Flame resistant matelasse fabrics

Abstract

The invention relates to the use of a flame resistant three-layer double-knit or woven fabric, also know as a matelasse fabric. The top layer is of standard non-flame resistant face yarn, the middle layer is of flame resistant filler yarn and the bottom layer is of flame resistant core wrap spun yarn. This flame resistant matelasse fabric can be used to protect a mattress, foundation, mattress pad, pillow, comforter, upholstery cushion, pillow, office panel, transportation seat or any other article requiring flame resistant protection. In this invention, a matelasse fabric is formed by circular double knitting or weaving a flame resistant core spun yarn into the bottom portion of the fabric, utilizing a heavy cotton count flame resistant filler yarns for the middle layer and using conventional non-flame resistant yarns for the top layer. The invention has particular applicability in the formation of flame resistant mattresses and foundations that require passage of large open flame tests such as CPSC's 16 CFR part 1633, California's Test Bulletin 603 and Test Bulletin 129 and in the formation of flame resistant upholstered furniture that requires passage of California's Test Bulletin 133 or British Standard 5852 using the crib 5 ignition source or higher.

Description

Background technique [0001] 1. technical field [0002] The present application relates to flame-retardant three-layer double-knitted or woven fabrics, which are especially suitable for the manufacture of mattresses and their foundations. [0003] 2. Description of related technologies [0004] It is well known in the textile field that needle punched, high Loft, spunbond or spunlace nonwovens, traditional woven or traditional knitted fabrics, and then treat these fabrics with flame retardant chemicals. Traditional flame retardant chemistries include those based on borates, halogens, phosphorus, melamine and / or antimony. However, these treated fabrics are heavier and have a reduced service life than their non-flame-retardant counterparts. Although chemically treated fabrics self-extinguish when the flame is removed and have limited melting properties, they often brittle, char, shrink and crack when placed in a direct flame that can ignite the underlying material. Anoth...

AI Technical Summary

Problems solved by technology

[0016] g) Flame Retardant High Loft Fabrics, although well suited for applications that require filling and bulk, are not conducive to fire protection areas that require thin fire resistant materials for increased manufacturing speed and / or aesthetic appeal