Mattress with variable friction flame barrier cap and related method

Abstract

An improved mattress FR cap structure incorporating skirting with zones of different friction character. The skirting incorporates a first zone positioned for placement across upper portions of the mattress' vertical sides and a second zone positioned for placement over lower edges of the vertical sides. The first zone forms a first high friction interface with the underlying mattress foam or other material providing substantially stable, fixed positioning between the first zone and the underlying material restricting relative movement. The second zone provides a low friction interface with the underlying mattress foam or other material permitting relative movement between the second zone and the underlying material during compression and/or recovery. The FR cap may also include a third zone positioned for placement adjacent to the second zone for disposition at the underside of the mattress in the final construction and providing a second high friction interface with the underlying material.

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 stitch-bonded flame resistant skirting disposed in overlying relation to sides of the core, wherein the skirting comprises at least one length of stitch-bonded fabric comprising a plurality of elastomeric stitching yarns disposed in stitched relation through a flame retardant fleece substrate in stitch lines running in the machine direction of the fabric, the skirting further comprising an irregular polymer surface layer of heat activated meltable polymer, the skirting comprising a first zone disposed in covering relation to upper portions of the sides, the first zone comprising a plurality of raised globules formed by the meltable polymer, said raised globules projecting outwardly away from the flame retardant fleece and positioned to engage the core, the skirting further comprising at least a second zone disposed below the first zone, wherein the second zone wraps around lower edges of the core, and wherein the first zone has higher sliding friction relative to the core than the second zone, the skirting further comprising a gripping power zone extending inboard from a distal free edge of the skirting adapted to grip the underside of the core.   
     
     
         2 . The mattress as recited in  claim 1 , wherein the first zone further includes a plurality of perforations between stitch lines 
     
     
         3 . The mattress as recited in  claim 1 , further comprising a third zone disposed between the second zone and the gripping power zone, said third zone comprising a plurality of raised globules formed by the meltable polymer and having higher sliding friction relative to the core than the second zone. 
     
     
         4 . The mattress as recited in  claim 1 , wherein the fleece substrate comprises a plurality of carded and cross-lapped flame-resistant staple fibers. 
     
     
         5 . The mattress as recited in  claim 4 , wherein the fleece substrate further comprises 1% to 20% heat activated bicomponent polyester. 
     
     
         6 . The mattress as recited in  claim 4 , wherein at least a majority of the staple fibers are FR Rayon. 
     
     
         7 . The mattress as recited in  claim 4 , 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. 
     
     
         8 . 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, wherein the skirting comprises at least one length of stitch-bonded fabric comprising a plurality of elastomeric stitching yarns disposed in stitched relation through a flame retardant fleece substrate in stitch lines running in the machine direction of the fabric, the skirting further comprising an irregular polymer surface layer of heat activated meltable polymer, the skirting comprising a first zone disposed in covering relation to upper portions of the sides, the first zone comprising a plurality of raised globules formed by the meltable polymer, said raised globules projecting outwardly away from the flame retardant fleece and positioned to engage the core, the skirting further comprising at least a second zone disposed below the first zone, wherein the second zone wraps around lower edges of the core, and wherein the first zone comprises a first plurality of stitch lines and the second zone comprises a second plurality of stitch lines, the second zone having an average stitching gauge with at least 50% more stitch lines per inch than the first zone, and wherein the first zone has higher sliding friction relative to the core than the second zone, the skirting further comprising a gripping power zone extending inboard from a distal free edge of the skirting adapted to grip the underside of the core, the gripping power zone having an average stitching gauge greater than the second zone.   
     
     
         9 . The mattress as recited in  claim 8 , wherein the first zone further includes a plurality of perforations between stitch lines 
     
     
         10 . The mattress as recited in  claim 8 , further comprising a third zone disposed between the second zone and the gripping power zone, said third zone comprising a plurality of raised globules formed by the meltable polymer and having higher sliding friction relative to the core than the second zone. 
     
     
         11 . The mattress as recited in  claim 8 , wherein the fleece substrate comprises a plurality of carded and cross-lapped flame-resistant staple fibers. 
     
     
         12 . The mattress as recited in  claim 11 , wherein the fleece substrate further comprises 1% to 20% heat activated bicomponent polyester. 
     
     
         13 . The mattress as recited in  claim 11 , wherein at least a majority of the staple fibers are FR Rayon. 
     
     
         14 . The mattress as recited in  claim 4 , 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.