EP3834669A1 - A lightweight and fireproof mattress - Google Patents
A lightweight and fireproof mattress Download PDFInfo
- Publication number
- EP3834669A1 EP3834669A1 EP20150985.8A EP20150985A EP3834669A1 EP 3834669 A1 EP3834669 A1 EP 3834669A1 EP 20150985 A EP20150985 A EP 20150985A EP 3834669 A1 EP3834669 A1 EP 3834669A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- mattress
- foam layer
- layer
- foam
- basotect
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000006260 foam Substances 0.000 claims abstract description 104
- 229920000877 Melamine resin Polymers 0.000 claims abstract description 12
- 239000004640 Melamine resin Substances 0.000 claims abstract description 9
- 239000013518 molded foam Substances 0.000 claims abstract description 3
- 239000000463 material Substances 0.000 claims description 44
- 229920005832 Basotect® Polymers 0.000 claims description 14
- 230000009970 fire resistant effect Effects 0.000 claims description 8
- 238000010521 absorption reaction Methods 0.000 claims description 7
- 239000003190 viscoelastic substance Substances 0.000 claims description 4
- 229920005830 Polyurethane Foam Polymers 0.000 claims description 3
- 239000011496 polyurethane foam Substances 0.000 claims description 3
- 229920005834 BASOTECT® G+ Polymers 0.000 claims description 2
- 239000000654 additive Substances 0.000 claims description 2
- 239000003063 flame retardant Substances 0.000 claims description 2
- 238000007541 indentation hardness test Methods 0.000 claims 1
- 239000010410 layer Substances 0.000 description 101
- XUMBMVFBXHLACL-UHFFFAOYSA-N Melanin Chemical compound O=C1C(=O)C(C2=CNC3=C(C(C(=O)C4=C32)=O)C)=C2C4=CNC2=C1C XUMBMVFBXHLACL-UHFFFAOYSA-N 0.000 description 6
- 231100001261 hazardous Toxicity 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 3
- 230000001105 regulatory effect Effects 0.000 description 3
- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical compound [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 229920000742 Cotton Polymers 0.000 description 2
- 208000034972 Sudden Infant Death Diseases 0.000 description 2
- 206010042440 Sudden infant death syndrome Diseases 0.000 description 2
- 239000011358 absorbing material Substances 0.000 description 2
- GDTBXPJZTBHREO-UHFFFAOYSA-N bromine Substances BrBr GDTBXPJZTBHREO-UHFFFAOYSA-N 0.000 description 2
- 229910052794 bromium Inorganic materials 0.000 description 2
- 239000013013 elastic material Substances 0.000 description 2
- 239000006261 foam material Substances 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 231100000331 toxic Toxicity 0.000 description 2
- 230000002588 toxic effect Effects 0.000 description 2
- UTPYTEWRMXITIN-YDWXAUTNSA-N 1-methyl-3-[(e)-[(3e)-3-(methylcarbamothioylhydrazinylidene)butan-2-ylidene]amino]thiourea Chemical compound CNC(=S)N\N=C(/C)\C(\C)=N\NC(=S)NC UTPYTEWRMXITIN-YDWXAUTNSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 235000019504 cigarettes Nutrition 0.000 description 1
- 239000002355 dual-layer Substances 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000004619 high density foam Substances 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 230000007794 irritation Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000000241 respiratory effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Images
Classifications
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C31/00—Details or accessories for chairs, beds, or the like, not provided for in other groups of this subclass, e.g. upholstery fasteners, mattress protectors, stretching devices for mattress nets
- A47C31/001—Fireproof means
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
- A47C27/056—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers with different layers of foamed material
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/148—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/15—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
Definitions
- the present invention relates to a mattress and more specifically to an elastic fireproof mattress.
- a visco-foam mattress which offers a high support because of its high density (typically over about 50 Kgs to M3 density) and feels soft and desirable to the user because it typically has an Indentation force-deflection of 15 or under.
- the high cost, bulkiness and heavy weight of the visco-foam remain disadvantages for the end user.
- a mattress comprising a lightweight first foam layer made of melamine resin, said first foam layer comprises a top surface and a bottom surface, wherein the first foam layer is formed from a single piece of molded foam and a covering layer configured to cover the first foam layer, said covering layer is made of a fire-resistant material.
- the top surface of the first foam layer is shaped as an egg crate pattern.
- the mattress defines an elevated portion adjacent to a rear surface of the first layer, and wherein the elevated portion forms a pillow.
- the elevated portion is designed with an inclination to form elongated wedge-shaped notches.
- the density of the first foam layer is in a range of 4-10 kg/m3.
- the mattress lacks fire retardant additives.
- the first foam layer is formed of a polyurethane foam. In some cases, the first foam layer consists of polyurethane foam. In some cases, the first foam layer is formed solely from a melamine resin. In some cases, the melamine resin is a product designated by the trade name "BASOTECT" in the name of BASF, Germany. In further embodiments, the melamine resin is a product designated by the trade name "BASOTECT UF" in the name of BASF, Germany. In some cases, the elastic material is classified as fireproof in accordance with ISO EN 13501-1 as B, s1, d0.
- the mattress comprising a second layer, abutting at least one of the first foam layer surfaces, and wherein the second layer is formed from a viscoelastic material.
- the second layer abutting the top surface of the material.
- the first foam layer top surface and the first foam layer bottom surface have different widths.
- fireproof used herein depicts a quality of material in which the material resists damages arising from direct fire or high temperatures derived from indirect fire or heat source.
- direct fire may be a lit cigarette placed on the mattress.
- indirect heat source may be a heating element such as a radiator or convector touching the mattress.
- Fig. 1 discloses a lightweight and fireproof mattress comprising a single layer, according to exemplary embodiments of the subject matter.
- Fig. 1 discloses a mattress 100 comprising at least a first foam layer 110.
- the first foam layer 110 is placed on a support base 120.
- the first foam layer 110 has a top surface 111, a bottom surface 112, a front side surface 113 a rear side surface 114, a first lateral surface 115 and a second lateral surface 116.
- the first foam layer 110 is formed from a single piece of molded lightweight foam.
- the top surface 111 of the first foam layer 110 may be designed in a pattern to enhance the comfortability of the mattress. In such cases, the top surface of the first foam layer may be designed, for example, as an egg crate pattern.
- the support base 120 is traditionally configured to provide elevation and support for the mattress 100.
- the support base 120 is typically formed from wood or other material as a solid frame.
- the support base 120 may be embedded in the mattress 100 as a second layer, located under the first foam layer 110.
- the first foam layer 110 and the support base 120 may be formed of the same material yet with a different density.
- the first foam layer 110 may be placed on the ground/floor as a replacement for the support base 120.
- the top surface 111 of the first foam layer 110 may have a different width than the bottom surface 112.
- the first lateral surface 115 and the second lateral surface 116 form elongated wedge-shaped notches.
- the support base 120 may comprise lateral support extensions for supporting the elongated wedge-shaped notches of the first foam layer 110.
- the first foam layer 110 is formed from an elastic material. Elasticity, which is an important concept for the aesthetics and firmness of the mattress 100, is expressed by measurements of resilience and permanent set. In some embodiments, the first foam layer 110 is formed from a material comprising an average tensile strength in the range of 90-110 kPa and/or average elongation at break in the range of 20%-30% in accordance with ISO 1798.
- the first foam layer 110 is formed from an open-cell material. In further embodiments, the first foam layer 110 is formed from a low-density material. In some embodiments, it is desirable that the first foam layer 110 would be lightweight and have a density in the range of 4-10 kg/m3 which makes the mattress significantly lighter compared to regular mattresses.
- the low density of the mattress derives from an open-cell structure of the material from which the mattress is made. Open-cell structure with low density allows air to flow through the material, making the material breathable. It is desirable to prevent infants to lie on a non-breathable foam surface, to prevent sudden infant death syndrome (SIDS) may be caused by the accumulation of carbon dioxide in bedding. Thus, allowing air to flow through the first foam layer 110, results in fresh air provided to the user sleeping thereon, which is especially relevant for infants.
- SIDS sudden infant death syndrome
- the first foam layer 110 is formed from a fire-resistant material.
- the fire-resistant material, which the first foam layer 110 is formed of lacks any additional fire redundant materials orconsist of a fire redundant material.
- material of the first foam layer 110 comprises fire redundant capabilities in accordance with ISO EN 13501-1 and classified as B, s1 and d0.
- the fire-resistant material, which the first foam layer 110 is formed of comprises high thermal endurance properties. Specifically, in some embodiments, the thermal endurance of the material forming the first layer is measured in accordance with ISO 2578 (and as defined in ISO 3386-1) as resistant to a heat of 220 °C for 1000 hours.
- the fire-resistant material, which the first foam layer 110 is formed of comprising low thermal conductivity properties.
- the thermal conductivity of the material may be in the range of 0.02- 0.05 W/mK. In more specific cases, the thermal conductivity of the material may be in the range of 0.03-0.04 W/mK. In some embodiments, the thermal conductivity is measured in accordance with the DIN EN 12667 regulation.
- the first foam layer 110 is formed from a sound absorbing material. Since many people require a low amount of noise in order to fall asleep, such material would be very beneficial to the formation of a mattress.
- the sound absorbing material is formed from an open cell material, comprising a high sound absorption quality. The open cell structure causes the sound waves touching the first foam layer 110 to penetrate the cell structure of the material unhindered in contrast to being reflected from the surface of the first foam material 110 as an echo. Thus, the sound energy is reduced in the cell structure, giving the first foam material 110 an excellent sound absorption capacity.
- the material may be formed in accordance with regulation ATSM C 426 (U.S.A) as class A.
- the thickness of the first foam layer 110 may be determined by the desired level of sound absorption. In some embodiments, the sound absorption for a 50 mm thick layer with a frequency of 2000 Hz is more than 90 percent absorption in accordance with ISO 10534.
- the first foam layer 110 of the mattress 100 may consist of a block of melamine resin, which may be formed as a foam.
- the block of melamine foam is formed as an open cell structure.
- the block of melamine foam may be the product designated by the trade name "BASOTECT” in the name of BASF, Germany.
- the first foam layer 110 of the mattress 100 may consist of the product designated by the trade name "BASOTECT UF” in the name of BASF, Germany.
- the "BASOTECT UF” is characterized by a very high elasticity and by improved fire properties.
- the product designated by the trade name "BASOTECT" is either one of: “BASOTECT UF", “BASOTECT UF+", "BASOTECT G” and "BASOTECT G+”.
- the entire mattress 100 may be cut out from a single block of material.
- the mattress 100 is not limited to a cubic rectangular shape and may be shaped in any form desirable by a user.
- the mattress 100 can be formed to have a shape of a circle fitting on a circular bed, polygonal shapes and the like.
- the mattress 100 is shaped to snugly fit inside an infant crib.
- the mattress 100 may be slightly larger than the dimensions of the crib and inserted into the crib when pressed.
- the mattress may snugly fit into a crib, despite small variations in the dimensions of the mattress caused by inconsistent manufacturing processes.
- the crib comprising such mattress is safer because there is no gap in which an infant's limb could become lodged in.
- the width of the mattress 100 may be in the range of 10-50 centimeters, made from a single sheet of lightweight and fireproof material and covered by a covering sheet which is a thin sheet, for example having width in the range of 1.5-20 millimeters, and made of an open-cell structure.
- the covering layer may be made of cotton.
- the length of the mattress 100 may be in the range 80-220 centimeters and the breadth of the mattress 100 may be in the range 30-180 centimeters.
- Figs. 2A-2B disclose a lightweight and fireproof mattress comprising a plurality of layers, according to exemplary embodiments of the subject matter.
- Fig. 2A discloses a mattress 200 comprising dual layers.
- the mattress 200 comprises a first foam layer 210 and a second foam layer 220.
- each layer of the first foam layer 210 and a second foam layer 220 may be assembled of a plurality of sublayers.
- the first foam layer 210 is identical to the first foam layer of Fig. 1 as aforementioned.
- the shape of the first foam layer 210 may vary, and may be rectangular, circular, polygonal or any other shape fitting a user's needs.
- the second foam layer 220 abuts at least one surface of the first foam layer 210.
- the second foam layer 220 may be formed from a different material from the material of the first foam layer 210 and which can provide a better comfort to the user than the first foam layer 210.
- the second foam layer 220 may be formed of viscoelastic material, adapted to distribute the user's weight and to provide a softer layer than the first foam layer 210.
- the second foam layer 220 may coat the entire surface of the first foam layer 210.
- the density of the first foam layer 210 is greater than the density of the second foam layer 220 topping the first foam layer 210.
- the first foam layer 210 is firm and provides sturdy support to the second foam layer 220, for a uniform texture across the external surface of the mattress 200.
- the overall thickness of the mattresses depends on the thicknesses of the layers 210, 220 with any additional layer of foam that may optionally be added over the second foam layer 220.
- the mattress 200 comprises three foam layers shaped in accordance with a user's preference.
- the mattress 200 comprises a bottom layer 230, a middle layer 232, and a top layer 234.
- Bottom layer 230 may be formed of regular high-density foam in order to provide stability and support for the mattress 200.
- the middle layer 232 is formed of a viscoelastic material and provides a first cushioning layer for the mattress 200.
- the middle layer 232 comprises an egg crate pattern on its top surface. Utilizing an egg crate pattern on the top surface provides a softer feel for the user.
- the top layer 234 may be formed as a thin sheet of an open cell material having an especially low density to provide a second cushioning interface for the mattress 200.
- the bottom layer 230, the middle layer 232, and the top layer 234 may be made of melamine foam. In some other embodiments, the bottom layer 230, the middle layer 232, and the top layer 234 may be made of another material that is both fire resistant and of a density lower than 10 kilograms per cubic meter (m3).
- Fig. 3 discloses a lightweight and fireproof mattress comprising an elevated portion.
- Fig. 2 discloses a mattress 300 comprising a first foam layer 310.
- the first foam layer has a top surface 311, a bottom surface 312 and a front side surface 313 a rear surface 314, a first lateral surface 315 and a second lateral surface 316.
- the first foam layer comprises an elevated foam layer 320 extending from the top surface 311, and adjacent to the rear surface 314 of the first foam layer 310.
- the elevated foam layer 320 is shaped a single pillow or two adjacent pillows. The pillows are configured to serve as a head rest for providing additional comfort to a user sleeping thereon.
- the first foam layer 310 and the elevated foam layer 320 are formed from a single block of foam.
- the elevated foam layer 320 may be inclined to create a wedge shape.
- the claimed invention may also disclose use of a melanin foam in the production of a mattress or another cushioning apparatus.
- the melanin foam is sliced from a sheet of material according to a predefined shape and covered by cotton or another open-cell structure.
- the claimed invention also discloses use of melanin foam in the fabrication of a mattress, such that the mattress allows air flow from a bottom surface of the mattress to the top surface of the mattress.
- the claimed invention also discloses a mattress made of fire resistant material that does not emit gasses, such as bromine. The fire resistance means that the mattress remains solid and firm even when caught by fire and does not change its shape and/or chemical characteristics.
Landscapes
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
Abstract
Description
- The present invention relates to a mattress and more specifically to an elastic fireproof mattress.
- The average adult spends about 7-9 hours of sleep a day. Young children spend about 9-14 hours of sleep a day and infants spend about 16 hours a day sleeping. Today, many mattresses are provided in order to provide comfortable and safe sleep. Various attempts have been made to create a mattress which can provide sufficient hardness, elasticity, softness, and comfort. For example, a visco-foam mattress, which offers a high support because of its high density (typically over about 50 Kgs to M3 density) and feels soft and desirable to the user because it typically has an Indentation force-deflection of 15 or under. However, the high cost, bulkiness and heavy weight of the visco-foam remain disadvantages for the end user.
- Additionally, many countries have legislated or regulated that mattresses should comply with regulatory standards for being fire-proof. In order to comply with those regulatory standards, many mattresses are formed with fire-redundant materials, which sometimes may be hazardous and/or toxic. With regards to infant mattresses, the addition of hazardous and/or toxic fire redundant is extremely dangerous since infants are more susceptible to the damages caused by unsafe fire redundant. Common fire redundant materials such as bromine, PBDE and the like are known to emit hazardous materials absorbed in the human body which may directly cause respiratory irritation and additional illness.
- Therefore, there is a great need for a lightweight mattress which does not comprise hazardous fire redundant materials and provides a desirable material to sleep on and nevertheless, be sufficiently fire proof.
- It is an object of the subject matter to disclose a mattress, comprising a lightweight first foam layer made of melamine resin, said first foam layer comprises a top surface and a bottom surface, wherein the first foam layer is formed from a single piece of molded foam and a covering layer configured to cover the first foam layer, said covering layer is made of a fire-resistant material.
- In some cases, the top surface of the first foam layer is shaped as an egg crate pattern. In some cases, the mattress defines an elevated portion adjacent to a rear surface of the first layer, and wherein the elevated portion forms a pillow. In some cases, the elevated portion is designed with an inclination to form elongated wedge-shaped notches. In some cases, the density of the first foam layer is in a range of 4-10 kg/m3.
- In some cases, the mattress lacks fire retardant additives. In some cases, the first foam layer is formed of a polyurethane foam. In some cases, the first foam layer consists of polyurethane foam. In some cases, the first foam layer is formed solely from a melamine resin. In some cases, the melamine resin is a product designated by the trade name "BASOTECT" in the name of BASF, Germany. In further embodiments, the melamine resin is a product designated by the trade name "BASOTECT UF" in the name of BASF, Germany. In some cases, the elastic material is classified as fireproof in accordance with ISO EN 13501-1 as B, s1, d0.
- In some cases, the mattress comprising a second layer, abutting at least one of the first foam layer surfaces, and wherein the second layer is formed from a viscoelastic material. In some cases, the second layer abutting the top surface of the material. In some cases, the first foam layer top surface and the first foam layer bottom surface have different widths.
- The invention may be more clearly understood upon reading of the following detailed description of non-limiting exemplary embodiments thereof, with reference to the following drawings, in which:
-
Fig. 1 discloses a lightweight and fireproof mattress comprising a single layer, according to exemplary embodiments of the subject matter; -
Figs. 2A-2B disclose a lightweight and fireproof mattress comprising a plurality of layers, according to exemplary embodiments of the subject matter; and -
Fig. 3 discloses a lightweight and fireproof mattress comprising an elevated portion, according to exemplary embodiments of the subject matter. - The following detailed description of embodiments of the invention refers to the accompanying drawings referred to above. Dimensions of components and features shown in the figures are chosen for convenience or clarity of presentation and are not necessarily shown to scale. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts.
- Illustrative embodiments of the invention are described below. In the interest of clarity, not all features and/or components of an actual implementation are necessarily described.
- The subject matter in the present invention discloses a fireproof lightweight mattress that lacks any materials that emit gasses to the air, as these gasses may damage the user's health. The term "fireproof' used herein depicts a quality of material in which the material resists damages arising from direct fire or high temperatures derived from indirect fire or heat source. An example for direct fire may be a lit cigarette placed on the mattress. An example of indirect heat source may be a heating element such as a radiator or convector touching the mattress.
-
Fig. 1 discloses a lightweight and fireproof mattress comprising a single layer, according to exemplary embodiments of the subject matter.Fig. 1 discloses a mattress 100 comprising at least afirst foam layer 110. In some embodiments, thefirst foam layer 110 is placed on asupport base 120. Thefirst foam layer 110 has atop surface 111, abottom surface 112, a front side surface 113 arear side surface 114, a firstlateral surface 115 and a secondlateral surface 116. In some embodiments, thefirst foam layer 110 is formed from a single piece of molded lightweight foam. In some embodiments, thetop surface 111 of thefirst foam layer 110 may be designed in a pattern to enhance the comfortability of the mattress. In such cases, the top surface of the first foam layer may be designed, for example, as an egg crate pattern. - The
support base 120 is traditionally configured to provide elevation and support for the mattress 100. Thesupport base 120 is typically formed from wood or other material as a solid frame. In some embodiments, thesupport base 120 may be embedded in the mattress 100 as a second layer, located under thefirst foam layer 110. In some embodiments, thefirst foam layer 110 and thesupport base 120 may be formed of the same material yet with a different density. In other embodiments, thefirst foam layer 110 may be placed on the ground/floor as a replacement for thesupport base 120. - In some embodiments, the
top surface 111 of thefirst foam layer 110 may have a different width than thebottom surface 112. In such cases, the firstlateral surface 115 and the secondlateral surface 116 form elongated wedge-shaped notches. In such cases, thesupport base 120 may comprise lateral support extensions for supporting the elongated wedge-shaped notches of thefirst foam layer 110. - In some embodiments, the
first foam layer 110 is formed from an elastic material. Elasticity, which is an important concept for the aesthetics and firmness of the mattress 100, is expressed by measurements of resilience and permanent set. In some embodiments, thefirst foam layer 110 is formed from a material comprising an average tensile strength in the range of 90-110 kPa and/or average elongation at break in the range of 20%-30% in accordance with ISO 1798. - In some embodiments of the present invention, the
first foam layer 110 is formed from an open-cell material. In further embodiments, thefirst foam layer 110 is formed from a low-density material. In some embodiments, it is desirable that thefirst foam layer 110 would be lightweight and have a density in the range of 4-10 kg/m3 which makes the mattress significantly lighter compared to regular mattresses. - In some embodiments, the low density of the mattress derives from an open-cell structure of the material from which the mattress is made. Open-cell structure with low density allows air to flow through the material, making the material breathable. It is desirable to prevent infants to lie on a non-breathable foam surface, to prevent sudden infant death syndrome (SIDS) may be caused by the accumulation of carbon dioxide in bedding. Thus, allowing air to flow through the
first foam layer 110, results in fresh air provided to the user sleeping thereon, which is especially relevant for infants. - In some embodiments, the
first foam layer 110 is formed from a fire-resistant material. In further embodiments, the fire-resistant material, which thefirst foam layer 110 is formed of, lacks any additional fire redundant materials orconsist of a fire redundant material. In some embodiments, material of thefirst foam layer 110 comprises fire redundant capabilities in accordance with ISO EN 13501-1 and classified as B, s1 and d0. In further embodiments, the fire-resistant material, which thefirst foam layer 110 is formed of, comprises high thermal endurance properties. Specifically, in some embodiments, the thermal endurance of the material forming the first layer is measured in accordance with ISO 2578 (and as defined in ISO 3386-1) as resistant to a heat of 220 °C for 1000 hours. - In further embodiments, the fire-resistant material, which the
first foam layer 110 is formed of, comprising low thermal conductivity properties. In some cases, the thermal conductivity of the material may be in the range of 0.02- 0.05 W/mK. In more specific cases, the thermal conductivity of the material may be in the range of 0.03-0.04 W/mK. In some embodiments, the thermal conductivity is measured in accordance with the DIN EN 12667 regulation. - In some embodiments, the
first foam layer 110 is formed from a sound absorbing material. Since many people require a low amount of noise in order to fall asleep, such material would be very beneficial to the formation of a mattress. In some embodiments, the sound absorbing material is formed from an open cell material, comprising a high sound absorption quality. The open cell structure causes the sound waves touching thefirst foam layer 110 to penetrate the cell structure of the material unhindered in contrast to being reflected from the surface of thefirst foam material 110 as an echo. Thus, the sound energy is reduced in the cell structure, giving thefirst foam material 110 an excellent sound absorption capacity. For example, the material may be formed in accordance with regulation ATSM C 426 (U.S.A) as class A. In some embodiments, the thickness of thefirst foam layer 110 may be determined by the desired level of sound absorption. In some embodiments, the sound absorption for a 50 mm thick layer with a frequency of 2000 Hz is more than 90 percent absorption in accordance with ISO 10534. - In some embodiments, the
first foam layer 110 of the mattress 100 may consist of a block of melamine resin, which may be formed as a foam. In further embodiments, the block of melamine foam is formed as an open cell structure. In a non-limiting manner, the block of melamine foam may be the product designated by the trade name "BASOTECT" in the name of BASF, Germany. In further embodiments, thefirst foam layer 110 of the mattress 100 may consist of the product designated by the trade name "BASOTECT UF" in the name of BASF, Germany. The "BASOTECT UF" is characterized by a very high elasticity and by improved fire properties. In further embodiments, the product designated by the trade name "BASOTECT" is either one of: "BASOTECT UF", "BASOTECT UF+", "BASOTECT G" and "BASOTECT G+". - In some embodiments, the entire mattress 100 may be cut out from a single block of material. In some embodiments, the mattress 100 is not limited to a cubic rectangular shape and may be shaped in any form desirable by a user. For example, using a mold, the mattress 100 can be formed to have a shape of a circle fitting on a circular bed, polygonal shapes and the like. For example, in some embodiments, the mattress 100 is shaped to snugly fit inside an infant crib. In such cases, the mattress 100 may be slightly larger than the dimensions of the crib and inserted into the crib when pressed. Thus, the mattress may snugly fit into a crib, despite small variations in the dimensions of the mattress caused by inconsistent manufacturing processes. In such embodiments, the crib comprising such mattress is safer because there is no gap in which an infant's limb could become lodged in.
- The width of the mattress 100 may be in the range of 10-50 centimeters, made from a single sheet of lightweight and fireproof material and covered by a covering sheet which is a thin sheet, for example having width in the range of 1.5-20 millimeters, and made of an open-cell structure. The covering layer may be made of cotton. The length of the mattress 100 may be in the range 80-220 centimeters and the breadth of the mattress 100 may be in the range 30-180 centimeters.
-
Figs. 2A-2B disclose a lightweight and fireproof mattress comprising a plurality of layers, according to exemplary embodiments of the subject matter.Fig. 2A discloses a mattress 200 comprising dual layers. In some embodiments, the mattress 200 comprises afirst foam layer 210 and asecond foam layer 220. In some embodiments, each layer of thefirst foam layer 210 and asecond foam layer 220 may be assembled of a plurality of sublayers. In some embodiments, thefirst foam layer 210 is identical to the first foam layer ofFig. 1 as aforementioned. The shape of thefirst foam layer 210 may vary, and may be rectangular, circular, polygonal or any other shape fitting a user's needs. In some embodiments, thesecond foam layer 220 abuts at least one surface of thefirst foam layer 210. In some embodiments, thesecond foam layer 220 may be formed from a different material from the material of thefirst foam layer 210 and which can provide a better comfort to the user than thefirst foam layer 210. In some embodiments, thesecond foam layer 220 may be formed of viscoelastic material, adapted to distribute the user's weight and to provide a softer layer than thefirst foam layer 210. In some embodiments, thesecond foam layer 220 may coat the entire surface of thefirst foam layer 210. - In some embodiments, the density of the
first foam layer 210 is greater than the density of thesecond foam layer 220 topping thefirst foam layer 210. In other embodiments, thefirst foam layer 210 is firm and provides sturdy support to thesecond foam layer 220, for a uniform texture across the external surface of the mattress 200. The overall thickness of the mattresses depends on the thicknesses of thelayers second foam layer 220. - In some embodiments, as shown in
Fig. 2B , the mattress 200 comprises three foam layers shaped in accordance with a user's preference. In such cases the mattress 200 comprises abottom layer 230, amiddle layer 232, and atop layer 234.Bottom layer 230 may be formed of regular high-density foam in order to provide stability and support for the mattress 200. In some embodiments, themiddle layer 232 is formed of a viscoelastic material and provides a first cushioning layer for the mattress 200. In some cases, themiddle layer 232 comprises an egg crate pattern on its top surface. Utilizing an egg crate pattern on the top surface provides a softer feel for the user. Thetop layer 234 may be formed as a thin sheet of an open cell material having an especially low density to provide a second cushioning interface for the mattress 200. Thebottom layer 230, themiddle layer 232, and thetop layer 234 may be made of melamine foam. In some other embodiments, thebottom layer 230, themiddle layer 232, and thetop layer 234 may be made of another material that is both fire resistant and of a density lower than 10 kilograms per cubic meter (m3). -
Fig. 3 discloses a lightweight and fireproof mattress comprising an elevated portion.Fig. 2 discloses a mattress 300 comprising afirst foam layer 310. The first foam layer has atop surface 311, abottom surface 312 and a front side surface 313 arear surface 314, a firstlateral surface 315 and a secondlateral surface 316. In some embodiments, the first foam layer comprises anelevated foam layer 320 extending from thetop surface 311, and adjacent to therear surface 314 of thefirst foam layer 310. In some embodiments, theelevated foam layer 320 is shaped a single pillow or two adjacent pillows. The pillows are configured to serve as a head rest for providing additional comfort to a user sleeping thereon. In some embodiments, thefirst foam layer 310 and theelevated foam layer 320 are formed from a single block of foam. In some embodiments, theelevated foam layer 320 may be inclined to create a wedge shape. - The claimed invention may also disclose use of a melanin foam in the production of a mattress or another cushioning apparatus. In some exemplary cases, the melanin foam is sliced from a sheet of material according to a predefined shape and covered by cotton or another open-cell structure. The claimed invention also discloses use of melanin foam in the fabrication of a mattress, such that the mattress allows air flow from a bottom surface of the mattress to the top surface of the mattress. The claimed invention also discloses a mattress made of fire resistant material that does not emit gasses, such as bromine. The fire resistance means that the mattress remains solid and firm even when caught by fire and does not change its shape and/or chemical characteristics.
- It should be understood that the above description is merely exemplary and that there are various embodiments of the present invention that may be devised, mutatis mutandis, and that the features described in the above-described embodiments, and those not described herein, may be used separately or in any suitable combination; and the invention can be devised in accordance with embodiments not necessarily described above.
Claims (15)
- A mattress, comprising:a lightweight first foam layer comprising a top surface and a bottom surface, wherein the first foam layer is formed from a single piece of molded foam,wherein said lightweight first foam layer is formed at least partly from a melamine resin.
- The mattress of claim 1, wherein the top surface of the first foam layer is shaped as an egg crate pattern.
- The mattress of claim 1, wherein the mattress defines an elevated portion on the top surface and adjacent to a rear surface of the first foam layer, and wherein the elevated portion forms a pillow.
- The mattress of claim 3, wherein the elevated portion is designed with an inclination to form elongated wedge-shaped notches.
- The mattress of any one of claims 1-4, wherein the density of the first foam layer is in a range of 4-10 kg/m3.
- The mattress of any one of claims 1-5, wherein the mattress lacks fire retardant additives.
- The mattress of any one of claims 1-6, wherein the first foam layer is partly formed of a polyurethane foam or wherein the first foam layer is formed solely from /composed of a melamine resin.
- The mattress of claim 7, wherein the melamine resin is a product designated by the trade name "BASOTECT" in the name of BASF, Germany.
- The mattress of claim 8, wherein the product designated by the trade name "BASOTECT UF" is either one of: "BASOTECT UF", "BASOTECT UF+", "BASOTECT G" and "BASOTECT G+".
- The mattress of any one of claims 1-9, wherein the first foam layer is formed from a material that is classified as fireproof in accordance with ISO EN 13501-1 in categories B, s1 and d0.
- The mattress of any one of claims 1-10, wherein• the first foam layer comprises low thermal conductivity properties, wherein the low thermal conductivity is measured in the range of 0.02- 0.05 W/mK and/or• the first foam layer is formed from a material comprising a tensile strength in the range of 90-110 kPa and average elongation at break in the range of 20%-30% in accordance with ISO 1798 and/or• the first foam layer is formed from a material providing more than 25 N under an indentation hardness test and/or• the sound absorption for a 50 mm thick first layer with a frequency of 2000 Hz is more than 90 percent absorption in accordance with ISO 10534.
- The mattress of any one of claims 1-11, wherein the first foam layer top surface and the first foam layer bottom surface have different widths.
- The mattress of any one of claim 1-12, wherein the first foam layer is formed with an open cell structure.
- The mattress of any one of claims 1-13, further comprising a covering layer configured to cover the first foam layer, said covering layer is made of a fire-resistant material.
- The mattress of any one of claims 1-14, wherein the mattress comprises a second layer, abutting at least one of the first foam layer surfaces, and wherein the second layer is formed from a viscoelastic material, particularly wherein the second layer abuts the top surface of the material.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US16/711,468 US20210177158A1 (en) | 2019-12-12 | 2019-12-12 | Lightweight and fireproof mattress |
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EP3834669A1 true EP3834669A1 (en) | 2021-06-16 |
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ID=69157609
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP20150985.8A Withdrawn EP3834669A1 (en) | 2019-12-12 | 2020-01-09 | A lightweight and fireproof mattress |
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US (1) | US20210177158A1 (en) |
EP (1) | EP3834669A1 (en) |
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US20230027662A1 (en) * | 2021-07-20 | 2023-01-26 | Ruth Mendoza Nonnemaker | Bedsore relieving bed |
Citations (5)
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---|---|---|---|---|
US20070290542A1 (en) * | 2006-06-16 | 2007-12-20 | Inoac Corporation | Cushion body and manufacturing method for a cushion body |
US20100223732A1 (en) * | 2009-03-06 | 2010-09-09 | Noel Group Llc | Unitary composite/hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam(s) and a thermoset material(s) |
US20120284926A1 (en) * | 2011-05-12 | 2012-11-15 | Tyree Steven | Low shear mattress topper constructions |
CN206303545U (en) * | 2016-09-08 | 2017-07-07 | 史菊英 | A kind of Portable aerated mattress with heating function |
US20180298264A1 (en) * | 2010-02-26 | 2018-10-18 | Peterson Chemical Technology Llc | Enhanced Thermally Conductive Cushioning Foams by Addition of Metal Materials |
-
2019
- 2019-12-12 US US16/711,468 patent/US20210177158A1/en not_active Abandoned
-
2020
- 2020-01-09 EP EP20150985.8A patent/EP3834669A1/en not_active Withdrawn
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070290542A1 (en) * | 2006-06-16 | 2007-12-20 | Inoac Corporation | Cushion body and manufacturing method for a cushion body |
US20100223732A1 (en) * | 2009-03-06 | 2010-09-09 | Noel Group Llc | Unitary composite/hybrid cushioning structure(s) and profile(s) comprised of a thermoplastic foam(s) and a thermoset material(s) |
US20180298264A1 (en) * | 2010-02-26 | 2018-10-18 | Peterson Chemical Technology Llc | Enhanced Thermally Conductive Cushioning Foams by Addition of Metal Materials |
US20120284926A1 (en) * | 2011-05-12 | 2012-11-15 | Tyree Steven | Low shear mattress topper constructions |
CN206303545U (en) * | 2016-09-08 | 2017-07-07 | 史菊英 | A kind of Portable aerated mattress with heating function |
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