Mattress with flame barrier cap and related method

Abstract

A mattress including a stretchable flame-retardant textile cap incorporating a top panel of flame retardant material operatively connected to a stitch-bonded flame retardant textile skirting with machine direction stretch and recovery properties disposed over a resilient mattress core to provided flame barrier protection to the mattress core.

What is claimed is: 
     
         1 . A mattress comprising:
 a resilient foam core; and   a flame barrier cap disposed over the core, wherein the flame barrier cap comprises a top panel of flame resistant fabric disposed in overlying relation to a substantially planar upper surface of the core, the flame barrier cap further comprising a stitch-bonded flame resistant skirting disposed in overlying relation to sides of the core perpendicular to the upper surface, wherein the skirting comprises at least one length of stitch-bonded fabric including a plurality of elastomeric stitching yarns disposed in stitched relation through a flame retardant fleece substrate in a plurality of substantially parallel adjacent stitch lines running in a machine direction of the stitch-bonded fabric, wherein the skirting has a recoverable stretch capacity of at least 30% in the machine direction when measured according to the Tietex Stretch and Recovery Evaluation and wherein the recoverable stretch capacity perpendicular to the machine direction is less than the recoverable stretch capacity in the machine direction.   
     
     
         2 . The mattress as recited in  claim 1 , wherein the top panel has recoverable stretch capacity of at least 5% in all directions when measured according to the Tietex Stretch and Recovery Evaluation. 
     
     
         3 . The mattress as recited in  claim 2 , wherein the skirting is attached in a stretched and tensioned state around a perimeter of the top panel. 
     
     
         4 . The mattress as recited in  claim 3 , wherein the skirting is attached around a perimeter of the top panel by sewn stitching. 
     
     
         5 . The mattress as recited in  claim 4 , wherein the skirting is attached around a perimeter of the top panel by Kevlar stitches. 
     
     
         6 . The mattress as recited in  claim 4 , wherein the skirting comprises a single continuous length of stitch-bonded fabric. 
     
     
         7 . The mattress as recited in  claim 6 , wherein the fleece substrate comprises a plurality of carded and cross-lapped flame-resistant staple fibers. 
     
     
         8 . The mattress as recited in  claim 7 , wherein at least a majority of the staple fibers are FR Rayon. 
     
     
         9 . The mattress as recited in  claim 7 , wherein at least a majority of the staple fibers are oriented within plus or minus 30 degrees of a line running perpendicular to the machine direction. 
     
     
         10 . The mattress as recited in  claim 4 , wherein the recoverable stretch capacity perpendicular to the machine direction is not more than 65% of the recoverable stretch capacity in the machine direction. 
     
     
         11 . The mattress as recited in  claim 10 , wherein the elastomeric stitching yarns are wrapped yarns. 
     
     
         12 . The mattress as recited in  claim 11 , wherein the elastomeric stitching yarns are disposed in a predefined discontinuous pattern across the stitch-bonded fabric with an enhanced concentration of elastomeric stitching yarns disposed adjacent to at least one lateral edge of the stitch-bonded fabric. 
     
     
         13 . The mattress as recited in  claim 11 , wherein the elastomeric stitching yarns are disposed in a predefined discontinuous pattern across the stitch-bonded fabric with an enhanced concentration of elastomeric stitching yarns disposed adjacent to each lateral edge of the stitch-bonded fabric. 
     
     
         14 . A mattress comprising:
 a resilient foam core; and   a flame barrier cap disposed over the core, wherein the flame barrier cap comprises a top panel of stretchable flame resistant fabric disposed in overlying relation to a substantially planar upper surface of the core, the top panel having recoverable stretch capacity of at least 10% in all directions when measured according to the Tietex Stretch and Recovery Evaluation, the flame barrier cap further comprising a stitch-bonded flame resistant skirting sewn in a stretched and tensioned state around a perimeter of the top panel, wherein the skirting comprises a single continuous length of stitch-bonded fabric including a plurality of wrapped elastomeric stitching yarns disposed in stitched relation through a fleece substrate in a plurality of substantially parallel adjacent stitch lines running in a machine direction of the stitch-bonded fabric, the fleece substrate comprising a plurality of FR staple fibers, wherein a majority of the staple fibers are oriented within plus or minus 30 degrees of a line running perpendicular to the machine direction, wherein the skirting has a recoverable stretch capacity of at least 50% in the machine direction when measured according to the Tietex Stretch and Recovery Evaluation and wherein the recoverable stretch capacity perpendicular to the machine direction is not more than half the recoverable stretch capacity in the machine direction and wherein the elastomeric stitching yarns are disposed in a predefined pattern across the stitch bonded fabric with an enhanced concentration of elastomeric stitching yarns disposed adjacent to at least one lateral edge of the stitch-bonded fabric.   
     
     
         15 . The mattress as recited in  claim 14 , wherein the elastomeric stitching yarns are disposed in a predefined discontinuous pattern across the stitch-bonded fabric with an enhanced concentration of elastomeric stitching yarns disposed adjacent to each lateral edge of the stitch-bonded fabric. 
     
     
         16 . A method of forming a flame barrier cap for a mattress, the method comprising:
 providing a top panel of flame resistant fabric;   attaching a stitch-bonded flame resistant skirting at least partially around the perimeter of the top panel to form the flame barrier cap, wherein the skirting comprises at least one length of stitch-bonded fabric including a plurality of elastomeric stitching yarns disposed in stitched relation through a flame retardant fleece substrate in a plurality of substantially parallel adjacent stitch lines running in a machine direction of the stitch-bonded fabric; and   steaming and drying the flame barrier cap to contract the elastomeric stitching yarns, wherein the skirting in the flame barrier cap after steaming and drying has a recoverable stretch capacity of at least 30% in the machine direction when measured according to the Tietex Stretch and Recovery Evaluation and wherein the recoverable stretch capacity perpendicular to the machine direction is less than the recoverable stretch capacity in the machine direction.   
     
     
         17 . The method as recited in  claim 16 , wherein the skirting in the flame barrier cap after steaming and drying has a recoverable stretch capacity of at least 50% in the machine direction when measured according to the Tietex Stretch and Recovery Evaluation. 
     
     
         18 . The method as recited in  claim 16 , wherein the skirting in the flame barrier cap after steaming and drying has a recoverable stretch capacity of at least 70% in the machine direction when measured according to the Tietex Stretch and Recovery Evaluation. 
     
     
         19 . The method as recited in  claim 16 , wherein the skirting in the flame barrier cap after steaming and drying has a recoverable stretch capacity of at least 90% in the machine direction when measured according to the Tietex Stretch and Recovery Evaluation.