Decorative mattress border fabric with inherent flame barrier

Abstract

A flame barrier substrate consisting principally of non-fire-retardant (non-FR) fiber with fire-resistant properties and affinity for sublistatic dyes. The flame barrier substrate includes a balanced fine core-spun yarn whose face may include fibers with an affinity for dyes, e.g., sublistatic dyes. The balanced fine core-spun yarn may also include a heat-stable core enveloped in a sheath of low-temperature-resistant fibers such as, for example, non-fire-retardant (non-FR) fibers. The balanced fine core-spun yarns may be further combined with other balanced fine core-spun yarns made with a sheath of fire-retardant fibers for added flame barrier performance. This flame barrier substrate may be constructed to concentrate the dye-receptive yarns on the technical face of the fabric for optimal aesthetics.

What is claimed: 
     
         1 . A flame barrier substrate, comprising:
 a balanced fine core-spun yarn, and   a sheath of low-temperature-resistant fibers comprising non-fire retardant fibers with an affinity for sublistatic dyes,   wherein the balanced fine core-spun yarn comprises a heat-stable core enveloped in the sheath of low-temperature-resistant fibers.   
     
     
         2 . The flame barrier substrate of  claim 1 , wherein the non-fire retardant fibers comprise at least one of: polyester, nylon, and any other fiber that has an affinity for sublistatic dyes. 
     
     
         3 . The flame barrier substrate of  claim 1 , wherein the non-fire retardant fibers are configured to melt in presence of a flame reducing air permeability and simultaneously depriving the potential fuel of oxygen while creating a physical impediment to progress of the flame to potential fuel within a mattress or other upholstered article thereby creating a flame barrier. 
     
     
         4 . The flame barrier substrate of  claim 1 , wherein the heat-stable core comprises at least one of: multi-filament fiberglass, aramid, and steel. 
     
     
         5 . The flame barrier substrate of  claim 1 , wherein the flame barrier substrate is configured to be used as a decorative outer fabric that comprises the side and end walls of a mattress. 
     
     
         6 . A method for manufacturing a flame barrier substrate with decorative or functional patterns comprising:
 providing a balanced fine core-spun yarn,   wherein the balanced fine core-spun yarn further comprises a heat stable core enveloped in a sheath of fibers; and   printing a decorative or functional patterns onto the sheath of fibers.   
     
     
         7 . The method of  claim 6 , wherein the printing comprises at least one of: digital printing, and heat-transfer printing. 
     
     
         8 . The method of  claim 6 , wherein the heat-stable core comprises at least one of: multi-filament fiberglass, aramid, and steel. 
     
     
         9 . The method of  claim 6 , wherein the sheath of fibers comprises fibers with an affinity for sublistatic dyes. 
     
     
         10 . The method of  claim 6 , wherein the sheath of fibers comprise non-fire retardant fibers that are configured to melt in presence of a flame thereby limiting air permeability for the flame and creating a physical impediment to the progress of the flame to potential fuel within a mattress or other upholstered article thereby creating a flame barrier. 
     
     
         11 . The method of  claim 10 , wherein the non-fire retardant fibers comprise at least one of: polyester, nylon, and any other fiber that has an affinity for sublistatic dyes. 
     
     
         12 . A method for manufacturing a flame barrier substrate with decorative or functional patterns comprising:
 providing a first balanced fine core-spun yarn;   providing a sheath of non-fire retardant fibers with an affinity for sublistatic dyestuffs and a second balanced fine core-spun yarn;   providing a sheath of fibers with fire-retardant properties; and   combining the first balanced fine core-spun yarn and the second balanced core-spun yarn in a woven substrate,   wherein the first core-spun yarn comprises a heat stable core, and   wherein the second balanced fine core spun yarn comprises a heat stable core.   
     
     
         13 . The method of  claim 12 , wherein the fabric is configured to be engineered in a way to concentrate the sheath of non-fire retardant fibers with an affinity for sublistatic dyestuffs on one side of the substrate, thereby creating a decorative, technical face of the fabric. 
     
     
         14 . The method of  claim 12 , wherein the non-fire retardant fibers comprise at least 60% of the flame barrier substrate. 
     
     
         15 . The method of  claim 12 , wherein the heat stable core comprises at least one of: multi-filament fiberglass, aramid, and steel. 
     
     
         16 . The method of  claim 12 , wherein the sheath of fibers with fire-retardant properties comprise at least one of: modacrylics, treated cotton or rayon, fire-retardant lyocell, meta-aramids, para-aramids, fluoropolymers and copolymers thereof, chloropolymers, polybenzimidazole, polyimides, polyamideimides, partially oxidized polyacrylonitriles, novoloids, poly (p-phenylene benzobisoxazoles), poly (p-phenylene benzothiazoles), polyphenylene sulfides, flame-retardant viscose rayons, polyvinyl chloride homopolymers and copolymers thereof, polyetheretherketones, polyketones, polyetherimides, polylactides, and any combinations thereof. 
     
     
         17 . The method of  claim 12 , wherein the non-fire retardant fibers comprise at least one of: polyester, nylon, and any other fiber that has an affinity for sublistatic dyes. 
     
     
         18 . The method of  claim 12 , wherein the woven substrate comprises a twill weave or other warp face fabric. 
     
     
         19 . The method of  claim 12 , wherein the woven substrate is formed to impart a three-dimensional surface texture. 
     
     
         20 . A flame barrier substrate, comprising:
 a balanced fine core-spun yarn, and   a sheath of low-temperature-resistant fibers comprising non-fire retardant fibers with an affinity for sublistatic dyes wherein the non-fire retardant fibers are configured to melt in presence of a flame reducing air permeability and simultaneously depriving the potential fuel of oxygen while creating a physical impediment to progress of the flame to potential fuel within a mattress or other upholstered article thereby creating a flame barrier,   wherein the balanced fine core-spun yarn comprises a heat-stable core enveloped in the sheath of low-temperature-resistant fibers.