Mattress Fire Barrier Technology

Presented to:

U.S. Consumer Product Safety Commission

Upholstered Furniture Fire Safety Technology Meeting

April 25, 2013

By:Steve Wolf

Jones Fiber Products, Inc.

Topics Discussed

1. Brief overview of 16 CFR 1633, mattress open flame standard

2. Mattress fuel loads protected by FR barrier materials3. Mattress geometries protected by FR barrier materials4. Various types of FR barriers used in the mattress

industry5. Technologies and FR treatments6. Bench scale test methods addressing both cigarette and

open flame ignition7. Cigarette versus open flame ignition8. Cost considerations

16 CFR 1633

Unprotected bed set – Start of test

16 CFR 1633

Unprotected bed set – 70 seconds

16 CFR 1633

Unprotected bed set – 2 minutes

16 CFR 1633

Unprotected bed set – 2 minutes, 50 seconds

16 CFR 1633

Protected bed set – start of test

16 CFR 1633

Protected bed set result

Mattress Industry Desires for FR Barriers

1. “Drop-in” or “Substitute” product for manufacturer2. White in color3. No free FR chemicals on product4. Durable over the life of the end use product5. Comfortable and invisible to the consumer6. Availability of national distribution channels7. Economical

Mattress Fuel Loads Protected by FR Barriers

1. Wood in foundations2. Non-FR fiber pads3. Standard polyurethane foam4. Memory foam5. Latex foam6. Gel foam

Mattress Geometries

Vertical and horizontal surfaces

Mattress Geometries

Tight-top mattress with foundation crevice

Mattress Geometries

Euro top

Mattress Geometries

One-sided pillow top crevice

Mattress Geometries

Two-sided pillow top with foundation crevice

Mattress Geometries

Crevice burn

Various Types of FR Barriers

Highloft Nonwoven Densified Nonwoven Densified Nonwoven Laminated Nonwoven Laminated Nonwoven

Knitted Socks

Technologies and FR Treatments

1. Highloft nonwovens

Technologies and FR Treatments

1. Highloft nonwovens2. Densified nonwovens

Technologies and FR Treatments

1. Highloft nonwovens2. Densified nonwovens3. Mattress tickings laminated to nonwovens

Technologies and FR Treatments

1. Highloft nonwovens2. Densified nonwovens3. Mattress tickings laminated to nonwovens4. FR fabrics and FR tickings

Technologies and FR Treatments

1. Highloft nonwovens2. Densified nonwovens3. Mattress tickings laminated to nonwovens4. FR fabrics and FR tickings5. Socks

FR Treatments

1. Inherent FR rayon

FR Treatments

1. Inherent FR rayon2. Wool

FR Treatments

1. Inherent FR rayon2. Wool3. Glass fibers, ceramic fibers and para-aramids

FR Treatments

1. Inherent FR rayon2. Wool3. Glass fibers, ceramic fibers and para-aramids4. Chemical treatments for cotton and non-FR

rayon fibers

UFAC Test Method for Cigarette Ignition Resistance

Cigarette Test – ASTM D5238-10

Cigarette Test – ASTM D5238-10

Open Flame Test Methods

Open Flame Test Methods Temperature Sensing Device Horizontal Specimen Mounting Vertical Specimen Mounting

Horizontal Meeker/Fisher Burner Vertical T-Burner

Open Flame Test MethodsVertical

Open Flame Test Methods

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

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46

47

48

49

50

51

52

53

54

55

0

50

100

150

200

250

300

350

400

450

500

Vertical Thermal Transfer

1 23.7

2 24.8

3 23.9

4 24.8

5 24.1

Average

Time Sec.

Tem

p.

F

Open Flame Test MethodsHorizontal – Based on ASTM 7140-07

Open Flame Test MethodsHorizontal – Based on ASTM 7140-07

10

100

200

300

400

500

600

700

800

Horizontal Thermal Transfer

1 7.7

2 7.8

3 7.7

4 7.7

5 7.8

Average

Time Sec.

Tem

p. F

Char Strength Test MethodsBall Burst – Based on ASTM 6797-07

Char Strength Test MethodsBall Burst – Based on ASTM 6797-07

0.00

00.

067

0.13

30.

200

0.26

70.

333

0.40

00.

467

0.53

30.

600

0.66

70.

733

0.80

00.

867

0.93

31.

000

1.06

71.

133

1.20

01.

267

1.33

30

20

40

60

80

100

120

140

160

180

200

Char Strength

Series1

Series2

Series3

Series4

Series5

Average

Travel Inch

Fo

rce

Gra

m

Cigarette vs. Open Flame Ignition

FR barriers and the materials FR barriers are designed to protect can react very differently to

cigarette versus open flame ignition sources.

Cost ConsiderationsThe choice of FR barrier used in the mattress industry is

very dependent on the fuel load the FR barrier is designed to protect and the geometries of the mattress

Cost ConsiderationsThe choice of FR barrier used in the mattress industry is

very dependent on the fuel load the FR barrier is designed to protect and the geometries of the mattress

For most mattress applications using high loft or densified nonwoven materials, the weight basis used ranges from 0.5 to 1.0 ounces per square foot. In generalities, the cost of these barriers will be in the range of $0.065 to $0.135 per square foot. The cost of laminating nonwoven FR barriers to mattress tickings can be estimated at $0.045 to $0.055 per square foot as a ball park range.