Mattress containing microencapsulated phase change material

Abstract

A mattress containing a core section, a high loft non-woven layer at least partially covering a first side of the core section and containing a plurality of heat and flame resistant fibers, bulking fibers, and binder fibers, a ticking layer at least partially covering the high loft non-woven layer and containing a textile layer, a pattern coated layer. The pattern coated layer may be printed on the high loft non-woven layer, the ticking layer, or any layer between the high loft non-woven layer and the ticking layer. The pattern coated layer contains a blend of microencapsulated phase change material (PCM) and a binder, wherein the PCM is fully encapsulated by the binder.

What is claimed is: 
     
         1 . A mattress comprising:
 a core section, wherein the core section comprises a first side and an opposing second side connected by at least one side wall;   a high loft non-woven layer having an inner side, and an outer side, a length, and a width, wherein the high loft non-woven layer at least partially covers the first side of the core section, wherein the high loft non-woven layer is oriented such that the inner side of the high loft non-woven layer faces the first side of the core section, and wherein the high loft non-woven layer comprises a plurality of heat and flame resistant fibers, bulking fibers, and binder fibers;   a pattern coated layer having a thickness and comprising a blend of microencapsulated phase change material (PCM) and a binder in a pattern, wherein the PCM is fully encapsulated by the binder and wherein the pattern coated layer overlays at least a portion of the outer side of the high loft non-woven layer, wherein the pattern is a regular, repeating pattern; and,   a ticking layer having an inner side and an outer side, wherein the ticking layer at least partially covers the high loft non-woven layer, wherein the ticking layer is oriented such that the inner side of the ticking layer faces the outer side of the high loft non-woven layer, and wherein the ticking layer comprises a textile layer.   
     
     
         2 . The mattress of  claim 1 , wherein the outer side of the ticking layer forms the outermost surface of the mattress. 
     
     
         3 . The mattress of  claim 1 , wherein the patterned coating is discontinuous. 
     
     
         4 . The mattress of  claim 1 , wherein the patterned coating covers between about 45 and 75% of the outer side of the high loft non-woven layer. 
     
     
         5 . The mattress of  claim 1 , wherein the patterned coating has an add-on weight of between about 50 and 200 g/m 2 . 
     
     
         6 . The mattress of  claim 1 , wherein the heat and flame resistant fibers comprise FR rayon. 
     
     
         7 . The mattress of  claim 1 , wherein the pattern of the patterned coating is continuous. 
     
     
         8 . The mattress of  claim 1 , wherein the pattern of the patterned coating is a dot pattern. 
     
     
         9 . A mattress comprising:
 a core section, wherein the core section comprises a first side and an opposing second side connected by at least one side wall;   a high loft non-woven layer having an inner side and an outer side, wherein the high loft non-woven layer at least partially covers the first side of the core section, wherein the high loft non-woven layer is oriented such that the inner side of the high loft non-woven layer faces the first side of the core section, and wherein the high loft non-woven layer comprises a plurality of heat and flame resistant fibers, bulking fibers, and binder fibers;   a ticking layer having an inner side, and an outer side, a length, and a width, wherein the ticking layer at least partially covers the high loft non-woven layer, wherein the ticking layer is oriented such that the inner side of the ticking layer faces the outer side of the high loft non-woven layer, and wherein the exterior ticking layer comprises a textile layer; and,   a pattern coated layer having a thickness and comprising a blend of microencapsulated phase change material (PCM) and a binder in a pattern, wherein the PCM is fully encapsulated by the binder and wherein the pattern coated layer overlays at least a portion of the inner side of the ticking layer, wherein the pattern is a regular, repeating pattern.   
     
     
         10 . The mattress of  claim 9 , wherein the outer side of the ticking layer forms the outermost surface of the mattress. 
     
     
         11 . The mattress of  claim 9 , wherein the patterned coating is discontinuous. 
     
     
         12 . The mattress of  claim 9 , wherein the pattern of the patterned coating is continuous. 
     
     
         13 . The mattress of  claim 9 , wherein the pattern of the patterned coating is a dot pattern. 
     
     
         14 . A mattress comprising:
 a core section, wherein the core section comprises a first side and an opposing second side connected by at least one side wall;   a high loft non-woven layer having an inner side and an outer side, wherein the high loft non-woven layer at least partially covers the first side of the core section, wherein the high loft non-woven layer is oriented such that the inner side of the high loft non-woven layer faces the first side of the core section, and wherein the high loft non-woven layer comprises a plurality of heat and flame resistant fibers, bulking fibers, and binder fibers;   a ticking layer having an inner side and an outer side, wherein the ticking layer at least partially covers the high loft non-woven layer, wherein the ticking layer is oriented such that the inner side of the ticking layer faces the outer side of the high loft non-woven layer, and wherein the exterior ticking layer comprises a textile layer;   an additional layer having a length and a width; and,   a pattern coated layer comprising a blend of microencapsulated phase change material (PCM) and a binder in a pattern, wherein the PCM is fully encapsulated by the binder and wherein the pattern coated layer overlays a portion of the inner side of the additional layer, wherein the pattern is a regular, repeating pattern.   
     
     
         15 . The mattress of  claim 14 , wherein the outer side of the ticking layer forms the outermost surface of the mattress. 
     
     
         16 . The mattress of  claim 14 , wherein the patterned coating is discontinuous. 
     
     
         17 . The mattress of  claim 14 , wherein the patterned coating covers between about 45 and 75% of the inner side of the ticking layer. 
     
     
         18 . The mattress of  claim 14 , wherein the patterned coating has an add-on weight of between about 50 and 200 g/m 2 . 
     
     
         19 . The mattress of  claim 14 , wherein the pattern of the patterned coating is continuous. 
     
     
         20 . The mattress of  claim 14 , wherein the pattern of the patterned coating is a dot pattern.