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

CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of prior filed provisional application No. 60 / 675,467, filed Apr. 28, 2005, which provisional application is hereby incorporated by referenced in its entirety.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a flame resistant three layer, double-knit or woven fabric, which has particular application in the formation of mattresses and its foundations. [0004] 2. Description of the Related Art [0005] It is well known in the textile industry to produce flame resistant products for use in upholstered furniture, mattresses, foundations, automotive seating, public transportation seating, aircraft seating and the like, using needlepunched, highloft, spunbond or spunlace nonwoven, conventional woven or conventional knit fabrics formed of natural or synthetic fibers, and then treating these fabrics with fire retarding chemicals. Conventional fire retarding che...

AI Technical Summary

Benefits of technology

[0019] To overcome or conspicuously ameliorate the disadvantages of the related art, it is an object of the present invention to provide a novel flame resistant three-layer double-knit (matelasse) fabric that is easily applied to articles for which flame resistant protection is desired. In its preferred usage in the present application, the term “flame resistant” means a product which helps to reduce the level of flammability of the final article to the point at which it is able to pass a large open flame composite type flammability test, such as: California Test Bulletin 129 (TB129) or California Test Bulletin 603 (TB603) for mattresses and foundations and California Test Bulletin 133 (TB133) for upholstered furniture. The flame resistant matelasse fabric, of the present invention, allows for the continued use of conventional fill materials such as polyester fiberfill and polyurethane foams, while still passing these stringent large open flame tests. It is understood by someone skilled in the art that flame resistant matelasse fabrics of different constructions then mentioned specifically in this invention, can be designed and produced to pass less stringent open flame tests such California's Revised Test Bulletin 117 (TB117—draft 02 / 02 version) and British Standard 5852, etc.

Problems solved by technology

Unfortunately, such treated fabrics are heavier than similar types of non-fire retardant fabrics, and have reduced wear life.

Although chemically treated fabrics will self-extinguish and exhibit limited melt behavior when a flame is removed, they typically form brittle chars, shrink and crack open after exposure to a direct flame allowing the underlying materials to ignite.

Another disadvantage of chemically treated fabrics are that they are not considered durable in that they can lose their flame retardant properties if exposed to water and it is also possible that the fire retardant chemical can migrate over time, causing a loss in flame resistant performance.

The disadvantages of the above mentioned flame barrier solutions for more stringent open-flame applications in upholstered furniture, mattress, foundations and other fiber-filled applications include: a) Woven flame barriers, especially when coated with fire retardant chemicals, impart a stiff “hand” to the composite article, which negatively affect the feel of the final product.

This increases the number and complication of the dress cover fabrics, thereby increasing manufacturing costs.

c) 100% fiberglass flame barriers have poor durability due to glass-to-glass abrasion.

This negatively impacts the workplace by having to handle these chemicals and increases the exposure of chemicals to the consumer who uses the composite article.

f) Hydroentangled nonwoven spunlace flame barriers, containing significant amounts of p-aramid fibers, which impart a yellow color to the flame barrier and negatively effect the look of the composite article, especially when used directly under white or light-colored decorative upholstery and / or mattress ticking fabrics and are negatively affected by UV light.

They also are difficult to cut when manufacturing the quilt panels of mattresses or the upholstering a piece of furniture.

g) Flame resistant highloft barrier fabric, although well suited for applications where fill power and bulk are desired characteristics, are a detriment in barrier applications where thin barrier materials are desired for increased manufacturing speed and / or aesthetic appeal.