Mattress construction including stitch-bonded flame barrier having stretch and recovery character

Abstract

A mattress construction having a resilient core incorporating deformable foam either alone or in combination with integrated springs with a complimentary flame barrier fabric disposed in overlying relation to the resilient core. The flame barrier fabric has a stitch-bonded construction with elastomeric yarns extending in stitched relation through a fleece substrate of substantially inelastic character incorporating a percentage of flame retardant fibers. In a relaxed condition, the fleece substrate is bunched between stitch lines formed by the elastomeric yarns. Upon the application of tension, the barrier fabric stretches by the extension of the elastomeric stitching yarns in combination with a flattening of the fleece substrate.

1 . A mattress construction comprising:
 a deformable foam core comprising a foam having a density in the range of about 1 to 12 pounds per cubic foot; and   a flame blocking overlay structure disposed at least partially around the foam core, wherein the overlay structure comprises at least one layer of flame barrier fabric of stitch-bonded construction having a machine direction and a cross-machine direction, the flame barrier fabric including an inelastic nonwoven fibrous substrate material including at least 30% by weight flame retardant fiber with a plurality of elastomeric yarns stitched through the fibrous substrate material, the elastomeric yarns defining a plurality of zigzag stitch lines extending in the machine direction of the flame barrier fabric, wherein the stitch lines include diagonal float segments extending between stitch points, wherein in an unstretched state, the fibrous substrate material is bunched in an undulating pattern defining a plurality of raised profile rows extending in the machine direction across one side of the flame barrier fabric, and wherein upon application of a stretching force, the flame barrier fabric is stretchable by at least 50% in each of the machine direction and cross-machine direction followed by elastic recovery to within 5% of the unstretched state upon removal of the stretching force.   
     
     
         2 . The mattress construction as recited in  claim 1 , wherein the foam is visco-elastic polyurethane foam. 
     
     
         3 . The mattress construction as recited in  claim 2 , wherein the foam has a density in the range of 3 to 7 pounds per cubic foot. 
     
     
         4 . The mattress construction as recited in  claim 1 , wherein the foam surrounds internal springs. 
     
     
         5 . The mattress construction as recited in  claim 1 , wherein the elastomeric yarns are wrapped yarns comprising an elastomeric core wrapped with inelastic textured yarn. 
     
     
         6 . The mattress construction as recited in  claim 1 , wherein the nonwoven fibrous substrate material has a mass per unit area of about 80 to about 200 grams per square meter. 
     
     
         7 . The mattress construction as recited in  claim 1 , wherein the nonwoven fibrous substrate comprises 30% to 100% silica rayon fibers and optionally about 5% to 65% polyester fibers and optionally about 5% to 25% para-aramid or meta-aramid fibers. 
     
     
         8 . The mattress construction as recited in  claim 1 , wherein the nonwoven fibrous substrate comprises substantially 100% silica rayon fibers. 
     
     
         9 . The mattress construction as recited in  claim 1 , wherein the flame barrier fabric is stretchable by at least 75% in each of the machine direction and cross-machine direction followed by elastic recovery to within 5% of the unstretched state upon removal of the stretching force. 
     
     
         10 . The mattress construction as recited in  claim 1 , wherein a stretch zone of the flame barrier fabric is characterized by a modulus of elasticity in both the machine direction and the cross-machine direction such that 50 percent elongation requires less than 500 grams applied force per centimeter width. 
     
     
         11 . The mattress construction as recited in  claim 1 , wherein a stretch zone of the flame barrier fabric is characterized by a modulus of elasticity in both the machine direction and the cross-machine direction such that 50 percent elongation requires less than 300 grams applied force per centimeter width. 
     
     
         12 . The mattress construction as recited in  claim 1 , wherein the overlay structure includes covering layer of decorative fabric disposed in overlying relation to the flame barrier fabric. 
     
     
         13 . A mattress construction comprising:
 a deformable foam core comprising a visco-elastic polyurethane foam having a density in the range of about 3 to 7 pounds per cubic foot; and   a flame blocking overlay structure disposed at least partially around the foam core, wherein the overlay structure comprises a decorative outer fabric overlying at least one layer of flame barrier fabric of stitch-bonded construction having a machine direction and a cross-machine direction, the flame barrier fabric including an inelastic nonwoven fibrous substrate material including at least 30% by weight of carded silica rayon fiber with a plurality of elastomeric yarns stitched through the fibrous substrate material, the elastomeric yarns defining a plurality of zigzag stitch lines extending in the machine direction of the flame barrier fabric, wherein the stitch lines include diagonal float segments extending between stitch points at spaced-apart parallel needle lines, wherein in an unstretched state, the fibrous substrate material is bunched in an undulating pattern defining a plurality of raised profile rows extending in the machine direction across one side of the flame barrier fabric, and wherein upon application of a stretching force, the flame barrier fabric is stretchable by at least 50% in each of the machine direction and cross-machine direction followed by elastic recovery to within 5% of the unstretched state upon removal of the stretching force.   
     
     
         14 . The mattress construction as recited in  claim 13 , wherein the foam surrounds internal springs. 
     
     
         15 . The mattress construction as recited in  claim 13 , wherein the elastomeric yarns are wrapped yarns comprising an elastomeric core wrapped with inelastic textured yarn. 
     
     
         16 . The mattress construction as recited in  claim 13 , wherein the nonwoven fibrous substrate material has a mass per unit area of about 80 to about 200 grams per square meter. 
     
     
         17 . The mattress construction as recited in  claim 13 , wherein the nonwoven fibrous substrate comprises 30% to 100% silica rayon fibers and optionally about 5% to 65% polyester fibers and optionally about 5% to 25% para-aramid or meta-aramid fibers. 
     
     
         18 . The mattress construction as recited in  claim 1 , wherein the nonwoven fibrous substrate comprises substantially 100% silica rayon fibers. 
     
     
         19 . The mattress construction as recited in  claim 1 , wherein a stretch zone of the flame barrier fabric is characterized by a modulus of elasticity in both the machine direction and the cross-machine direction such that 50 percent elongation requires less than 500 grams applied force per centimeter width. 
     
     
         20 . A mattress construction comprising:
 a deformable foam core comprising foam having a density in the range of about 3 to 7 pounds per cubic foot; and   a flame blocking overlay structure disposed at least partially around the foam core, wherein the overlay structure comprises a decorative outer fabric overlying at least one layer of flame barrier fabric of stitch-bonded construction having a machine direction and a cross-machine direction, the flame barrier fabric including an inelastic nonwoven fibrous substrate material including at least 30% by weight of flame retardant cellulosic fiber with a plurality of elastomeric yarns stitched through the fibrous substrate material, the elastomeric yarns defining a plurality of zigzag stitch lines extending in the machine direction of the flame barrier fabric, wherein the stitch lines include diagonal float segments extending between stitch points at spaced-apart parallel needle lines, wherein in an unstretched state, the fibrous substrate material is bunched in an undulating pattern defining a plurality of raised profile rows extending in the machine direction across one side of the flame barrier fabric, and wherein upon application of a stretching force, the flame barrier fabric is stretchable by at least 50% in each of the machine direction and cross-machine direction followed by elastic recovery to within 5% of the unstretched state upon removal of the stretching force, and wherein a stretch zone of the flame barrier fabric is characterized by a modulus of elasticity in both the machine direction and the cross-machine direction such that 50 percent elongation requires less than 300 grams applied force per centimeter width.