test to assess the breathability of the fabric, i.e. the ease with which air passes through the fabric structure
• Spacer material mattress cover (tested fabric side) 1 . 7mm H 2 0 100% p.v.c. mattress cover > 40.0mm H 2 0 Cotton woven mattress cover 5. 1mm H,0 The closer the result is to zero the better the airflow through the mattress cover.
• the spacer material mattress cover has a significantly higher permeability and thus, improved breathability.
• the spacer material mattress cover is at least as good as a cotton woven mattress cover even when in combination with a flannelette sheet overlay.
• a waterproofness test of the liquid impermeable layer of the spacer material (BS EN 20811:1992) is carried out and the layer is found to pass as waterproof.
• the Mattress is tested for fire retardancy to the standard laid down in the Furniture and Furnishing (Fire)(Safety) Regulations 1988. The result is a pass.
• washability tests are carried out.
• the suitable care instructions are:
• thermocouples 1 and 6 were disposed under the hot plate in the central region thereof and 10 cms apart.
• Thermocouples 2 and 7 were disposed at the edge of the hot plate.
• Thermocouples 3 to 5 were disposed in a line, respectively 4cms, 8cms and 12 cms from the edge of the hot plate.
• Tables 1 and 2 give the results for all the thermocouples 1 to 10.
• Figure 3 shows graphically the temperature rise with time for thermocouples 1, 3, and 5. The results show that, using the mattress cover of the invention, the temperature rises more slowly, and even after 75 minutes, the temperature under the hot plate using the mattress cover of the invention is significantly lower than that of the PVC control.
• Figure 1 shows the upper surface of a portion of the spacer material in plan view
• Figure 2 shows a sectional side elevation of the spacer material of Figure 1.
• the spacer material illustrated generally at 1 comprises a spacer fabric 2 having an upper surface 3 comprising a mesh with holes 4.
• FIG. 2 there is shown the spacer layer 5, having spacer threads 6, disposed in generally V-shaped groups 7, with an acute angle ⁇ , as illustrated, between threads of opposed inclination.
• the lower surface 8 of the spacer fabric 2 has laminated thereto a flexible liquid impermeable polymeric film 9.
• Preferred embodiments of the mattress cover material of the invention have a number of advantages over spacer fabrics hitherto proposed.
• the spacer materials can achieve breathability by using a mesh as the upper surface and maintaining a spacer layer between the upper and lower surfaces to create a route for the relative free movement of air.
• the linking threads connecting the upper and lower surfaces of the spacer fabric can be of a stiffness and orientation sufficient to maintain the spacer layer against compression in use, and to maintain a good air movement ability, which allows convection air currents within the spacer layer to transfer heat away from the baby's body, thereby preventing heat build-up and heat stress to the baby.
• the mesh upper surface can allow drainage of body fluids into the spacer layer and the open structure of the spacer layer can allow the fluids to be dissipated, thus reducing discomfort to the baby.
• the liquid impermeable lower surface of the spacer material can protect the foam plastics mattress core from body fluids thus maintaining hygienic conditions.
• the spacer material can be washable, thus preventing or reducing bacterial growth, and enhancing the hygiene of the cot environment.
• the spacer material can retain sufficient compressibility and "give” to allow comfort and an improved rest environment.
• the spacer material can be used with a foamed core mattress which does not need to be perforated, thereby simplifying manufacturing procedures.

Applications Claiming Priority (5)

Publications (1)

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ID=26306847

Family Applications (1)

Country Status (4)

Cited By (1)

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• 1996
  • 1996-04-04 EP EP96909241A patent/EP0820541A1/de not_active Withdrawn
  • 1996-04-04 GB GB9625774A patent/GB2305191B/en not_active Expired - Lifetime
  • 1996-04-04 WO PCT/GB1996/000834 patent/WO1996032526A1/en not_active Application Discontinuation
  • 1996-04-04 AU AU52813/96A patent/AU5281396A/en not_active Abandoned

Non-Patent Citations (1)

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