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.

1 . A three-layer double-knit or woven fabric where the top layer is composed of standard non-flame resistant face yarn, a middle layer comprised of flame resistant filler yarn and the bottom layer comprising flame resistant core wrap spun yarn.  
   
   
       2 . The fabric of  claim 1 , wherein the top layer yarn is comprised of cotton, rayon, lyocell, polyesters, acrylic, nylons, wool, silk, mohair, cashmere, kenaf, jute, sisal, polyolefins, cellulose acetates, triacetate and polylactides or any combination thereof.  
   
   
       3 . The fabric of  claim 1 , wherein the middle layer filler yarn comprised of fiber blends of polyester/modacrylic, cotton/modacrylic, acrylic/modacrylic, rayon/modacrylic, lyocell/modacrylic or nylon/modacrylic fibers or polyester/modacrylic/melamine, cotton/modacrylic/melamine, acrylic/modacrylic/melamine, rayon/modacrylic/melamine, lyocell/modacrylic/melanime or nylon/modacrylic/melamine fibers.  
   
   
       4 . The fabric of  claim 1 , wherein the middle layer filler yarn is comprised of fiber blends of polyester/chloropolymeric fiber, cotton/chloropolymeric fiber, acrylic/chloropolymeric fiber, rayon/chloropolymeric fiber, lyocell/chloropolymeric fiber or nylon/chloropolymeric fiber.  
   
   
       5 . The fabric of  claim 1 , wherein the bottom layer is comprised of flame resistant core wrap spun yarns selected from a nylon and glass core wrap spun yarn or a glass core wrap spun yarn.  
   
   
       6 . A flame resistant barrier material useful in mattresses or foundation, upholstered furniture, top of the bed or transportation seating, which barrier material is comprised of the fabric of  claim 1.