Durable, comfortable, air-permeable allergen-barrier fabrics

Abstract

An allergen-barrier fabric includes a tightly-constructed fabric substrate, woven from 0 to 45% continuous synthetic filament yarns and 55 to 100% natural or synthetic spun yarns. The fabric substrate is finished to produce a fabric with a mean pore size of 4 to 10 microns, an air permeability of 0.5-25 cfm, a mean fabric flexibility of 0.5 to 6.5 grams (bending resistance), and a moisture vapor permeability in excess of 800 g/m 2 /24 hours. This fabric provides a barrier to mite-induced allergen particles. Various additional finishes can be included on the fabric. For example, an antimicrobial finish may be provided on the fabric to extend fabric wearlife by providing protection against mold and mildew. As another alternative, a fluorochemical finish can be provided to extend fabric wearlife by providing protection against fluid stains.

We claim:  
     
         1 . An allergen-barrier fabric comprising: 
 a fabric substrate, woven from 0 to 45% continuous synthetic filament yarns and 55 to 100% natural or synthetic yarns, finished to produce a fabric with a mean pore size of 4 to 10-microns, an air permeability of 0.5-25 cfm, a mean fabric flexibility of 0.5 to 6.5 grams, and a moisture vapor permeability in excess of 800 g/m 2 /24 hours, wherein the fabric provides a barrier to mite-induced allergen particles.    
     
     
         2 . The allergen-barrier fabric according to    claim 1   , wherein the fabric has a maximum pore size of 10 microns.  
     
     
         3 . The allergen-barrier fabric according to    claim 1   , further comprising an antimicrobial finish on the fabric, wherein the finish provides protection against mold and mildew.  
     
     
         4 . The allergen-barrier fabric according to    claim 1   , further comprising a fluorochemical finish on the fabric, wherein the finish provides protection against fluid stains.  
     
     
         5 . The allergen-barrier fabric according to    claim 1   , wherein the fabric is in the form of a pillow ticking or mattress ticking.  
     
     
         6 . The allergen-barrier fabric according to    claim 1   , wherein the fabric is in the form of a pillow cover, mattress cover, mattress pad, bedspread or duvet cover.  
     
     
         7 . A method for providing an allergen-barrier for a pillow, comprising: p 1  covering the pillow with a non-coated, non-laminated fabric, wherein the fabric is woven from 0 to 45% continuous synthetic filament yarns and 55 to 100% natural or synthetic spun yarns and finished to a fabric with a mean pore size of 4 to 10 microns, an air permeability of 0.5-25 cfm, a mean fabric flexibility of 0.5 to 6.5 grams, and a moisture vapor permeability in excess of 800 g/m 2 /24 hours, wherein the fabric provides a barrier to mite-induced allergen particles.  
     
     
         8 . The method according to    claim 7   , wherein the fabric has a maximum pore size of 10 microns.  
     
     
         9 . The method according to    claim 7   , wherein the fabric further includes an antimicrobial finish to provide protection against mold and mildew.  
     
     
         10 . The method according to  7  wherein the fabric further includes a fluorochemical finish to provide protection against fluid stains.  
     
     
         11 . A method according to    claim 7   , wherein the fabric is used as a pillow ticking .  
     
     
         12 . A method according to    claim 7   , wherein the fabric is used in a pillow cover.  
     
     
         13 . A method for providing an allergen-barrier for a mattress, comprising: 
 covering the mattress with a non-coated, non-laminated fabric, wherein the fabric is woven from 65-100% continuous synthetic filament yarns and finished to a fabric with a mean pore size of 4 to 10 microns, an air permeability of 0.5-25 cfm, a mean fabric flexibility of 0.5 to 6.5 grams, and a moisture vapor permeability in excess of 800 g/m 2 /24 hours, wherein the fabric provides a barrier to mite-induced allergen particles.    
     
     
         14 . The method according to    claim 13   , wherein the fabric has a maximum pore size of 10 microns.  
     
     
         15 . The method according to    claim 13   , wherein the fabric further includes an antimicrobial finish to provide protection against mold and mildew.  
     
     
         16 . The method according to    claim 13   , wherein the fabric further includes a fluorochemical finish to provide protection against fluid stains.  
     
     
         17 . The method according to    claim 13   , wherein the fabric is used as a mattress ticking, mattress cover, mattress pad, bedspread or duvet cover.  
     
     
         18 . The allergen-barrier fabric according to    claim 1   , wherein the fabric substrate is woven from 55-65% spun polyester and 35-45% filament polyester by weight.  
     
     
         19 . The allergen-barrier fabric according to    claim 1   , wherein the fabric substrate is woven from 55-65% spun cotton and 35-45% filament polyester by weight.  
     
     
         20 . The allergen-barrier fabric according to    claim 1   , wherein the fabric substrate is woven from 100% spun cotton.  
     
     
         21 . The method according to    claim 7   , wherein the fabric is woven from 55-65% spun polyester and 35-45% filament polyester by weight.  
     
     
         22 . The method according to    claim 7   , wherein the fabric substrate is woven from 55-65% spun polyester and 35-45% filament polyester by weight.  
     
     
         23 . The method according to    claim 7   , wherein the fabric substrate is woven from 100% spun cotton.