Mattress with substantially uniform fire resistance characteristic

Abstract

A fire resistant (FR) mattress comprising a core comprising a first densified nonwoven fiber batt, and a ticking comprising a first fabric, the ticking enclosing the core and the fill layer, wherein the core and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress. In another aspect, the invention includes a mattress comprising a core, a plurality of substantially adjacent similarly oriented spring coils arranged in a common plane within the core, and a ticking comprising a first fabric, the ticking enclosing the core and the fill layer, wherein the core and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.

1 . A fire resistant (FR) mattress comprising: 
 a core comprising a first densified nonwoven fiber batt; and    a ticking comprising a first fabric, the ticking enclosing the core and the fill layer;    wherein the core and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.    
     
     
         2 . The mattress of  claim 1  further comprising: 
 a fill layer comprising a first high-loft nonwoven fiber batt, the fill layer positioned between the core and the ticking; and    wherein the core, the fill layer, and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.    
     
     
         3 . The mattress of  claim 2  wherein the common fiber composition consists essentially of synthetic fibers.  
     
     
         4 . The mattress of  claim 3  wherein the mattress further comprises a plurality of similarly oriented spring coils arranged in a common plane within the core.  
     
     
         5 . The mattress of  claim 4  wherein a coil spring path is adjacent to each of the spring coils in the core.  
     
     
         6 . The mattress of  claim 5  further comprising an insulator pad comprised of a second densified nonwoven fiber batt consisting essentially of the common fiber composition, the insulator pad positioned between the core and the fill layer such that the insulator pad separates the core from the fill layer.  
     
     
         7 . The mattress of  claim 6  further comprising: 
 a quilt panel positioned above the fill layer, the quilt panel comprising: 
 a quilt backing comprised a second fabric consisting essentially of the common fiber composition; and  
 a quilt layer comprised a second high-loft nonwoven fiber batt consisting essentially of the common fiber composition.  
   
     
     
         8 . The mattress of  claim 7  further comprising: 
 a tape comprised of a third fabric consisting essentially of the common fiber composition; and    a thread comprising at least one filament consisting essentially of the common fiber composition;    wherein the tape and the thread join the edges of the ticking together, thereby creating a seam.    
     
     
         9 . The mattress of  claim 8  wherein the core, the insulator pad, the fill layer, the ticking, the quilt panel, the tape, and the thread are fire resistant.  
     
     
         10 . The mattress of  claim 9  wherein the core, the insulator pad, the fill layer, the ticking, the quilt panel, the tape, and the thread are substantially free of fiberglass.  
     
     
         11 . The mattress of  claim 10  wherein the common fiber composition consists essentially of fibers selected from the group consisting of: polyester and polypropylene.  
     
     
         12 . A mattress comprising: 
 a core;    a plurality of substantially adjacent similarly oriented spring coils arranged in a common plane within the core; and    a ticking comprising a first fabric, the ticking enclosing the core and the fill layer;    wherein the core and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.    
     
     
         13 . The mattress of  claim 12  further comprising: 
 a fill layer comprising a first high-loft nonwoven fiber batt, the fill layer positioned between the core and the ticking; and    wherein the core, the fill layer, and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.    
     
     
         14 . The mattress of  claim 13  wherein the common fiber composition consists essentially of synthetic fibers.  
     
     
         15 . The mattress of  claim 14  wherein the core further comprises a first densified nonwoven fiber batt.  
     
     
         16 . The mattress of  claim 15  wherein a coil spring path is adjacent to each of the spring coils in the core.  
     
     
         17 . The mattress of  claim 16  further comprising an insulator pad comprised of a second densified nonwoven fiber batt consisting essentially of the common fiber composition, the insulator pad positioned between the core and the fill layer such that the insulator pad separates the core from the fill layer.  
     
     
         18 . The mattress of  claim 17  further comprising: 
 a quilt panel positioned above the fill layer, the quilt panel comprising: 
 a quilt backing comprised a second fabric consisting essentially of the common fiber composition; and  
 a quilt layer comprised a second high-loft nonwoven fiber batt consisting essentially of the common fiber composition.  
   
     
     
         19 . The mattress of  claim 18  further comprising: 
 a tape comprised of a third fabric consisting essentially of the common fiber composition; and    a thread comprising at least one filament consisting essentially of the common fiber composition;    wherein the tape and the thread join the edges of the ticking together, thereby creating a seam.    
     
     
         20 . A mattress comprising: 
 a core;    a plurality of substantially adjacent similarly oriented spring coils arranged in a common plane within the core;    a fill layer comprising a first high-loft nonwoven fiber batt, the fill layer positioned above the core;    an insulator pad comprised of a first densified nonwoven fiber batt, the insulator pad positioned between the core and the fill layer such that the insulator pad separates the core from the fill layer;    a ticking comprising a first fabric, the ticking enclosing the core, the insulator pad, and the fill layer;    a quilt panel positioned above the fill layer, the quilt panel comprising: 
 a quilt backing comprised a second fabric; and  
 a quilt layer comprised a second high-loft nonwoven fiber batt;  
   a tape comprised of a third fabric consisting essentially of the common fiber composition; and    a thread comprising at least one filament consisting essentially of the common fiber composition;    wherein the tape and the thread join the edges of the ticking together, thereby creating a seam; and    wherein the core, the fill layer, the insulator pad, the quilt backing, the quilt layer, the tape, the thread, and the ticking consist essentially of a common fiber composition having substantially identical FR characteristic, thereby imparting the substantially uniform FR characteristic upon the mattress.