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Edited by: Dale T. Read, Editor-in-Chief

Celestia Line Delivers Flammability Performance and Mattress Shape Retention. Available as Separate FR Materials or "All-In-One" Structural Components.

If mattress manufacturers and their retail partners have their way, the arrival of fire retardant mattresses on the retail floor in July will turn out to be a non-event, because customers won’t even notice the difference. At least that’s what they hope will happen. Ever since the first FR regulations were passed nearly three years ago,

manufacturers, while supportive of improved safety, have been concerned that the addition of new materials might detract from the overall appearance and comfort that retailers and their consumers demand. Early reactions from the retail side were equally tentative, given the possible negative implication of having to contend with the uncertainty of customer reaction and the possibility of increased cost.

Happily these conflicts have now been resolved. Most FR materials as it turns out will not compromise mattress aesthetics, and consumer focus groups have settled the issue of safety. These research studies show that people not only want fire retardant properties, they are willing to pay for them. The big question at this point is whether the industry will play the whole thing down, or will mattress manufacturers and retailers seize the moment and find something to sell. Only time will tell.

For those who are not familiar with the mechanics of fire retardant technology, the Consumer Product Safety Commission requires mattresses to incorporate fire barriers that will either extinguish the flame totally or retard progress long enough for occupants to get out of the building safely. The need for flammability protection was established in the late 90’s, when the state of California unilaterally decided to require that only flame retardant mattresses could be sold in the state. The rest of the country predictably followed suit—and on this coming July 1st, mattresses sold nationally will have to meet the same requirements.

To satisfy these requirements, mattress manufacturers must add specially constructed FR materials to strategic areas throughout the mattress infrastructure so that the entire surface is protected. When the material comes into contact with the flame, it reacts by forming what is known as a "char layer" which essentially smothers the flame by depleting the oxygen around it. The objective is to either extinguish the flame totally or retard it to the point that its progress is significantly decreased, buying time for the occupants leave the area safely. A typical mattress, depending upon configuration, may require as many as five different barriers.

Value Added Solutions

Manufacturers and mattress retailers alike are extremely sensitive to performance, feel, value and eye-appeal or aesthetics of their mattress lines. This consumer-driven sensitivity has motivated FR suppliers to continue improving the quality of their products so that physical appearance, feel and performance meet the expectations of manufacturers, retailers and consumers. As a result, comfort testing as well as flammability performance have been accorded equal weight to remove even the perception of any unwanted change. One supplier has even gone an extra mile toward eliminating the problem by adding a line of composite materials to its overall product selection. As part of its overall line of Celestia mattress materials, Freudenberg North America is offering actual mattress structural components with integrated flame retardant properties. The FR protection is part of the structural component itself, giving the customer an option that eliminates the need for separate FR materials as well as the concern for appearance.

According to Mr. Jim Frasch, the company’s program director for bedding, Freudenberg determined early in the product development cycle that while everyone had to meet compliance issues as a matter of course, gaining manufacturer acceptance in terms of aesthetics would be critical to product success. According to Frasch, the FR supplier is constantly fighting the battle of making a fabric that performs a required safety function while not disrupting the retailer’s and consumer’s perception of the end product. "We’re in the very unusual position of developing a product that is best described as being totally imperceptible. To be truly successful, it has to perform its function without anybody knowing it is there. It’s quite a challenge to build a national brand out of a product that nobody ever sees. We believe that by developing the Celestia line, we offer the depth and breadth of characteristics available to mattress manufacturers and dealers, we successfully contend with that challenge every day."

Incorporating the various designs to match performance characteristics as closely as possible to the physical characteristics of the mattress itself.

All Freudenberg FR materials are marketed under the umbrella brand name Celestia, incorporating the various designs to match performance characteristics as closely as possible to the physical characteristics of the mattress itself. Responding to the needs of manufacturers and retail buyers, Celestia materials are made for all mattress designs including: innerspring tight top, pillow top, euro top and foam cores such as visco-elastic and latex rubber cores. The line features a variety of mono-layered and dual-layered single function fabrics, multifunction composites and ready-to-assemble materials, all formulated according to the individual application. These materials are used for panel and border application, filler cloth, and high loft surface applications.

Basic Celestia, the company’s universal FR line for all applications, Freudenberg offers multiple material designs with physical characteristics ranging from thin and light to thick and heavy with multiple gradations in between. Depending on the specifications required, basic Celestia can be used for side panels, borders, filler cloth and top layer applications. The line is also available in a wide range of densities, depending on mattress design. The Celestia line of composites (Celestia Stretch, Celestia Novo) initially introduced as an alternative to separate FR materials, is made up of fully functioning structural materials that incorporate FR properties with mattress ticking, thereby eliminating the need for a separate FR fabric. While initially more expensive than separate FR materials, Freudenberg representatives are quick to point out that composites allow the manufacturer to achieve economies of scale on the production floor, thereby recouping the higher initial cost. Composites eliminate the need for quilting, slitting, serging etc. It also allows the manufacturer to reduce the number of SKU’s that he has to deal with.

Please visit their website at www.freudenberg-nw.com