FIRE-RESISTANT STRUCTURAL MATERIAL AND COVERED FABRICS PREPARED WITH SUCH CROSS-REFERRED MATERIAL RELATED REQUESTS This application is a continuation of part of US application serial number 09/663, 255 filed on September 15, 2000, which claims priority in accordance with 35 USC §119 (e) on provisional application number 60/168, 057, filed on November 30, 1999; and this application is also a continuation in part of the pending US application serial number 09/955, 395 filed on September 18, 2001; and that request also claims priority in accordance with 35 U.S.C. §119 (e) on provisional applications number 60/352, 691, 60/352, 692, and 60/352, 693, which were all filed on January 29, 2002. FIELD OF THE INVENTION This invention relates to fire-resistant structural materials and fire-resistant fabric materials made from them and more particularly to materials that can be adhered on decorative fabrics to provide fire-resistant decorative fabrics especially suitable for use in mattresses, upholstery, upholstery for furniture, and similar. The invention relates
BACKGROUND OF THE INVENTION Several attempts were made to produce fire resistant fabrics having characteristics that make such fabrics suitable for use in mattresses and other applications, for example, upholstery and upholstery. U.S. Patent No. 5,540,980 focuses on a fire resistant fabric useful for wrapping a mattress. The fabric is formed of a core spun yarn comprising a core of continuous filament glass fiber resistant to high temperatures and a fiber wrap resistant to low temperatures. The fiberglass core forms approximately 20 to 40% of the total weight of the core spun yarn while the envelope forms approximately 80% to approximately 60% of the total weight of the spun core yarn. The core spun yarn can be woven or knitted to needle stitch to form a fabric with fire resistant characteristics. When exposed to a flame, the envelope is burned and the fiberglass core serves as a fire barrier. In a preferred embodiment, the wrap is made of cotton. U.S. Patent No. 5,091,243 discloses a fire barrier fabric comprising a substrate formed of spun yarns with a core and a coating carried by a surface of the substrate. Other fabrics resistant to fire include Phoenix Trademark? ¾t ±±± ¾-ß-t-LaG-r-acuge, GA) and fabrics made by Freudenberg (Lowell, MA), Ventex Inc. (Great Falls, VA), BASF , Basofil Fiber Division (Enka, NC), Carpenter Co. (Richmond, VA), Legget and Platt (Nashville, TN), Chiquala Industries Products Group (Kingspoint, TN), and Sandel (Amsterdam, NY). DuPont also manufactures a fabric made from Kevlar trademark yarns. In addition, the mattress industry has tried to manufacture mattresses by using Kevlar yarn trademark glass thread, fire retardant polyurethane foams, flame retardant casings, flame retardant cotton padding as well as fire retardant tape. However, the use of these materials can increase the cost of mattresses and can result in an excessively expensive product. In addition, some fire resistant yarns such as glass threads are difficult to work with and can break which increases the time required to manufacture the mattresses and also results in increased costs. Flame retardant tapes are also difficult to work with and increase production time. In addition, fire retardant ribbons are available only in a limited number of colors and sizes. Flame retardant polyurethanes can release toxic gases when they burn or when they are consumed. further, the flame retardant wrapping process frequently affects the desired characteristics of softness, flexibility, folding capacity, etc.). For many years substrates such as glass fiber have been coated with various compositions to produce useful materials, among other applications, in the construction industry. U.S. Patent No. 5,001,005 relates to structural laminates made with facing sheets. The laminates described in this patent include plastic thermosetting foam having flat facing sheets consisting of 60% to 90% by weight of glass fibers (exclusively of micro glass fibers), 10% to 40% by weight of material of non-glass filling and from 1% to 30% of non-asphalt binder material. The filling materials are indicated as clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony trioxide, cellulose fibers, plastic polymer fibers or a combination of two or more of these substances. The patent further indicates that the filler materials are bonded to the glass fibers using binders such as urea-, phenol- or melamine-formaldehyde resins (UF, PF, and MF resins) or a modified polyester or acrylic resin. Ordinary polymeric latexes used in accordance with the disclosures are styrene-butadiene-rubber (SBR), ethylene-vinyl chloride (EVC1), chloride des poliviri? ~ ?? s¾? G0 t ^ dd-, crto-rare-de-- modified peüviftüe (PVC), polyvinyl alcohol (PVOH), and polyvinyl acetate (PVA). The glass fibers, the non-glass filler material and the non-asphalt binder are mixed together to form the coating sheets. U.S. Patent No. 4,745,032 discloses an acrylic coating comprising an underlying acrylic resin that includes fly ash and an acrylic coating resin that differs from the underlying resin. U.S. Patent No. 4,229,329 discloses a flame retardant coating composition comprising fly ash and a vinylacrylic polymer emulsion. The flying ash comprises 24 50% of the composition. The composition may also preferably contain one or more of the following: a dispersing agent, a foam remover, a plasticizer, a thickener, a drying agent, a preservative, a fungicide and an ingredient for controlling the pH of the composition and therefore inhibit corrosion of a metal surface on which the composition is applied. U.S. Patent No. 4,784,897 discloses a coating layer material based on a mat or fabric that is especially for the production of gypsum boards and hard polyurethane foam boards. The cover layer material has a coating on one side consisting of 70% to 94% inorganic powder, such as calcium carbonate, and from 6% to 30% In addition, thickening agents and crosslinking agents are added and a high density mat is used, U.S. Patent No. 4,495,238 discloses a heat insulating, fire resistant composite structure comprising a blend of approximately 50% to 94% by weight. of inorganic microfibers, especially glass, and from about 50% to 6% by weight of a heat-resistant binder agent. U.S. Patent No. 5,965,257, issued to the present beneficiary, the entire disclosure of which is incorporated herein by reference discloses a structural article having A coating that includes only two main constituents, while eliminating the need for viscosity modifiers, stabilizers or blowers. No. 5,965,257 is prepared by coating a substrate having an ionic charge with a coating having essentially the same ionic charge. The coating consisting essentially of a filler material and a binder material. The beneficiary, Elk Corporation of Dallas, produces a product in accordance with the invention of U.S. Patent No. 5,965,257 which is marketed under the name VersaShield®. In accordance with what is unacceptable with the pa-rcori_reaffiex-i-Ra-number 5,965,257, VersaShield® has many uses. However, it has been found that products made according to U.S. Patent No. 5,965,257 are unsatisfactory for certain uses since they do not have sufficient upholstery capacity. US Patent Serial No. 09 / 955,395 filed September 18, 2001, also assigned to the present beneficiary, the entire disclosure of which is incorporated herein by reference, addresses these deficiencies with a fire-resistant fabric material comprising a substrate that it has an ionic charge coated with a coating having essentially the same ionic charge wherein the coating comprises a filler component including a clay and a binder component. The fire-resistant fabric material produced in this way has satisfactory characteristics in terms of flexibility, folding capacity and upholstery. However, while this material is suitable as a fire-resistant fabric material, it is desirable to provide a fire-resistant material that could also exhibit cushioning or "bounce" characteristics. According to the present invention, a layer of structural material comprising a component of surfactant, microcells generated by surfactant, a filler component and a component is formed. Take TTT preferably on a substrate forming a cloth material, or alternatively as a separate sheet. Both in fabric material and the independent sheet have a high resistance to fire and when combined with an outer layer of decorative fabric, proportion decorative fire-resistant fabrics having characteristics suitable for use in mattresses, upholstery, upholstered furniture and the like. COMPENDIUM OF THE INVENTION The present invention relates to a structural material comprising a surfactant component, microcells generated by surfactant, a filler component and a binder component. The structural material is fire resistant and is useful, inter alia, for making fire resistant fabric materials comprising a substrate coated with a coating comprising the structural materials of the present invention. The fabric materials of the present invention may be planar and may have, on one side or both sides of the substrate, a coating with the structural materials of the present invention. The fabric materials may further include a water repellent material, an a.nti fungal material, an antibacterial material, a surface friction agent, a flame retardant material and / or an algicide. In addition, the fabric materials can be dyed with c ^ Toráñ e ";
The present invention also relates to a mattress fabric comprising a decorative fabric and a fabric material comprising a substrate coated with the structural materials of the present invention. In addition, the present invention relates to a mattress comprising a decorative fabric and a fabric material comprising a substrate coated with the structural materials of the present invention. In a particularly referred embodiment, the coating does not run through the substrate during the material processing process. The substrate can be any suitable reinforcing material capable of withstanding the processing temperatures and is preferably a woven glass fiber. The binder is preferably an acrylic latex and the filler preferably comprises clay. The surfactant can be any surfactant capable of forming microcells. In a preferred embodiment, the surfactant is a fast soap, such as, for example, lauryl ammonium sulfate (ALS). A fast soap generates microcells quickly in quantity and / or volume. The structural fire-resistant material of the present invention can be used as a stand-alone product, for example, by the fire-resistant foam material, or it can also be used in combination with a decorative fabric (for example a lining for decorative effect). The invention also relates to an article of manufacture comprising the structural material of the present invention and / or the fire resistant fabric materials of the present invention. and includes, inter alia, mattress fabrics, mattress covers, mattresses, upholstered articles, building materials, bedroom items (including children's bedroom items), upholstery, carpets, tents, awnings, fire-resistant sheds, sleeping bags, ironing board covers, grill covers, fire resistant gloves, airplane seats, motor linings, clothes resists Join the fire for race car pilots, firefighters, warplane pilots, and the like. The use of fire resistant materials and fire resistant fabric materials of the present invention for the manufacture of fabrics for use in articles such as, for example, mattresses, cots, upholstery, and upholstered furniture, may allow the article exceed the current fire resistance standards for these types of items. BRIEF DESCRIPTION OF THE FIGURES The present invention will be better understood with reference to the attached figures in which: Figure 1 is a graph showing the results of the resistance test ~~: Fire a ??? Or ra ~ TBr2-9 -ue-in-di-ea- ^ The heat release rate (HRR) for various embodiments of the mattress made in accordance with the present invention (* indicates extended 60 minute test) for a control mattress; Figure 2 is a graph showing the results of the California TB129 fire resistance test indicating the total heat release for various embodiments of the mattress manufactured in accordance with the present invention (* indicates the extended 60-minute test) and for a control mattress; Figure 3 is a graph showing the results of the California TB129 fire resistance test indicating the weight loss of various embodiments of the mattresses made in accordance with the present invention (* indicates the extended 60-minute test) and for a control mattress; Figures 4A and 4B are photographs respectively of the control mattress before and after a California TB129 fire resistance test procedure; Figure 5? is a photograph of a mattress manufactured in accordance with a preferred embodiment of the present invention before and after a 3 minute fire resistance test procedure in a California TB129 and Figure 5B is a photograph of a mattress manufactured in accordance with a preferable modality "ote la pTe ~ 3 ~ 5n" tre "'invention before and after a 60-minute fire resistance test procedure in a California TB129; Figure 6 is a graph showing the softness ratio of various embodiments of the mattresses of the present invention of a control mattress; Figure 7 is a photograph showing microcells generated by surfactant of an exemplary embodiment of a fire resistant fabric material of the present invention. Figure 8 is a photograph showing the microcells generated by surfactant of another exemplary embodiment of the present invention; and Figure 9 is an illustration of an exemplary embodiment of a mattress of the present invention. DETAILED DESCRIPTION The structural material of the present invention comprises a surfactant component, microcells generated by surfactant, a filler component and a binder component. As used herein, the microcells generated by surfactant are essentially hollow or hollow spheres formed in the presence of a surfactant during the manufacturing process of the fire resistant material. Accordingly, the surfactant components of the present invention can form microcells. The microcells generated by surfactant provide several characteristics to the "fabric materials of the present invention, including inter alia, improved fire resistance, increased flexibility, folding ability, upholstery and" bounce. "In accordance with the present invention, a Fabric material is manufactured by coating a substrate with a coating comprising the structural material mentioned above In a preferred embodiment, the coating does not pass through the substrate during the process of making the fabric material. of the present invention preferably includes clay.The clay is preferably Chinese clay which is very soft and light.Alternatively, the clay can be Paragon ™, which is also a soft clay (ie, it is soft to the touch), Suprex ™ which is a clay hard (that is, hard to touch), clay treated with amino silane SuprexriR, which is used for crosslinking put which binds chemically with binder and also for high loads, Ballclay1, which has elastic properties (ie, provides a rubber feel to the touch), Texwhite 185 (available from Huber, Dry Branch, GA), and ECC 1201 (available in Huber). All the products and clay listed above, unless otherwise indicated, are available, for example, from the Kentucky-Tennessee Clay Company of Langley, SC. In one modality, clay is Ballclay1"1
3380 which is particularly economical compared to other clays. In a preferred embodiment, the clay is Kaolin clay which is a lower grade Chinese clay. In particularly preferred embodiments, the clay is Texwhite 185 and / or ECC 1201 (see Tala I and Table II below). In the present invention, clay is a preferred filler because of its elongation properties (it has a low modulus), its resistance to abrasion, its tear resistance, and its tensile strength. In addition, clay is a good thermal barrier; it does not disintegrate when applied directly to an open flame (temperature = 815 ° C (temperature> 1500 ° F) on a coating of the present invention that includes clay.In addition, the clay provides a soft, elastic, glassy surface that presents Furthermore, as indicated, the clay is inexpensive and can help keep the cost of cloth material low The filler material may alternatively or additionally comprise a filler selected from the group consisting of decabromodiphenyl oxide, antimony trioxide , calcium carbonate, charged calcium carbonate, titanium dioxide, fly ash (such as for example Alsil 04TRMk class F, flying clay produced by JTM Industries, Inc. of Martin Lake and Jewett, Texas which has a particle size such that less that 0.03% remains in a stirred mesh of 0.254 centimeters X 0.254 centimeters (0.1 inch X 0.1 inch), mica 3-X mineralité disponíbTe eñ E ngelhard, Inc. of Louisville, KY) and glass or ceramic microspheres (glass microspheres are 2.5 times lighter than ceramic microspheres and also provide fire resistance), or any mixture of these filler materials to meet criteria desired in terms of cost and weight. The glass and ceramic microspheres are manufactured by Zeelan Industries of 3M Center Bldg., 220-8E-04, St. Paul, MN 55144-1000. Calcium carbonate can be obtained from Franklin Industrial Minerals of 612 Tenth Avenue North, Nashville, TN 37203. Calcium carbonate, talcum and fly ash filler increase the weight of the product, but the use of glass and / or ceramic microspheres allows the manufacture of a product with reduced weight and with improved fire resistance properties. Clay can provide the product with the following non-limiting characteristics: (1) decreased heat buildup, (2) heat reflection properties, (3) heat barrier properties, (4) no weight loss when exposed to heat or to an open flame, and (5) reduced disintegration in case of exposure to heat and open flame. Decabromodiphenyl oxide and antimony trioxide provide the following non-limiting characteristics: (1) flame-retardant properties, (2) the ability to form a carbon layer, and (3) the ability to halt the expansion of the particles. Gas produced by the heating of decabromodiphenyl oxide can also act as a flame retardant agent since the gas consumes oxygen or depletes oxygen in the layer near the fabric and extinguishes the fire or prevents further advancement. Glass and ceramic microspheres can withstand a heat greater than 1093 ° C (2000 ° F). Also, glass and ceramic microspheres increase the resistance to compression, do not absorb latex and / or water and consequently allow a faster drying of the product. The glass and ceramic microspheres also increase the flexibility of the product. In addition, the glass and ceramic microspheres help increase the life of the coating canister. Heavier particles in the fillers, even though they can make up only a small percentage of the particles in the filler, have a tendency to settle near the bottom of the storage container. When mixing glass and ceramic microspheres with another filler, a diffraction occurs which has an increased life of the boat or an increased shelf life. Without wishing to be limited to any particular theory, it is believed that as the filler particles fall naturally into the vessel and the glass and ceramic microspheres rise, the filler particles of smaller size are supported by the glass microspheres and / or ceramic, thus allowing the microspheres to remain in solution and thus preventing the filler particles from falling to the bottom of the container, at least to some extent. The structural material of the present invention is prepared by using a binder component such as a high-performance thermo-reactive acrylic latex polymer and / or a non-heat-reactive styrene butadiene latex to bond the filler materials between they. When the structural material is used to coat a substrate, the binder also acts to attach the filler onto the substrate. In one embodiment of the invention, the Rhoplex 3349 binder component (Rohm and Hass, Philadelphia, PA) and / or Rovene 4402 (Mallard Creek Plymer, Inc., Charlotte, NC). Additional or alternative binders include, inter alia, HycarM 26469, HycarMR 26472, HycarMR 26484, HycarMR 26497, HycarMR 264552, HycarMR 264512, HycarMR 264582, HycarMR 26083 (low formaldehyde level), HycarMR 9201 (low formaldehyde level), HycarMR 1552 (nitrile), Hycar ™ 1571 (nitrile), Vycar ™ 552, Hycar® 2679 acrylic latex polymer (all Hycar ™ and Vycar ™ products are supplied by BF Goodrich Company of Cleveland, Ohio). The binder components Cyanamid), RHOPLEXMT TR 407 and R & amp;; H GL-618 both available at Rohm & Hass, and Borden resin FG-413F UF (available from Borden). It is believed, however, that any linear polymer, linear copolymer or branched polymer can be useful in coating preparation, such as those available from BASF and Goodyear. Additional possible binder materials include butyl rubber latex, SBR latex, neoprene latex, polyvinyl alcohol emulsion, SBS latex, water based polyurethane emulsions as well as elastomers, vinyl chloride copolymers, nitrile rubbers, and acetate copolymers of polyvinyl. In a preferred embodiment, an SBR latex is used. A latex BSR adds good smoothness characteristics, but it is not a flame retardant agent. To improve fire resistance, an acrylic latex can be added or replaced. The greater the amount of acrylic latex, the better the resistance of the material to fire. However, as the SBR latex is replaced, the softness decreases. The surfactant component can be any surfactant capable of forming microcells during the manufacturing process and fire resistant material. In a preferred embodiment, the surfactant comprises a soap, such as, for example, lauryl ammonium sulfate (ALS) (for example, Stepanol AM, Stepan Chemicals, Northfield, IL) and sodium lauryl sulfate (SLS) which can be used Tension süp ^ ic aT. For example, a "quick soap" is a soap that can efficiently modify the surface tension, such as "fast soaps." However, other surfactants can also be used that are not characterized as fast soaps but can form microcells.Simple soaps, such as ALS, form microcells that are resilient and generally stable to the heat of the body. Additional components can be added to further stabilize the microcells as further discussed below, however, if desired, a surfactant that forms "weak" microcells can be used.The "weak" microcells can explode during processing to produce a material less flexible fire resistant In one embodiment of the present invention, the structural material can be made by a combination of the binder component, the surfactant component and the filler component together and by the creation of microcells generated by surfactant. The microcells generated by surfactant can be created by any means known in the art, such as, for example, without limitation, air blown into the mixture, stirring or by using a foam former. The microcells generated by surfactant can be iritrotyric acid-tri-t-tz-a-nde-chemical blowing agents, such as for example nitrogen-releasing azo compounds In one embodiment of the invention, the mixture is subjected to a foam former The foam former acts to inject air into the mixture in such a manner that the surfactant forms microcells within the mixture.The foam former may comprise a tube-like component having several pins that can rotate in opposite directions (for example, some bolts rotate in the clockwise direction and others in the opposite direction.) The mixture of binder, surfactant and filler is added to the foam former through a port on one side and, in accordance with passes through the foam former, the pins rotate causing the surfactant to form microcells.In addition, air can also be introduced into the foam former in another port to further increase the formation of and microcells generated by surfactant. After having been subjected to the foam former, the mixture can be applied on a substrate such as a fiberglass mat. Alternatively, the mixture can be applied on a receiving platform, such as a steel tray to form a separate sheet. When applied on a substrate or on a restriction platform, the material is then subjected to heat in an oven. The processing temperatures are preferably from "about 138 ° C (280 ° F) to about 177 ° C (350 ° F)." In a preferred embodiment, the microcells generated by surfactant are stable to heat of processing. surfactant-generated are not stable above 350 ° F (177 ° C) Figure 7 and Figure 8 show the formation of microcells generated by surfactant in two exemplary embodiments of the present invention, It is preferred that microcells generated by surfactants they are relatively small and of uniform size In another embodiment of the present invention, the structural material is produced with collapsed microcells, said material can be prepared using a surfactant capable of forming microcells but which does not efficiently modify the surface tension of the water. heat of the processing, the microcells generated by surfactant expand due to the expansion of the gases that are collected Within them, they explode and collapse. In another embodiment, the resistant pyro material also includes a surfactant capable of regulating the formation of microcells generated by surfactant. A surfactant of this type is Stanfex 320, (Parachem, Dalton, GA). The surfactant capable of regulating the formation of microcells generated by surfactant can ensure that the microcells remain within the range of pre-ferred size, that they become excessively large, and form a relatively monodisperse state. (that is, they have the same general size). In a preferred embodiment, the microcells generated by surfactant have a diameter of about 5.0 μ to about 20.0 μ. In addition, citric acid can be used to ensure that the microcells generated by surfactant are uniformly dispersed. It may also be desirable that the fire resistant materials of the present invention include a dispersing agent that acts to maintain the mixture comprising the binder, surfactant and filler well dispersed during the material manufacturing process. For example, such dispersants may be, inter alia, TSPP, Accuma 9300 and Accuma 9000 (all available in Rohm &; Hass). The fire resistant fabric materials of the present invention are flexible, collapsible and have good upholstery characteristics. In addition, they are durable and preferably do not crack when bent. The durability of the fire resistant material can be increased by the addition of components capable of stabilizing the microcells generated by surfactant. Such components include surfactants such as ammonium stearate (available from Parachem, Dalton, GA), octosol Al 8 (Tiarco Tiarco Chemicals), 449 (potassium oleate, Tiarco Chemicals), and Stanfex 320. The microcell generated by surfactant can be stabilized by forming thicker microcell wall. A surfactant that has a long waxy chain can be particularly useful for stabilizing microcells. The structural material may further include a crosslinking component, such as melamine (Borden Chemicals, Morganton, NC) and / or ammonium chloride. The crosslinking component is useful for improving the durability and structural strength of the microcells. In order to control the amount and rate of crosslinking, it may be desirable to control the pH of the mixed components. For example, under acid conditions (pH ~ 4.0), the crosslinking will occur very quickly and the mixture will have a short pot life. At higher pH (~10.0), the crosslinking proceeds more slowly and can be thermally controlled. The structural material of the present invention may also comprise a resin that can provide a polymer shell for encapsulating air. In one embodiment, the resin is DPG-38, available from Parachem of Dalton, GA. In a preferred embodiment, the fire resistant material also has "bounce" characteristics. As used herein, "bounce" refers to the ability of the material to return to its original shape after it has been stretched or compressed. In such a modality, additional components are aggregated to achieve such rebound characteristics. These components can cover the internal part of the microcell in such a way that the microcell returns to its original shape after the distortion. Preferred components useful for achieving bounce characteristics include CT101 (silicon oil; Kelman Industries, Duncan, SC), Freepel 1225 (BF Goodrich, Cleveland, OH), Sequapel 409 (Omnovasolutions, Inc. of Chester, SC), Michem 41740 emulsion. (available from Michelman, Inc. of Cincinnati, OH), SylofÜ-1171A (available from Dow Corning, Corporation of Midland, MI), Syloff-62 (Dow Corning); Syloff-7910 (Dow Corning) and Aurapel 391 (available at Sybron / Tanatex in Norwich, Connecticut). These components also ensure that the microcells do not aggregate or form clumps of microcells. The substrate of the present invention can be any suitable reinforcement material capable of withstanding processing temperatures, such as glass fibers, polyester fibers, cellulosic fibers, asbestos, steel fibers, alumina fibers, ceramic fibers, fibers. nylon, graphite fibers, wool fibers, boron fibers, carbon fibers, jute fibers, polyolefin fibers, polystyrene fibers, acrylic fibers, phenol-formaldehyde resin fibers, aromatic and aliphatic polyanacide fibers, polyacrylamide fibers , polyacrylimide fibers or mixtures thereof which may include two component fibers. Examples of substrates in accordance with the present invention include, inter alia, glass, fiberglass, ceramics, graphite (carbon), PBI (polybenzimidazole), PTFE, polyaramides, for example KEVLAR trademark and NOMEX trademark, metals including metallic wire or metal mesh, polyolefins, for example TYVEK trademark, polyesters eg DACRON trademark or REEMAY registered trademark, polyamides, polyimides, thermoplastics such as KYNAR trademark and TEFZEL registered trademark, polyether sulfones, polyether imide, polyether ketones, novoloid phenolic fibers, for example KYNOL trademark, trademark KoSa polyester fibers, glass fibers JM-137 M, Owens-Corning M glass, Owens-Corning K glass fibers, fibers of Owens-Corning H glass, Evanite 413M glass microfibers, Evanite 719 glass microfibers, cellulose fibers, cotton, asbestos and other natural fibers as well as synthetic fibers. The substrate may comprise a yarn, filament, monofilament or other fiber material either as such or assembled in the form of a textile, or any woven, non-woven, knitted, mat-like, felt, etc. material. The polyolefin can be polyvinyl alcohol, polypropylene, polyethylene, polyvinyl chloride, polyurethane, etc., alone or in combination with each other. The acrylics can be DYNEL, ACRILAN and / or ORLON. RHOPLEX AC-22 and RHOPLEX AC-507 are acrylic resins sold by Rohm and Haas that can also be used. The cellulose fibers can be natural cellulose such as wood pulp, newsprint, Kraft pulp and cotton and / or chemically processed cellulose such as rayon and / or lyocell. Non-limiting examples of non-woven materials that may be useful within the scope of the present invention include continuous, non-woven glass fiber webs, for example Firmat trademark 100, trademark Pearlveil 110, trademark Pearlveil 210, trademark Curveil 120 , Curveil trademark 220, Flexiveil trademark 130, Flexiveil trademark 230 and Pultrudable veil (all available from Schmelzer Industries, Inc., Somerset, OH). Woven materials may be Airlaid trademark, Spunbond trademark and Needlepunch trademark (available from BFG Industries, Inc. of Greensboro, NC). Non-limiting examples of filament materials include D, E, B, C, DE, G, H, K filaments of various grades, including electrical grade, chemical grade and high strength grade (all available BFG Industries, Inc. of Greensboro, NC). In a preferred embodiment, the substrate is a "woven glass fiber mat." As used herein, a glass fiber mat includes woven, non-woven glass fiber mats, in a particularly preferred embodiment, the substrate of the present invention. invention is a woven glass fiber mat such as for example style 1625, style 1091 and style 1614 of BFG Industries (Greensboro, NC) The use of the structural materials of the present invention for the manufacture of fabrics for use in such articles such as mattresses, cribs, upholstery and upholstered furniture, may allow the item to exceed current flame resistance standards for these types of items, while standards for resistance to mattress flames have not been specifically established by federal governments. or state, some government agencies have provided recommended guidelines, for example, the North American Department of Commerce. io, National Institute of Standards and Technology (NIST) in Gaithersburg, Maryland has published a document related to a methodology to assess the flammability of mattresses. See T.J. Ohlemiller et al., Flammability Assessment Methodology for Mattresses, NISTIR 6497, June 2000. While no clear standard is given, it is recommended that a mattress can withstand the described testing procedures. NIST has noted that "Bedding poses a major fire hazard problem, offers a series of tests to determine mattress flammability, and the California Department of Consumer Affairs, the furniture office for the House and Thermal Insulation ("the Office") issued a Technical Bulletin in October 1992 that provides a flammability test procedure for mattresses See State of California Department of Consumer Affairs Bureau of Home Furnishings and Thermal Insulation Technical Bulletin 129, October 1992, Flammability Test Procedure for Mattresses for use in Public Buildings (California TB129). The technical bulletin offers standard methods for testing mattresses in terms of fire resistance. The methods produce data that describe the combustion behavior from the ignition of a mattress to the suspension of its combustion, or after a period of 1 hour. The rate of heat release is measured through an oxygen consumption technique. The Office indicates that mattresses that comply with the test method will be safer and expects manufacturers to try to manufacture mattresses that will pass the recommended tests. The Office indicates that "a mattress does not meet the requirements of the test if any of the following criteria is exceeded:" (1) a maximum rate of "liberty" of "heat" CT <; W cT plus, "(~ 2 ~ J üTa total heat release of 25 MJ or more in the first 10 minutes, (3) a weight loss of 1362 grams (3 pounds) or more within the first 10 minutes due to combustion A mattress made of a fire resistant cloth material of the present invention meets or exceeds the test standards recommended by both NTIS and California TB129, see example 1 and example 2 below. 3 and Table III below show the results of a fire resistance test according to California TB129 for mattresses comprising the fire resistant cloth materials of the present invention See also Example 2 below In accordance with California TB129 a release rate The peak of more than 100KW is a failure Figure 1 shows that the mattresses of the present invention, with the exception of Mattress 6 (see Table II) have a peak heat release rate between 18.32 and 56.71 fits, well below the range In addition, a total heat release greater than 25 MJ is a failure. Figure 2 shows that a control mattress (double number 3) has a total heat release of 129.79 MJ, while the mattresses of the present invention have total heat releases between 2.45 and 18.0, all well below the failure range. . In accordance with California TB129, the weight loss can not exceed 1362 grams (3 pounds). Figure ~ 3 shows "that the mattress has a weight of 2769.4 grams (6.1 pounds), while the mattresses made with the fire-resistant cloth material according to the present invention have weight losses inside. from a range of 45.4 to 1089.6 grams (0.1 to 2.4 pounds), also below the range of failure In accordance with the foregoing, the fire-resistant fabric material of the present invention is useful in the manufacture of mattresses. embodiment of the invention, the fire-resistant fabric material can be used to line a mattress fabric for decoration purpose in order to produce a fire-resistant mattress fabric.Non-limiting examples of mattress fabrics include sheath (it is known the technique as a tightly woven, strong fabric that includes cotton or linen and is especially used to form cushion or mattress covers), or fabrics comprising fibers selected within the group consisting of cotton, polyester, rayon, polypropylene, and combinations thereof. The liner can be achieved by methods known in the art. For example, the fire-resistant fabric material of the present invention can be simply placed under the mattress fabric. Alternatively, the fire-resistant mattress material can be bonded or adhered to the mattress fabric, for example, by using a flexible and preferably non-flammable glue, or else by using punctures with fire-resistant yarn, similar to a lining. The fire-resistant mattress fabric of the present invention can then be used by the person skilled in the art to make a mattress having better flame resistance characteristics.
The mattresses of the present invention comprising the fire-resistant fabric material may comprise several layers, including, but not limited to, a first layer comprising a layer of fabric (for example the mattress fabrics discussed above), a layer comprising the fire resistant fabric material of the present invention (which may for example be a second layer or a third layer) or a bearing layer, a layer of polyurethane foam, a nonwoven sheet forming layer, and a layer comprising springs. See, for example, Example 2 below, and particularly Mattresses 1, 2A-2F, 4, 5 and 6 and Figure 9. The layer comprising the fire resistant fabric material of the present invention in accordance with that indicated above, comprises a substrate and a coating. In one embodiment, the fire resistant fabric material is coated on one side and the side with the coating faces the first layer. However, as indicated above, the fire resistant fabric material can be coated on both sides. In a particular embodiment of the invention; The mattress comprises at least a first layer comprising a mattress fabric and at least a second layer adjacent to the first layer and comprising the fire resistant fabric material of the present invention. See, for example, Example 2 below, particularly Mattresses 1, 2, 2A-2F and 4. The fabric of the first layer can be the mattress fabric discussed above as for example a cover, or a fabric comprising selected fibers inside. of the group consisting essentially of cotton, polyester, rayon, polypropylene, and combinations thereof. See Example 2 below. The nonwoven sheet layer may be any suitable material known in the art. For example, the nonwoven sheet layer can be made from any fiber not
15 fuel. In a preferred embodiment, the non-woven sheet layer is made of glass fibers. The mattress according to the present invention may further comprise at least a third layer adjacent to the second layer and at least a fourth layer adjacent to the third layer in
Wherein each of the third layer and the fourth layer is a bearing layer and at least one fifth layer adjacent to the fourth layer and comprising polyurethane foam. The bearing layer can be made of polyester fibers or of any fiber known in the art as being suitable for
~ 2 ~ 5 manufacture a layer that provides cushioning: LIS polyurethane foam can be of variable thickness. In addition, the mattress of the present invention can comprise at least a sixth layer adjacent to the fifth layer and comprises a fire-resistant fabric material. See Example 2 below, Mattress # 1. Mattresses number 6-11 in Example 2 below exhibit various characteristics of polyester fiber as the second bearing layer between the first layer of dot fabric and the third layer of fabric resistant to fire of the present invention. In another embodiment of the invention, the polyurethane foam can be the second layer of the mattress, (i.e., below the dot layer and instead of the polyester fiber). See Table III and Mattress 12 below. The polyurethane foam layer provides a superior cushioning effect. However, the total weight of the polyurethane foam layer together with the dot layer must be less than 1362 grams (3 pounds) since the dot layer and the polyurethane foam will be burned and the mattress will not pass the tests. combustion if more than 1362 grams (three pounds) are lost. In one embodiment of this type, a preferred thickness of the foam is 0.635 cm (0.25 inch). See Table III and Mattress 12, The mattress in accordance with the present invention may further comprise a fire resistant edge. In one embodiment, the edge of the present invention comprises a first layer that includes a mattress fabric.; and a second layer adjacent to the first layer and comprising the fire resistant fabric material of the present invention. In addition, the edge may comprise a third layer adjacent to the second layer and comprising a polyurethane foam. The edge may also comprise a fourth layer, adjacent to the third layer and comprising a non-woven sheet. Alternatively, the edge may comprise a fourth layer adjacent to the third layer, and comprising the fire-resistant fabric material of the present invention and a fifth layer, adjacent to the fourth layer and comprising a non-woven sheet. In another embodiment of the present invention, the mattress comprises at least one first layer comprising a
15 mattress fabric, and at least one second layer, adjacent to the first layer, and comprising the fire-resistant fabric material of the present invention, at least a third layer adjacent to the second layer, and comprising a polyurethane foam, and at least a fourth layer
20 adjacent to the third layer, and comprising a non-woven sheet, at least a fifth layer adjacent to the fourth layer and comprising a fibrous bearing and at least a sixth layer adjacent to the fifth layer and comprising another a bearing fibrous. This modality is exemplified
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ See Example 2 below. In a preferred embodiment, the mattress of the present invention comprises at least a first layer comprising a mattress fabric, at least a second layer adjacent to the first layer wherein the second layer is a bearing layer, and at least a third layer adjacent to the second layer and comprising the fabric material
10 fire resistant of the present invention. The mattress may further comprise at least a fourth layer adjacent to the third layer and wherein a fourth layer is a bearing layer, at least a fifth layer adjacent to the fourth layer, and comprising a polyurethane foam, and
At least one sixth layer, adjacent to the fifth layer, and comprising a non-woven sheet. The bearing layer can be made of any fiber known in the art suitable for manufacturing a bearing. In a preferred embodiment, the bearing layer comprises polyester fiber. The best
20 modality from a perspective of comfort included as a second layer a layer of polyester fiber of 56 grams (two ounces). This embodiment of the present invention is exemplified in Example 2 below, Mattress 6. This modality resulted in a mattress with a softness greater than
~ 2 ~ 5 control mattresses (see "" Use 2 ~ "below, CbTcTTóñ It" control 3), but, as noted above, had unsatisfactory fire resistance characteristics. Mattress 6 had a total weight greater than 1362 grams (3 pounds) Therefore, since more than 1362 grams (3 pounds) were lost during the combustion test, the mattress did not pass the test. superior softness when the second layer is a polyester fabric or a polyurethane foam and the total weight of the layer together with the dot layer is less than 1362 grams (3 pounds) This preferred embodiment is exemplified in Example 2 below, Mattresses 7-12 As indicated above for certain embodiments of the mattresses of the present invention, the coating of the fire resistant fabric material faces the first layer As used herein, it faces the first layer "means that the tea material fire resistant has a coating on one side or both sides. If the coating is on one side, this side faces the first layer, with the uncoated side facing away from the first layer. In addition, the numbering of the layers indicates the order of the layers. (For example, if the mattress fabric is the first layer, this layer is the upper part of the mattress, with the second layer being adjacent to the first layer, the third adjacent layer ~ a Ta securrcta "layer, etc. As described above, the mattresses of the present invention may comprise other layers which may comprise one or more layers of fiber bearing and / or spring layer, see for example, Example 2 below, The mattresses may also comprise a board such as the board described above, see, for example, Example 2 below.Additional materials that may be incorporated in a mattress of the present invention include building materials such as flame retardant or non-flame retardant yarn for bonding mattress materials (e.g. glass or Kevlar yarn) as well as non-flame-retardant or flame-retardant tape, silicon with Kevlar thread can be used to reduce the breakdown and increase the time e production. In a particularly preferred embodiment of the present invention, conventional tape and / or conventional wire can be used and the mattress still meets the California TB129 test requirements. See Example 2 below and Mattresses 10 and 11. The fire-resistant materials of the present invention can be used to produce materials with characteristics similar to the foam and bearing layers that are used in mattresses and can replace or be added to such layers. In such an embodiment, the foam and cushion layers made with the flame retardant materials of the present invention provide fire resistance to the mattress when used therein. Table I below provides, in approximate percentages, the components of the coating that applicants have used in a preferred embodiment of fire-resistant fabric material of the present invention. TABLE I Coating Components% wet AGLOMERANTE Rhoplex 3349 34.76 TR407 3.96 FILLER ECC 1201 Clay (Huber) 42.07 SURFACTANT Octosol Al8 3.0 Ammonium Stearate 4.27 RETICULATION AGENT Melamine 1.18 MISCELLANEOUS Ammonium Nitrate 0.12 Aquamix 519 7.0 Acrysol ASE-95 NP 0.2 Water 3.46 Percentage "TotaT ± ü -SUSTRATO = BGF Industries Style 1625 Fiberglass Mat. Although the table shows possible combinations of binder, filler and surfactant, it is believed that other combinations may be used. according to another embodiment of the present invention TABLE II Coating components% wet AGLOMERANTE Rhoplex 3349 21.58 Rovene 4402 SBR 21.58 FILLER ECC 1201. Clay (Huber) 25 Decabromodiphenyl oxide 13 SURFACTANT Stepanol AM (ALS) 0.16 Octosol Al 8 1.68 Stanfex 4.27 RETICULATION AGENT Ammonium chloride 0.11 Melamine 3.49 MISCELLANEOUS Acrysol ASE-95NP 0. 14 Silicon oil CT101"U.5 Green dye 0.03 Foam remover 0.01 TSPP 0.07 Citric acid 0.05 Tinunin 292 0.05 Ammonium hydroxide 0.26 Water 8.02 Total percentage 100% SUBSTRATE = Glass fiber mat BGF Industries style 1625. Fabric materials Fire resistant, in accordance with the aforementioned, include a substrate and a coating comprising the structural material of the present invention. The coating (structural material) comprises 34% by weight of the fire resistant fabric material. In the coating, from about 34% by weight to about 55% by weight, it is binder, from about 0.1% to about 5.0% is surfactant, and from about 20% to about 55% is filler. In a preferred embodiment, the coating comprises about 50% binder, about 10% surfactant, and about 40% filler. The filler is preferably about 25% clay. The substrate is preferably woven glass. The substrate may also be a "~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ The binder that joins the glass fibers together is approximately 50% Rhoplex 3349 and 50% Rovene 4402 or any other suitable binder.Non-limiting examples of suitable binders are given above.The substrate can be coated by application with air, application by dipping, knife application, roller application, or film application such as thermal lamination / pressing, etc. The coating can be bonded to the substrate by chemical bonding, mechanical bonding, and / or thermal bonding. forced feeding of the coating onto the substrate with a blade The structural materials and fire-resistant fabric materials made in accordance with this invention can have Any form Preferably, such articles are flat. Structural materials can be used in any of several products, including but not limited to these examples, mattress / crib fabrics, mattress / crib covers, upholstered articles, bedroom items, (including items for children's bedrooms), upholstery, carpets, wall coverings (including wallpaper), stores campaign, sheds, against inc sñoTToT tolclos, sleeping bag, ironing board cover, fire resistant gloves, furniture, airplane seats, and carpets, fire resistant clothing for race car drivers, warplanes, firefighters , and the like, building materials such as for roofing, structural laminate type facing sheets, air duct lining for buildings, roof felt, lower layer for organic roof coating materials, roofing material in rolls, products in modified rolls, media for filter (including automotive filter), linings for vehicle chests, headliners, fire walls, ba Steam irrigation, etc. The structural material can be used alone or it can be used as a lining for a decorative fabric, for in the case used in mattresses, upholstery, sleeping bags, tents, etc., which can also be fire resistant. In fire resistant fabric materials according to the present invention, the substrate can be coated on one side or on both sides according to the contemplated application. For example, if one side of the substrate is coated with filler / surfactant / binder coating, the other surface may be coated with another material. In the case of the roofing industry, for example, the other material may be conventional asphalt for modified asphalt materials and non-asphalt coatings, and the article may be covered with roofing granules. It is believed that such roofing material will be lighter in weight, will offer better fire resistance, and better performance characteristics (such as flexibility in case of cold weather, dimensional stability and strength) than roofing materials of the previous technique. The mixture comprising the binder component, the prefabricated microcell component, the filler component may have a light foam consistency, such as shaving cream. It is believed that due to the low density of the mixture, the microcells do not pass through the substrate when applied to it. If desired, however, the viscosity of the coating can be increased through mixing to ensure that it does not run through the substrate. Non-limiting examples of thickening agents include Acrysol ASE-95NP, Acrysol ASE-60, Acrysol ASE-1000, Rhoplex ASE-75, Rhoplex ASE-108NP, and Rhoplex E-1961, all available from Rohm & amp;; Haas. In addition, the fire-resistant material can be coated with fire-resistant material can be coated with a water-repellent material or the water-repellent material can be added to the coating, (ie, internal waterproofing). Two water-repellent materials of this type are AurapéT "Enarca-regi l: adar- - ^ ftrra ner registered trademark 391 available at Sybron / Tanatex of Norwich, Connecticut In addition, Omnova Sequapel trademark and Sequapel 417 (available at Omnovasolutions, Inc. of Chester, SC), BS-1306, BS-15 and BS-29A (available in Wacker de Adrian, MI); Syl-off trademark-7922, Syl-off trademark-1171A, Syl-off registered trademark- 7910 and Dow Corning 346 Emulsion (available from Dow Corning, Corporation of Midland, MI) Freepel registered trademark - 1225 (available from BFG Industries of Charlotte, NC); and Michem trademark Emulsion-41740 and Michem trademark Emulsion-03230 (available in Michelman, Inc. of Cincinnati, OH) can also be employed It is believed that wax emulsions, oil emulsions, silicone emulsions, polyolefin emulsions, and sulfonyl as well as other products of similar performance can be suitable water repellent materials. As indicated by These materials are also useful in providing rebound characteristics to the fire resistant materials of the present invention. Water repellents can be particularly preferred, for example, in the manufacture of mattresses for cradles, for aircraft seats and in the case of the manufacture of furniture, especially for industrial use. A foam remover can also be added to the coating of the present invention to reduce and / or remove foam foam during the course of the operation. ür foam remover of this type is Y-250 available from Drews Industrial Division of Boston, NJ. Flame retardant materials can also be added to the fire resistant materials of the present invention to further improve the fire resistance characteristics. Non-limiting examples of flame retardant materials that can be used in accordance with the present invention include FRD-004 (decarbromodiphenyl oxide, Tiarco Chemicals, Dalton, GA), FRD-01, FR-10, FR-11, FR-12, FR-13 , FR-14 (all available from Tiarco Chemicals), zinc oxide, and aluminum trihydrate (ATH). In addition, color pigments, including, but not limited to, T-113 (Abco, Inc.), Pigment Blue W-4123, Pigment Orange W2090, Pigment Black W7717 and Pigment Green W6013, red pigments of iron oxide (available in Engelhard of Louisville, KY) can also be added to the coating of the present invention to provide desired characteristics, for example, the desired color. Additional coatings of, for example, water repellent material, anti-fungal material, antibacterial material, etc., may be applied on one side or on both sides of fire resistant materials and fire resistant fabric materials. For example, materials of fire-resistant fabrics comprising substrates coated in a "void" or both reagents in reagent / binder could be applied on one side with a water-repellent composition and on the other side with an agent antibacterial Alternatively, the water repellent material, the anti-fungal material, antibacterial material, etc., may be added to the coating before its use to coat the substrate. EXAMPLES Example 1; Fire Resistant Fabric Material In order to produce the structural materials of the present invention, the applicant formulated the coating using only four major components, water, filler, surfactant and binder (see Table I above). The largest constituent quantities were as follows: approximately 34.76% Rhoplex 3349 (Rohm &Haas, Philadelphia, PA), 42.07% clay ECC 1201 (Huber), and 3% of Octosol Al 8 (surfactant). In addition, 4.27% of ammonium stearate, 0.12% of ammonium nitrate, 1.18% of melamine, 7% of Aquamix, 3.96% of TR407 and 0.2% of Acrysol ASE-95NP were added. The materials were mixed in a reaction basin or mixing pit for 45 minutes. The mixture was used to cover a fiberglass mat on one side or on both sides. The mat was manufactured by BFG Industries, Inc. of Greensboro, North Carolina and was style number 1625 and presented a basis weight within a range of 0.817 kg / square (?? 8? 1ibras / square) to 0 8" 3 ~ kg / square (1.90 pounds / square) The mat exhibited a porosity within a range of 182.91 to 198.15 rtrVminute / rrr (600 to 650 cfm / square foot) .The coated article was durable and flexible and did not present cracks to the bending and presenting "bounce" characteristics Typical measurements of tensile strength for coated material versus uncoated material were 21,338 kilograms / 7.6 centimeters (47 pounds / 3") and 77,634 kilograms / 7.6 centimeters (171 pounds / 3"), respectively. Typical resistance measurements at the Elmendorff rupture were >; 3400 grams without rupture of the sample. The fire resistant cloth material was checked to determine its combustion capacity. When exposed to the flame of a Bunsen burner at a distance of 51 millimeters (two inches), the woven cloth and the wet-applied fabric failed the fire test (ie, the fiberglass was melted or created a hole in the place where the flame came into contact with the fabric). However, when a pyro-resistant fabric material of the present invention was exposed to the flame of a Bunsen burner at a distance of 51 millimeters (two inches) for a period of five minutes or more, no holes were created and the glass fibers did not melt. The coating protected the glass cloth with melting or disintegration and the integrity of the structure of the glass cloth was maintained. In addition, when cotton was placed on top of the fire-resistant cloth material such that the fire-resistant cloth material was between the Bunsen burner and the cotton, the cotton was also protected against the flame of the burner lighter. Bunsen. Technical Bulletin 129 of the Department of Consumer Affairs of the State of California, Office of Domestic Furniture and Thermal Insulation (October 1992) indicates that a cloth should maintain its integrity when exposed to an open flame for 20 minutes and this test was approved in the laboratory with the fire resistant fabric material of the present invention and the mattresses of the present invention comprising the fire resistant fabric material. The invention offers a fire-resistant fabric material that is flexible, foldable, and has a good upholstery characteristic and does not exhibit cracking, etc. The fire-resistant fabric material has a porosity of less than 5.49 mVminute / m (18 cfm) (no coating has a porosity
20 of 134.13 m3 / minute / m2 (440 cfm)) and can adhere very well to other materials, including decorative fabrics, polyurethane foam, isocyanurate foam, asphalt compounds, and granules (non-asphalt shingles). The fire resistant fabric material could have some
"2" 5 hole - ~ d¾ adf "rxer" ~ _o may have numerous "pin-holes" and continue to maintain a porosity less than approximately 3,048 mVminute / irr (10 cfm) to approximately 15.24 m3 / minute / m¿ (50 cfm) when coated with solvent-based adhesive, eg, Firestone Bonding Adhesive BA-2004, which does not run through the coated product.The coating application on the substrate was achieved by knife application. it can also be effected by foaming and knife application, foaming and blade application, foaming and blade application and crushing, dip coating, roller coating (tightening between two rolls having a space that determines the thickness of the coating), or through a hand held applicator that can be obtained from the Gardner Company, sprayed, immersed and coated by aqueous dispersion or solvent flow, calendering, lamination and the like, followed by baked and baked, as is known in the art. After application, the samples were placed in an oven at a temperature of approximately 177 ° C (350 ° F) for approximately 20 minutes to achieve drying and curing. In addition, the coating can be formed separately as a single or multi-layer film for subsequent combination with a substrate.
Example 2: Mattresses comprising the fire-resistant fabric material Modes of examples of mattresses of the present invention were produced, said embodiments included several layer components using the fire-resistant fabric material of Example 1 above, as shown with additional details below (Mattresses 1-12). The mattresses were tested to determine their fire resistance and to determine their comfort (softness). All of the mattresses listed below passed the fire resistance tests (except Mattress 6) and were comparable in terms of comfort to the Control Mattress 3 which does not include the fire resistant fabric material of the present invention. Figure 6 shows the softness rating for the example mattresses of the present invention and shows that the Mattresses 1, 2A, 2B, and 2C are virtually as soft as the Control Mattress 3. The Mattresses 2D, 2E, 2F, 4 and 5 had slightly lower results in terms of smoothness compared to the control mattress, and Mattress 6 significantly exceeded the softness rating of the control mattress. The mattresses were subjected to California TB129 fire resistance testing procedures. The test procedure is designed to evaluate mattresses contemplated for use in public buildings. "Your test procedure" was read as follows. All instruments were zeroed and calibrated before the test. Each of the test mattresses after conditioning at 23 ° C (73 ° F) and 50% relative humidity was placed in a steel structure, on a weight cell platform along the side of the test room. A propane burner was placed centrally and parallel to the bottom horizontal surface of the mattress at 2.54 centimeters (one inch) from the vertical side panel of the mattress. He started the computerized data acquisition system when the lighter was turned on and allowed to burn for 180 seconds. The test continued until the combustion has stopped or until one hour has elapsed. The mattress is considered a failure if any of the following criteria is exceeded: (1) weight loss of 1362 grams (3 pounds) or more in the first 10 minutes; (2) maximum rate of heat release of 100 K; and (3) total heat release of 25 MJ in the first 10 minutes. Figures 1-3 show that all mattresses, with the exception of Mattress 6, were well within acceptable limits for heat release rate (KW), total heat released (KJ) and weight loss in grams (in pounds) . Mattress 6 did not pass the heat release rate test (nor the total emissions test). However, it is believed that CoIcHoñ 6 would pay 3rd pxtreba .-- camb-tand © -1-a-f- ± fer-a-polyester used in the second layer of Mattress 6. For example, Mattresses 7-11 they use less polyester fiber allowing the mattress to pass the heat release test (or proof of total energy emission) without sacrificing the added comfort achieved by 56 grams (two ounces) of polyester fiber. In addition, Mattress 12 uses a polyurethane foam in place of the polyester fiber and continues to achieve improved smoothness while passing the heat release test. This is because the total weight loss is less than 1362 grams (3 pounds). Table III below shows a summary of the results of the California TB129 test. Notably, even exposed to a flame for 60 minutes instead of the three minutes suggested in the California TB129 test, particular embodiments of the present invention still approve the requirements of the California TB129 test. See Table III, Mattresses 1 and 2d. Figure 4 shows that a control mattress (Mattress 3 below) was fully burned during a 3 minute TB129 California test. In remarkable contrast, under the same conditions, Figure 5A shows that a mattress manufactured in accordance with the present invention (Mattress 2F below) has little fire damage. In addition, Figure 5B shows that a mattress made in accordance with the present invention (¾ rhóm -2 ~ fr) -presenta-urr ~ d-afto ^^ icrt-a-l-efflen: -e-Mge-rem ? -fttego- when exposed to an open flame for 60 minutes (time 20 times greater). It is especially noteworthy that the mattresses are particularly noticeable that mattresses made in accordance with the present invention can pass the 5 requirements of the California TB129 test even after being exposed to an open flame for 60 minutes since the products currently available do not pass or even after a 3-minute exposure unless the mattress construction is modified, sacrificing comfort. TABLE III Summary of Test Results California TB129 Test Sample Mattress Peak HRR (KW) State Requirements Less than 100 California 15 # 1 (Double) 60 minute extended flame See below 36.01 # 2A (Double) See below 30.09 20 # 2B (Double) See below 49.42 # 2C (Double) See below 23.76 # 2D (Double) See below 18.32 # 2D (Double) Extended Flame 60 -2-5 minutes jy: - &e-a-low-56 -_63 # 2E (Double) See below 45.71 # 2F (Double) See below 30.31 # 3 (Double) Control See below 1585.52 # 4 (Double) See below 20.68 # 5 (Double) See below 56.71 # 6 (Double) See below 1027 # 7 (Double) See below 20.9 # 8 (Double) See below 23.3 # 9 (Double) See below 23.6 # 10 (Double) See below 22.02 # 11 (Double) See aba or 20.05 # 12 (Double) See below 24.7 (Continued Table III) Test Sample Total Heat Weight Loss State Requirements Released (MJ) (grams) from California Less than 25 Less than 3.0 in the first few years imeros 10 minutes 10 minutes
# 1 (Double) Flame extended 60 minutes 10.84 181.6 # 2A (Double) 9.09 181.6 # 2B (Double) 9.11 317.8 # 2C (Double) 3.03 181.6 fr2BH-Befe ± -) # 2D (Double) Flame extended 60 minutes 10.74 136.20 # 2E (Double) 12.8 408.60 # 2F (Double) 6.95 45.40 # 3 (Double) Control 129.79 2769.40 # 4 (Double) 4.09 181.60 # 5 (Double) 12.96 1089.60 # 6 (Double) 10.86 1044.20 # 7 (Double) 2.86 272.40 # 8 (Double) 5.4 181.60 # 9 (Double) 7.2 227.00 # 10 (Double) 5.2 227.00 # 11 (Double) 4.7 363.20 # 12 (Double) 18.0 998.80
(Continued from Table III) Test Sample Weight Loss State State Requirements (pounds) of California Less than 3.0 in the first 10 minutes # 1 (Double) Extended Flare minutes 0.4 Hf2ftH obíe Pa-só- # 2B (Double) 0.7 Passed # 2C (Double) 0.4 Passed # 2D (Double) 0.1 Passed # 2D (Double) Extended Flame 60 minutes 0.3 Passed # 2E (Double) 0.9 Passed # 2F (Double) 0.1 Passed # 3 (Double) Control 6.1 Failed # 4 (Double) 0.4 Passed # 5 (Double) 2.4 Passed # 6 (Double) 2.3 Failed # 7 (Double) 0.6 Passed # 8 (Double) 0.4 Passed # 9 (Double) 0.5 Passed # 10 (Double) 0.5 Passed # 11 (Double) 0.8 Passed # 12 (Double) 2.2 Passed MATTRESS # 1 (Double) Cushioning: Cloak # 1 .O. # 23652-Type Hummingbird * "C" White Warp Polyester flat 150 d Padded cotton 6/1 64% cotton, 36¾ polyester Coat # 2 Elk fire barrier (Coated Glass Fabric) - coated side faces layer # 1 Layer # 3 56 grams (2.0 ounces) polyester fiber # 4 layer Polyester fiber, 56 grams (2.0 ounces) Layer # 5 0.635-centimeter (0.25-inch) polyurethane foam Layer # 6 Elk fire barrier (Glass cloth Coated) - coated side facing layer # 1 Layer # 7 Non-woven sheet (backing) 0.35 gram (0.0125 ounce) Other: Layer # 8 1.5875 cm (5/8 inch) fibrous bearing Layer # 9 Fibrous bearing 2.54 centimeters (1.0 inch) Layer # 10 Edge Spring: Layer # 1 Same as layer # 1 above (outer layer) Ga a # 2 |-Barrier-to ± f-tiege - (- Fiber-Coated Glass) - coated side facing layer # 1 Layer # 3 1.11 cm (7/16 inch) polyurethane foam Layer # 4 Barrier a l Fire Elk (Coated Glass Fabric) - side coated facing layer # 1 Layer # 5 Nonwoven sheet of 14 grams (0.50 oz) (backing) Construction material: 1. Kevlar - Thread 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with flame retardant agent) MATTRESS # 2A (Double) Cushioning: Cape # 1 WO # 23652-Type Hummingbird * "C" White Warp Flat polyester 150 d Padded cotton 6/1 Coated 64% cotton, 36% polyester Coat # 2 Elk fire barrier (Coated Glass Fabric) - coated side faces-; 1a-ea-pa - # - 1 Layer # 3 56-gram (2.0-ounce) polyester fiber Layer # 4 56-gram (2.0-ounce) polyester fiber Layer # 5 0.635-centimeter (0.25-inch) polyurethane foam Layer # 6 0.35 gram (0.0125 ounce) non-woven sheet (backing) Other: Layer # 7 1.5875 cm (5/8 inch) fibrous bearing Layer # 8 2.54 cm (1.0 inch) fibrous bearing Layer # 9 Edge Trim: Same that layer # 1 above (outer layer) Elk fire barrier (Coated Glass Fabric) - side coated facing layer # 1 1.11 cm (7/16 inch) polyurethane foam 14 gram nonwoven sheet (0.50 Material of construction: 1. Glass thread - Treated with flame-retardant agent 2. Tape: 1.27 centímet ros - 2.54 centimeters (1/2 - 1.0") (treated with flame-retardant agent) MATTRESS # 2B (Double) Cushioning: .O. # 23105 - Nuance Braunfels * Talc "C" Warp 30/2 Rayon Polypropylene Filler 300 d Uncoated 74% Rayon, 26% Polypropylene Elk Fire Barrier (Coated Glass Fabric) - Coated side faces layer # 1 56 Gram Polyester Fiber (2.0 oz) 56 Gram Polyester Fiber (2.0 oz) 0.635 cm (0.25 inch) polyurethane foam 0.35 gram uncoated sheet Backing! Other: Capa # 7 1.5875 cm (5/8 inch) fibrous bearing Layer # 8 2.54 cm (1.0 inch) fibrous bearing Layer # 9 Spring Edge: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Barrier Elk fire (Coated Glass Fabric) - coated side facing layer # 1 Layer # 3 1.11 cm (7/16 inch) polyurethane foam Layer # 4 Nonwoven sheet of 14 grams (0.50 oz) construction: 1. Glass thread - treated with flame-retardant agent 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with flame retardant agent) MATTRESS # 2C (Double) _A o_l_Gb_ona.dojL WO # 21710 - Palatial Jewel B Regency * White Honey Warm Polyester textured 150 d
Polypropylene 60 d stuffing Without coating 58% polypropylene, 42% polyester Elk fire barrier (Coated Glass Fabric) - coated side faces layer # 1 56 grams polyester fiber (2.0 ounces) 56 polyester fiber grams (2.0 oz.) 0.635 cm (1/4 inch) polyurethane foam 0.35 gram (0.0125 oz) non-woven sheet (backing)
1.5875 cm (5/8 inch) fibrous bearing 2.54 cm (1.0 inch) fibrous bearing Rim: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Coated Glass Fabric) - coated side facing layer # 1 Layer # 3 1.11 cm (7/16 inch) polyurethane foam Layer # 4 Nonwoven sheet of 14 grams (0.50 oz) (backing) Construction material: 1. Thread of glass - treated with flame-retardant agent 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with fire retardant) MATTRESS # 2D (Double) Cushion: Cloak # 1 wO # 21909- Select Oakmont + * Vanilla hite 2/150 Warp Textured polyester 150 d Textured polyester fill 300 d Coated 100% polyester Layer # 2 Fire barrier - FJJc_ (De-df cloth or Coated) - coated side faces layer # 1 Layer # 3 Polyester fiber 56 grams (2.0 ounces) Layer # 4 56 Gra polyester fiber mos (2.0 oz.) Layer # 5 0.635 cm (0.25 inch) polyurethane foam Layer # 6 0.35 gram (0.0125 oz) non-woven sheet (backing) Other: Layer # 7 1.5875 cm (5/8 inch) fibrous bearing ) Layer # 8 2.54 cm (1.0 inch) fibrous bearing Layer # 9 Spring Edge: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Coated Glass Fabric) - side coated facing layer # 1 Layer # 3 1.11 cm (7/16 inch) polyurethane foam Layer # 4 Nonwoven sheet of 14 grams (0.50 oz) (backing) Construction material: 1. Glass thread - treated with flame-retardant agent 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with flame retardant agent) 3. Silicone spray MAT # 2E (Double) Cushioning: Layer # 1 WO # 14557 - Classic Sea Life Blue Purchased 100% Polyester Coated Tip Coat # 2 Elk Fire Barrier (Coated Glass Fabric) - Coated Side Faces Layer # 1 Layer # 3 56 Gram Polyester Fiber (2.0 oz) Layer # 4 56 grams (2.0 oz) polyester fiber Layer # 5 0.635 cm (0.25 inch) polyurethane foam Layer # 6 0.35 gram (0.0125 oz) non-woven sheet (backing) Other: 1.5875 cm fibrous bearing (5/8 inches) 2.54 cm (1.0 inch) fibrous bearing Spring
Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Coated Glass Fabric) - faced side facing layer # 1 Layer # 3 1.11 cm polyurethane foam (7 / 16 inch) Layer # 4 1.4 gram (0.050 oz) nonwoven sheet (backing) Construction material: 1. Glass thread - treated with flame retardant 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0" ) (treated with_age_nt._e_ -ia retardante-) 3. Silicone spray MAT # 2F (Double) Cushioning: WO # 18655 - Lt. Wgt Premier Juliet Plumdust Bought from tip Without coating 100% polyester Fire Barrier Elk (Fabric) Coated Glass) - coated side faces layer # 1 56 grams polyester fiber (2.0 ounces) Polyester foam 56 grams (2.0 ounces) 0.635 centimeter (0.25 inch) polyurethane foam 0.35 gram nonwoven sheet ( 0.0125 ounces (Backup)
Fibrous bearing of 1.5875 centimeters (5/8 inch) £ © - ± ne-te-fib-t &so-of -2 - S-centímetíO-s (1.0 inch) Layer # 9 Edge Spring: Layer # 1 Himself that layer # 1 above (layer
5 external) Layer # 2 Fire Barrier Elk (Coated Glass Fabric) - side coated facing layer # 1 Layer # 3 Polyurethane foam 1.11
10 centimeters (7/16 inch) Layer # 4 1.4 grams (0.050 oz) non-woven sheet (backing) Construction material: 1. Glass thread - treated with flame retardant 2. Ribbon: 1.27 centimeters - 2.54 centimeters (1 / 2 - 1.0") (treated with flame-retardant agent) 3. Silicone spray 20 MATTRESS # 3 (Double) Cushioning: Layer # 1 WO # 21710-Palatial Jewel B Regency * White Honey Warp Polyester textured 150 d -2-5 R ^ J.-enG ^^ lipr-o. I-Leno - J5 -0 - d uncoated 58% polypropylene, 42% polyester Layer # 2 56 grams polyester fiber (2.0 ounces) 5 Layer # 3 Fiber polyester 56 grams (2.0 ounces) Layer # 4 0.635 cm (0.25 inch) polyurethane foam Layer # 5 0.35 gram nonwoven sheet (0.0125)
10 ounces) Other: Layer # 6 1.5875 centimeters (5/8 inch) fibrous bearing Layer # 7 2.54-inch fibrous bearing
15 (1.0 inch) Layer # 8 Edge Spring: Layer # 1 Same as layer # 1 above (outer layer) 20 Layer # 2 1.11 cm (7/16 inch) polyurethane foam Layer # 3 1.4 gram nonwoven sheet (0.050 oz) (backing) Material of construction: -2.5 1. Convention 1 - Thread 7C
2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (conventional tape) MATTRESS # 4 (Double) Cushioning: WO # 23652-Lineage Hummingbird *" C "White Warp Polyester flat 150 d Padded cotton 6/1 Coated 64 % cotton, 36% polyester Elk Fire Barrier (Coated Glass Fabric) - coated side faces layer # 1 56 gram (2.0 oz) polyester fiber 56 gram (2.0 oz) polyester foam Polyurethane foam 0.635 centimeter (0.25 inch) 0.35 gram nonwoven sheet (0.0125 ounce)
Layer # 7 1.5875 fibrous bearing Layer # 8 2.54 cm (1.0 inch) fibrous bearing Layer # 9 Spring Edge: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Glass cloth Coated) - side coated facing layer # 1 Layer # 3 1.11 centimeters (7/16 inch) polyurethane foam Layer # 4 1.4 grams (0.050 oz) nonwoven sheet (backing) Construction material: l . Kevlar - Thread 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with flame-retardant agent) MATTRESS # 5 (Double) Cushioning: Layer # 1 WO # 23105-Nuance Braunfels * talcum" C "Warp Rayon 30/2 d Polypropylene filling 300 d without coating 74% Rayon, 26% polypropylene Layer # 2 Elk fire barrier (Coated Glass Fabric) - coated side faces layer # 1 5 Layer # 3 Polyurethane foam 0.3175 cm (1/8 inch) Layer # 4 Nonwoven 3.5 gram (0.125 ounce) sheet (backing) Layer # 5 1,875 fibrous bearing
10 centimeters (5/8 inch) Layer # 6 2.54 cm (1.0 inch) fibrous bearing Other: Layer # 7 Spring 15 Edge: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Coated Glass Fabric) - Coated on side that faces layer # 1 Layer # 3 1.11 centimeters (7/16 inch) polyurethane foam Layer # 5 1.4 grams (0.050 ounce) nonwoven sheet (backing) _2J5 Ma ± s i.al-_jde-_j3-oj ^ 1. Kevlar - Thread 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with flame-retardant agent) MATTRESS # 6 (Double) Cushioning: .O. # 23105-Nuance Braunfels * Talc "C" Warp Rayon 30/2 Filler polypropylene 300 d uncoated 74% Rayon, 26% polypropylene Fiber polyester 56 grams (2.0 ounces) Elk fire barrier (Coated Glass Fabric ) - coated side facing layer # 1 56 gram (2.0 oz) polyester fiber 0.635 cm polyurethane foam (0.25 inches) 0.35 gram non-woven sheet (0.0125 ounces)
Layer # 7 1.5875 centimeters (5/8 inches) fibrous bearing Layer # 8 2.54 centimeters (1.0 inch) fibrous bearing Layer # 9 Edge Spring: Layer # 1 Himself that layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Coated Glass Fabric) - side coated 10 faces layer # 1 Layer # 3 1.11 centimeters (7/16 inch) polyurethane foam ) Layer # 5 Nonwoven sheet of 14 grams (0.50 oz) (backing) 15 Construction material: 1. Kevlar thread 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with flame retardant agent) 20 MATTRESS # 7 (Double) Cushion: Cape # 1 Williamsburg Vanilla 96 ends, 30 points Polyester warp _2J5 Fabric: 0.417 kilograms per linear meter (0.84 pound per linear yard) Filling: 6/1 cotton Finish: clear covering 65% cotton, 35% polyester
Layer # 2 42 gram (1.5 ounce) polyester fiber Cloak # 3 Elk fire barrier (Coated Glass Fabric) - coated side facing layer # 1 Layer # 4 56 gram (2.0 ounce) polyester fiber Layer # 5 0.635-cm (0.25-inch) polyurethane foam Layer # 6 0.35-gram (0.0125-ounce) non-woven sheet Other: Layer # 7 - Layer # 8 2.54-inch (1.0-inch) fibrous bearing Layer # 9 Edge Edge : Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Coated Glass Fabric) - faced side facing layer # 1 Layer # 3 1.11 cm polyurethane foam ( 7/16 inch) Layer # 4 Nonwoven sheet of 14 grams (0.50 oz) (backing) Construction material: 1. Kevlar thread 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with agent fire retardant) MATTRESS # 8 (Double) Cushion: Williamsburg Vanilla 96 ends, 30 points Polyester warp ter Fabric: 0.417 kilograms per linear meter (0.84 pound per linear yard) Filling: 6/1 cotton Finishing: clear coating 65% cotton, 35% polyester 28 gram (1 oz) polyester fiber Elk fire barrier (Fabric Coated Glass) - coated side facing layer # 1 Layer # 4 56 grams polyester fiber (2.0 ounces) Layer # 5 0.635 cm (0.25 inch) polyurethane foam Layer # 6 0.35 non-woven sheet gram (0.0125 ounce) Other: Layer # 7 Layer # 8 2.54 cm (1.0 inch) fibrous bearing Layer # 9 Spring Edge: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier ( Coated Glass Fabric) - side coated facing layer # 1 Layer # 3 1.11 centimeters (7/16 inch) polyurethane foam Layer # 4 Nonwoven sheet of 14 grams (0.50 oz) (backing) construction: 1. Thread evolve 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (tr bonded with flame retardant agent) MATTRESS # 9 (Double) Cushion: Williamsburg Vanilla 96 ends, 30 points Polyester warp Fabric: 0.417 kilograms per linear meter (0.84 pound per linear yard) Padding: 6/1 cotton Finish: clear coating 65% cotton, 35% polyester 21 grams polyester fiber (0.75 ounces) Elk fire barrier (Coated Glass Fiber) - coated side faces layer # 1 56 grams polyester fiber (2.0 ounces) Polyurethane foam of 0.635 centimeters (0.25 inches) Nonwoven sheet of 0.35 grams (0.0125 ounces)
Layer # 7 Layer # 8 2.54 cm (1.0 inch) fibrous bearing Layer # 9 Spring Edge: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Coated Glass Fabric) - coated on side facing layer # 1 Layer # 3 1.11 centimeters (7/16 inch) polyurethane foam Layer # 4 Nonwoven sheet of 14 grams (0.50 oz) (backing) Construction material: 1. Kevlar thread 2 Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with flame-retardant agent) MATTRESS # 10 (Double) Cushion: Williamsburg Vanilla 96 ends, 30 points Polyester warp Fabric: 0.417 kilograms per linear meter (0.84 pound) per linear yard Filling: 6/1 cotton Finish: clear covering 65% cotton, 35% polyester
Layer # 2 21 grams polyester fiber (0.75 ounces) Layer # 3 Elk fire barrier (Coated Glass Fabric) - coated side faces layer # 1 Layer # 4 56 grams polyester fiber (2.0 ounces) Layer # 5 0.635 cm (0.25 inch) polyurethane foam Layer # 6 0.35 gram non-woven sheet (0.0125 ounces) Other: Layer # 7 - Layer # 8 2.54 cm (1.0 inch) fibrous bearing Layer # 9 Edge Spring: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Coated Glass Fabric) - faced side facing layer # 1 Layer # 3 1.11 cm polyurethane foam (7 / 16 inch) Layer # 4 Nonwoven sheet of 14 grams (0.50 oz) (backing) Construction material: 1. Kevlar thread 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (Conventional) MATTRESS # 11 (Double) Cushioning: Williamsburg Vanilla 96 ends, 30 points Polyester warp Fabric: 0.417 kilograms per linear meter (0.84 pound per linear yard) Filler: 6/1 cotton Finish: clear coating 65% cotton, 35% polyester Polyester fiber 42 grams (1.5 ounces) Barrier to fire Elk (Coated Glass Fabric) - coated side faces layer # 1 56 grams polyester fiber (2.0 ounces) Layer # 5 0.635 centimeter (0.25 inch) polyurethane foam Layer # 6 Non woven sheet 0.35 gram (0.0125 ounce) Other: Layer # 7 Layer # 8 2.54 cm (1.0 inch) fibrous bearing Layer # 9 Spring Edge: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk fire barrier (Coated Glass Fabric) - side coated facing layer # 1 Layer # 3 1.11 centimeters (7/16 inch) polyurethane foam Layer # 4 Nonwoven sheet of 14 grams (0.50 oz) (backing) Material of construction: 1. Conventional thread 2. Tape: 1.27 centimeters - 2. 54 centimeters (1/2 - 1.0") (Conventional) MATTRESS # 12 (Double)
W.O. # 23105-Nuance Braunfels * talc "C" Rayon Warp 30/2 Filling: 300 d polypropylene without coating 74% Rayon, 26% polypropylene 0.635 cm (0.25 inch) polyurethane foam Elk Fire Barrier (Glass Cloth) Coated) - coated side facing layer # 1 56 gram (2.0 oz) polyester fiber 0.635 cm (0.25 inch) polyurethane foam 0.35 gram (0.0125 oz) nonwoven sheet
Layer # 7 1.5875 centimeters (5/8 inch) fibrous bearing Layer # 8 2.54 cm (1.0 inch) fibrous bearing Layer "G" 9 -Re-s ^ rte, Edge: Layer # 1 Same as layer # 1 above (outer layer) Layer # 2 Elk Fire Barrier (Coated Glass Fabric) - side coated facing layer # 1 Layer # 3 1.11 cm (7/16 inch) polyurethane foam Layer # 4 Non-woven sheet of 14 grams (0.50 oz) (backing) Construction material: 1. Kevlar thread 2. Tape: 1.27 centimeters - 2.54 centimeters (1/2 - 1.0") (treated with flame-retardant agent) It will be understood that the above examples are illustrative and what compositions other than those described above may be used employing the principles underlying the present invention. For example, other sources of filler as well as mixtures of acrylic latex and / or surfactants can be employed in the formulation of the structural materials of the present invention. In addition, the coating compositions can be applied to various types of substrates, in accordance with what is described above.