‘US 201802 us) United States 2) Patent Application Publication co) Pub. No.: US 2018/0279796 Al oy ow 2 ay @y @) (6) Valenta et al. MATTRESS CONTAINING MICROENCAPSULATED PHASE CHANGE MATERIAL, Applicant: Milken & Company, Spartanburg, SC ws) rte Valenta, Greer, SC (US); Patrick 1. Carroll, Spartaninons, SC (US); Will Ringo. Spartanburg, SC (US): Tripp oyee, Spartanburg, SC (US) Appl. Now 161001429 Filed: Jum, 6, 2018 Related US. Application Data Continuation of application No, 15/078,395, filed oa Mar. 23, 2016, Provisional application No, 62/141,587, filed om Apr. 1, 2015, 979681 (43) Pub. Date: Oct. 4, 2018 Publication Classification (1) Inte MTC 3702 (2006.01) Ad7C 2108 (2006.01), ANC 3100 (200501), ATC 2700 (200501), (2) US. oe AS7C 27/121 (2013.01), A47C 21/046 (Go13 01) 447 317001 (2013.01): 447C 27/122 201301); ANIC 277002 (2013.01) on ABSTRACT A mattress containing a core section, high loft non-woven layer at east partially covering a first side ofthe core section and containing a plurality of heat and flame resistant bers bulking fibers, and binder fibers, a ticking layer at least parially covering the high loft non-woven layer and con: faining a textile layer, a pattem coated layer. The patter coated layer may be ptinted on the high Toft non-woven layer the ticking layer, or any layer between the high lft non-woven Laver and the ticking layer The pattem coated layer contains a blend of microencapsulated phase change material (PCM) and a binder, wherein the PCM is fully encapsulated by the binder. 10 1000US 2018/0279796 AI Oct. 4,2018 Sheet 1 of 6 Patent Application Publication °001 ool qool 9002 00v coor -[- Dif \N WS Wy 200z, p> aa ore 00z ae SASSY WS WI WS Wy Wy WS Wy (RS ~N eS ae ~ ian QA NL WW a dog 900 4 OL Ow 7Patent Application Publication Oct. 4, 2018 Sheet 2 of 6 US 2018/0279796 AI FIG. -2-US 2018/0279796 AI Patent Application Publication Oct. 4, 2018 Sheet 3 of 6 -£- DI4US 2018/0279796 AI 2018 Sheet 4 of 6 3 Patent Application Publication SoS SSO OOOO loo 0 00 COCO; . loo 000000 loo 000 loo 000 loo oo loo eoccccced ° ba! jo ol ° ° | Joo co 0d ecco ey loco 00 FIG. -4- FIG, -5-Patent Application Publication Oct. 4, 2018 Sheet Sof 6 US 2018/0279796 AI 410Patent Application Publication Oct. 4, 2018 Sheet 6 of 6 US 2018/0279796 AI 410 200 410 200 410 FIG. -9-US 2018/0279796 AI MATTRESS CONTAINING. MICROENCAPSULATED PHASE CHANGE, ‘MATERIAL RELATED APPLICATIONS 10001] This application is a continuation of co-pending US. application Ser No. 151078,39S, filed on Mar. 28, 2016, hich elaims priority U.S, provisional application 62/141, 587, led on Apr. 1, 2015, both of which are incorporated herein in theie enor, TECHNICAL FIELD OF THE INVENTION 10002} ‘The invention provides a mattress having a pattera ‘outed layer of microencupsulate phase change material oa at least one of the high loft non-woven layer, the ticking layer, ora layer between the high loft non-woven layer and the ticking layer BACKGROUND [0003] Some foam mattress (and traditional inner spring ‘matiresses) sufer from an “overheating sensation” where the mattress absorbs the body heat from the user and makes the user feel overly hot. Its desirable to havea mattress that retains is breathability but reduces the “overheating sens BRIEF SUMMARY OF THE INVENTION 10003) A matiess containing a core setion, a high tof ron-woven layer atleast partially covering a irs side ofthe ‘core section and containing a plurality of eat and flame resistant fibors, bulking fibers, and binder fibers, a ticking Jayer at least partially covering the high loft non-woven layer and containing 8 textile layer. a pattern coated layer The pattem coated layer may be printed on the high loft non-woven layer, the ticking layer, or any layer between the high fot non-woven layer and the ticking layer. The pattera ‘coated layer contains @ blend of microeneapsulsted phase ‘change material (PCM) and a binder, wherein the PCM is, fully encapsulated by the binder. BRIEP DESCRIPTION OF THE FIGURES 10005] Aa embodiment ofthe present invention will now be deseribad by way of example, with reference to the ‘accompanying drawings. 10006] FIGS. 1-3 are cross-sectional views of different ‘embodiments of matiresses of the invention, [0007] FIG. 4 is a schematic of a top view of a fabric having a discontinuous dot pattern of an adhesion promoter ‘on surface of the Fabric, [0008] FIG. § is a schematic of a top view of a fabric having a discontinaous patter of random areas of an adhesion promoter on surface of the fabri, 10009] FIG. 6 is schematic of a top view of a fabric having 2 grid pattern of an adhesion promoter oa surface of the fabri, 10010] FIG. 7 schematic of top view ofa fabric having pattem ofa series of parallel lines of an adhesion promoter ‘on surface of the fabric, [0011] FIG. 8 is a schematic of a side view of a fabric showing the discontinoos pater ofthe adhesion promot- ing chemistry on both sides of the fabric. Oct. 4, 2018 [0012] FIG, 9 is a schematic of a top view of a fabsic having pater of a dots of varying density across the fabric. DETAILED DESCRIPTION OF THE INVENTION 0013] Unlike use of PCM fibers or PCM dispersed in Tam, sereen printing under ticking oF on ticking allows 10 bring significant mass of PCM tothe close proximity ofthe ‘human body. Unlike coating, sereen printing of patterns (not ina foam) provides a flexible layer whichis less susceptible to breaking when exposed to bending and stretching. [014] The core section 100 ofthe matress can be any suitable matress core including both foam and inner spring ‘mattress cores. On the fist side 1004 ofthe coe section 100 js high Toft non-woven layer 200. While the high loft non-woven layer 200 is shown diwclly on and in direct contat with the core section 100, there may be a space between the two layers 100, 200, or there may be additional layers between the core section 100 and the high loft joven layer 200. The high loft non-woven layer 200 nner side 2002 and an outer side 2006. The bigh ‘oven layer 200 is oriented such thatthe inne side 200 faces the second side 100h ofthe core section 100.’ The high Jolt non-woven layer 200 contains a plurality of heat And flame resistant fibers, bulking fibers, and binder fibers. [0015] As used herein, heat and Name resistant fibers shall ean fibers having Limiting Oxygea Index (LOD vale of | 20,95 or yreater, as determined by ISO 4589-1. Examples of heat and ame resistant fibers include, but are aot Kimited 0 the following: fibers including oxidized polyaerylonitile, ‘rami, oF polyimid, ume resistant treated fibers, FR rayon, FR polyester, FR nylon, modacryic, carbon fibers, oF the likes These heat and Mame resistant fibers may also vet as the bulking fihers or may be sued in addition to the bulking tibers, [0016] Bulking fibers ae fibers that provide volume to the high loft non-woven layer 200. Examples of bulking fibers would include fibers with high denier per lament (one denier por filament or larger, high crimp fibers, holow-fll ‘hers, nd the lke. These fibers provide mass and volume to the materia. Some examples of bulking fibers include polyester, polypropylene, and eotton, as well as other low cost fers. Preferably, the bulking fibers have a denier greater than about 12 denier In another embodiment, the bulking fibers have a denier greater than about 15 denier. The bulking fibers are preferably staple fibers. In one embodiment, the bulking fibors do not a circular cross section, but are fibers having a higher surface area, ineluding but not limited 10, segmented pic, 4DG, winged fibers, ‘eslobal et [0017] Tn one embodiment, the bulking fibers within the high loft non-woven layer 200 are randomly oriented within the high loft non-woven layer 200, In another embodiment, ‘majority of bulking fibers are oriented such thatthe fibers orm an angle with the innor side 200 of the high loft non-woven layer 200 of hetwcen about O and 25 degrees. la another embodiment, a majority of bulking fibers are ori- tented such thatthe fibers form an angle with the inner side 200 ofthe high ltt non-woven layer 200 of between about O and 25 degrees [0018] In another embodiment, the bulking fibers prfer- ably are oriented generally inthe direction (the Z-itection ‘is defined asthe direction perpendicular tothe plane formed by the inner side 200« ofthe hig loft non-woven layer 200.US 2018/0279796 AI The orientation of the bulking fibers allows for increased thickness ofthe high lot non-woven layer 200, Z-oricats tion allows for higher compression resistance and retention ‘fof during handing. Preferably, a majority of the bulking ‘bers have a tangential angle of between about 25 and 90 ‘degrees tothe normal ofan inner boundary plane (defined to be @ midpoint plane between the inner side 2000 and the ‘outer side 2004). This means that ia tangent was deawn on. the bulking fibers at the midpoint berween the outer side 200 and the inner side 2002, the angle formed by the tangent and the inner boundary plane would be between about 90 dearees and 25 degrees. More preferably, de angle formed by the tangent and the inner boundary plane would be between about 90 degrees and 4S degrees. 10019] The binder fibers within the high Toft non-woves layer 200 are honded together to create @ cohesive two- ‘dimensional fiber network which anchors the bulking fibers fand the heat and flame resistant fibers. The binder fibers are ‘bors that form an adhesion oF bon with the other fibers. Ia ‘one embodiment, the hinder preferably are fibers that are heat activated. Examples of heat activated binder fibers are fibers that ean met at lower temperatures, such as low melt fibers, bi-component fiber, sch 3s side-by-side or core and sheath fibers witha lower sheath melting temperature, and the ike. In one emboslimeat, the binder fibers area polyester ‘core ani shea fer with a lower melt temperature poly ‘ester sheath, 10020] -Thebinder fibers are preferably staple fibers. Inone ‘embodiment, the binder fibers are discernable fibers, Ia another embodiment, the binder fibers lose ther fiber shape ‘and form a coating on surrounding materials (the heat and flame resistant fibers and bulking fiber). 10021] In one embostiment, the binder fibers are in an amount of less than about 60% wt of the whole high loft non-woven layer 200. In another embodiment, the binder fibers are in an amount of less than about 508 wt of the whole high loft non-woven layer 200, In another embodi- rent, the binder fibers are in an amount of less than about 40% wt of the whole high loft non-woven layer 200, Preferably, the binder fibers 40 have a denier less than oF about equal o 15 denies, more preferably less than about 6 ‘denier. In one embodiment, at least some ofthe binder fibers are nano-fibers (their diameter is less than one micrometer) 10022] In one embodiment, dhe high loft non-woven layer 200 contains additonal fibers, These may inelude, but are not limited toa second binder fiber having a different denier, staple length, composition, or melting point, a second bullk- ing ber having a dlfereat denier, staple lengt, or compo- sition, and an effect fiber, providing benefit a desired aes- thetic or funtion, These effet fibers may be used to impart color, chemical resistance (such as polyphenylene sulfide fibers and polytetrlluoroethylene fibers), moisture resis- tance (such as polyetrafluorbethylene fibers and topically treated polymer bers), oF others 10023] The fibers (hinder fibers, bulking fibers, het and flame resistant fibers, and any other fiber inthe high lot non-woven layer 200) may additionally contain additives. Suitable additives include, but are not limited to, fillers, Stabilizers, plasticizers, tackifers, flow control agents, cure Fate retardrs, adhesion promoters (For example, silanes and titanates), adjuvants, impact modifiers, expandable micro- spheres, thermally conductive particles, electrically conde tive particles, silica, glass, clay, tale, pigments, colorants lass beads or bubbles, aatioxidants, optical brightenes, Oct. 4, 2018 antimicrobial agents, surfactants, fre retardants, and fuo- ‘polymers. One of more of the above-described additives may be used to reduce the weight andor eost ofthe resulting fiber and layer, adjust viscosity, or modify the thermal properties ofthe fiber of conte a range of physiel proper tics derived trom the physical property activity of the adtive including electrical, optical, density-related, liquid barrier or adhesive tack related properties. [0024] In one embodiment, the heat and fame resistant {thers bulking bers, and binder bers are within the high Joft non-woven layer 200 in an approximately uniform distribution. This would be consider # non-staiied con- struction. In another embodiment, the high loft non-woven layer 200 has a stratified constriction meaning that the concentration of atleast one of the fers (the heat and flame resistant fibers, bulking fibers, and binder fibers) varies as a function of thickness ofthe layer (thickness being messed between the inner side 2002 and the outer side 2006). in some applications, itis preferred to have a stratified non- ‘Woven as one ean ereate @ non-woven having certain fbers ‘more concentrated at one of the sides (for example, where ‘one Wool like to ereate a “ski” of meld binder oma ide, stratified construction can produce @ non-woven having & higher concentration of binder fiber on a desired side), [0025] Referring back to FIG. 1. there is shown a ticking Jayer 300 having a inner side 300a and sa outer side 3005, Preferably, the outer side 300 of the ticking layer 300 forms the outermost surface of the mattress 10, The ticking layer ‘comprises at least one suitable textile layer, including kn woven, oF non-woven, and preferably contains decorative clements within the textile for visual appeal. The ticking layer may be formed of any suitable fibers and/or yarns, including but not limited to, cotton, polyester, nylon, rayon, ‘and wool and may have any suitable thickness (defined to be the distance between the inner side 300a and the outer side 3005), The teking layer may also be quilted, meaning that the ticking layer is actually comprised of mitiple fabric Jayers that are then attached together through the use of stitching, adhesives, or other attachment means. While the ticking layer 300 js adjacent and directly touching the high Jot non-woven layer 200 in FIG. 1, the ticking layer 300 may be set off from the high loft non-woven layer 200 by & space or may have a edlditional layer between the high loft non-woven layer 200 and the tiking layer 300, 0026] The mattress 10 contains a pattern coated layer +400. This patter coated layer contains a blend of microen- ‘apsulated phase change material (PCM) and a binder, This pattem coated layer may be on or between any suitable ayers within the mattress, but it is advantageous o have the pattem coated layer 400 as close tothe outermost surface of the mattress as possible. In one embodiment, the pattern the outermost surface (ticking layer) the PCM material closer t the ‘outermost surface of the matress serves to increase its clliieney, [0027] In one embodiment, as shown in FIG. 1, the pattern coated layer 400 is onthe cuter side 200% of the high lft ‘non-woven layer 200. In another embodiment, as shown in FIG. 2, the pattem coated layer 400 is on the outer side 3005 of the ticking layer. In another embodiment, as shown in FIG. 3, the pattera coated layer 400 is on an aitional layer (for example a scrim or other textile) whichis between the high Jot non-woven layer 200 and te ticking layer 300, On coating layer can be oUS 2018/0279796 AI Which layer (and which side of the layer) the patterned ‘coated layer ison depends on manufacturability and desired ‘end properties [0028] There are tradcofls in the mattress of best heat transfer versus silliness of the ticking for the placement of the PCM. The PCM may be printed on top of ticking and that would provide the best heat transfer and lence the best ‘cooling effect. On the other hand, it would be exposed to increased abrasion and may cause ticking to be sille. In nother embodiment, the PCM could be printed on the bottom of the ticking, In this case the cooling effect would be lower than having the PCM on the outermost surface of| the mattress, but the PCM print would be better protected fiom abrasion and the siffess of the ticking. would be similar, In another embodiment, the PCM could be printed ‘on the top layer ofthe non-woven, In tis case the cooling ‘effect would be similar 10 the PCM being on the inside surface of the ticking but the protection from abrasion woud be the best from the thre eases. The stifinss ofthe ticking ‘wold be the lowest since the print isnot onthe ticking. In nother embodiment, the pater coated layer 400 is on two ‘or more of the layers (200, 300, $00) of the mattress, 10029] Within the pattem coated layer 400, the mieroen- ‘capsulated PCM are preferably completely encapsulated by the binder. Preferably the PCM is That PCM is onzanie and js based on fydrocarbons. Preferably the average particle size of the PCM is between about 0.5 and 100 jm and are ‘encapsulated by aryl, melamine-formaldehyde or simila polymers, Preferably, the PCM have a melting point (melt- Ing temperature) of between about 15 and 35°C. Preferably, the PCM is not ina foam or foam-like material, Foam my tend to insulate the PCM and reduce its effectiveness 10020] | Examples of different types of pattern coatings are shown in FIGS. 4.9. While exch of these Figs. show the pallem costing 410 of the pater coated layer 400 on the high loft non-woven 200, the patter coated layer 400 may be applied in the same manner to any suitable layer within the mattress. [0031] The patterned coating 410 may be continuous or liscontinaous, regular and repeating or random. “Contin ‘ous in this application means that from one edge of the fabric to the other edge there is a path that contains the patlemed coating, and that at least some of the patterned ‘coating areas are connected, Examples of continuous coal ings include FIGS. 6 and 7. “Discontinuous” in this appli ‘cation means that the pattered coated areas are dixcoatinu ‘ous and not touching one another. In a discontinuous pallemed coating, thee i ao path from one edge of the Tabsic to the other that contains the patterned coating. Examples of discontinuous coatings include FIGS. 4, § and ‘8. Regular or repeating pattems mean that the pattern has 2 repeating structure to it FIGS. 4, 6, 7, and 8 illustrate repeating oF regular pattems. FIG. § illstrates a random pattem where there is no repeat to the patterned coating. ln random patter, it is preferred that the random patter is ‘also discontinuous, not continuous 10032] FIG. 4 ilustates the embodiment where the pat- ‘eened coating isin dot pattern. This pattem is discontinu- ‘ous and repeating. The dats may be equally spaced on the Iabric, or may have differing densities of dots or sizing of dots across the surface of the fabric. A dot patter may be preferad for as its resistant 1 breaking der mechanical pressure, FIG. § ilstrates the embodiment where the pat- termed coating 410 is in random, discontinuous spotting Oct. 4, 2018 pattem, FIG. 6 illustrates the embodiment where the pats femed costing 410 isin a grid. This pate is ogo and continuous. FIG, 7 ilustates the embadiment where the paltemed coating 410 isin a serice of panel lies. This pattem is also regular and continoows. The patterned coating 410 may take any other patterned form including but not Timitad 10 indicia, geometric shapes or patterns, and text [0033] FIG. 9 illustrate side views of the high loft ‘non-woven layer 200 illustrating the patterned coating 410 both sides of the high loft non-woven layer. The pattems coatings 410 may be the same or different pattems and ‘ovemige on cther sce ofthe high loft non-woven layer 200. [0034] The patterned coated layer 400 may be formed by any known method of fomning a patterned coating inluding but not Fimited to sereea printing, inkjet printing, gravure printing, pattemed printing, thermal transfer, spray coating, ‘nd silk printing. Screen printing i preferred because is simple, cheap, common, versatile in terms of add-on, pate tem. Is albo mild to the mieroencapsulated PCM particles [0035] The thickness andor physical composition of the pattemed coating 410 may vary aver the length and/or width ofthe layer coated. For example, itmay be preferred in some embodiments o have s thicker coating or more densely ‘packed pattern in some areas of layer such as the head or fest areas of a mattress. This can be seen, for example, in FIG. 8 where the dot pattem of the paterned coating layer 400 varies over the width of the layer 200, 0036] In one embodiment, the pattemed coating 410 of | the pattern coated layer 400 covers between about 5 and 95% of the surface area of the layer coated (high loft non-woven layer 200, ticking layer 400, addtional layer 300, or other). In other embodiments, the patterned coating ‘may cover between about 5 and 70%, 10 and 60%, 45 and 90%, 45 and 75%, greater than 15%, greater than 20% and arcater than 3096 of the surface area ofthe layer coated. fone embodiment, the patterned coating has a (dry) add-on ‘weight of berween about 50 and 500 g/m, more preferably between sbout 50 and 200 win*. In one embodiment, the thickness ofthe coating is between about 0.1 and 2.0 mu. In another embodiment, the air penneabilty of the coated fabrics is between about Sand 500 cfm. [0037] The claims are directed wo a mattress and preferably the mattress is a Mat (or mostly flat) mattress that people sleep one, but the mattress of the claims includes cushions, sch as enshions on a sofa or couch) and plows, EXAMPLE [0038] A PALADIN FR barrier available from Milliken ‘& Company was used asthe high loft noa-woven layer. The FR barrier isan 80/20 FR rayonfow melt PET blend having 1 o2/f? 30S pm?) areal densi [0039] _ pattemed coating was applied to one side of the FR baie. The patterned coating contained 2 microencap- slated PCM and a binder. The microoncapsulated PCM was PURETEMP® 24 evailable from Encapsys/Enthropy and the binder was SERA PRINTR M-PHC available from Daystar which is believed 1 be a carboxymethylated cell lose. [0040] The printing material contained 88% OWB (on ‘weight of bath) of PURETEMP® 24 slurry (42% wt solids) ‘and. 12% OWB of SERA PRINT binderihickener (35% wt solids). The dynamic viscosity ofthe print paste as §,000 cP and the total solids of the paste was 40% wtUS 2018/0279796 AI {0041} The paste was printed by sexcen py Patlem onto one side ofthe FR bare. The dot pa ‘rele andeepeating, nooeontinvous pattem eating, The ‘ots Were approimately 12 mm in diameter and there Was approximately 2 mm of space between the dats. Adjacent rox of dos Were it from one anther fr beter packing term coated layer overlays at least a portion ofthe ianer side of the ticking layer, wherein the patiem is a regular, repeating patter. 10. The mattress of claim 9, wherein the outer side ofthe sicking layer forms the outemost surface of the matress. 11, The mattress of claim 9, wherein the patterned coating is discontinuous 12, The mattress of claim 9, wherein the pattem of the pattemed coating is continuous.US 2018/0279796 AI 13, The mattress of claim 9, wherein the pattern of the pattemed coating is dot patter, 14, A mattress comprising: ‘core section, wherein the core section comprises a frst ‘Side and an opposing second side connected by a east fone side wall, 4 high lof non-woven layer having sn inner sie and ao ‘uter side, wherein the high loft nonwoven layer at least partially covers the frst side of the eore section, ‘wherein the high loll non-woven layer is oriented such thatthe inner side of the high lot non-woven layer faces the first side of the core section, and wherein the bigh loft non-woven layer comprises a plurality of eat and Mame resistant fibers, bulking hers, and binder fiers: licking layer having an inner side and an outer side ‘wherein the ticking layer atleast partially covers the high lof non-woven layer, wherein the ticking layer is foriented such that the ianer side of the ticking layer faces the outer side of the high loft non-woven layer, and wherein the exter ticking layer comprises & textile layer Oct. 4, 2018 an additional layer having a length and a width; and, 4 pattem coated layer comprising a blend of microencap- sulated phase change material (PCM) and a binder in patter, wherein the PCM is fully encapsulated by the binder and wherein the pattem coated layer overlays portion of the inner side ofthe addtional layer, wherein the pattem is a regular, repeating pattern 15, The mattress afelaim 14, wherein the outer side ofthe sicking layer forms the outermost surface of the mattress. 16. The matiess of claim 14, wherein the pattemed coating i discontinuous. 17. The mattress of chim 14, wherein the pattemed coating covers between about 45 and 75% of the inner side ofthe licking layer 18, The mattess of chim 14, wherein the pattemed coating has an add-on weight of between about $0 and 200 wim 19, The mattress of claim 14, wherein the pattern of the patvemed coating is continuo. 20. The mattress of claim 14, wherein the pattern ofthe pattem coating is dot pater,