Flame retardant bedding product and method of making same

Abstract

A flame-retardant bedding product, such as a pillow or mattress topper, includes an inner core, an inner cover, and an outer cover. The inner cover covers the inner core. The inner cover comprises a knit fabric. The knit fabric has a weight of at least 225 grams per square meter (gsm). The outer cover covers the inner cover.

What is claimed is: 
     
         1 . A flame-retardant bedding product, comprising:
 an inner core;   an inner cover
 wherein the inner cover comprises a knit fabric, 
 wherein the knit fabric has a weight of at least 225 grams per square meter (gsm), and 
 wherein the inner cover covers the inner core; and 
   an outer cover,
 wherein the outer cover covers the inner cover. 
   
     
     
         2 . The flame-retardant bedding product of  claim 1 , wherein the bedding product comprises a pillow or a mattress topper. 
     
     
         3 . The flame-retardant bedding product of  claim 1 , wherein the knit fabric comprises a flame-retardant rayon material. 
     
     
         4 . The flame-retardant bedding product of  claim 1 , wherein the outer cover comprises a flame-retardant material. 
     
     
         5 . The flame-retardant bedding product of  claim 1 , wherein the outer cover comprises a non-flame-retardant material. 
     
     
         6 . The flame-retardant bedding product of  claim 1 , wherein the inner cover comprises at least one open end and a flap at the open end, the flap folded so that the inner cover covers the inner core. 
     
     
         7 . The flame-retardant bedding product of  claim 1 , wherein the knit fabric comprises a flame-retardant material, and the inner cover comprises at least one seam formed of a flame-retardant thread. 
     
     
         8 . The flame-retardant bedding product of  claim 7 , wherein the flame-retardant thread comprises polyaramid. 
     
     
         9 . The flame-retardant bedding product of  claim 1 , wherein the knit fabric comprises a flame-retardant material, and wherein the inner core comprises at least one of fiber, feathers, and foam. 
     
     
         10 . The flame-retardant bedding product of  claim 9 , wherein the knit fabric comprises rayon material. 
     
     
         11 . The flame-retardant bedding product of  claim 10 , wherein the inner core comprises at least one of polyester fibers, duck down feathers, goose down feathers, polyurethan foam, and latex foam. 
     
     
         12 . The flame-retardant bedding product of  claim 11 , wherein the outer cover comprises a flame-retardant material. 
     
     
         13 . The flame-retardant bedding product of  claim 12 , wherein the outer cover comprises a material that is the same as the flame-retardant material of the inner cover. 
     
     
         14 . The flame-retardant bedding product of  claim 12 , wherein the outer cover comprises a non-flame-retardant material. 
     
     
         15 . A method, comprising the steps of:
 obtaining an inner core;   obtaining an inner cover;
 wherein the inner cover comprises a knit fabric, 
 wherein the knit fabric has a weight of at least 225 grams per square meter (gsm). 
   obtaining an outer cover;   covering the inner core with the inner cover; and   covering the inner cover with the outer cover to form a bedding product.   
     
     
         16 . The method of  claim 15 , wherein the bedding product comprises a pillow or a mattress topper. 
     
     
         17 . The method of  claim 15 , wherein the knit fabric comprises a flame-retardant rayon material. 
     
     
         18 . The method of  claim 15 , wherein covering the inner core with the inner cover comprises sewing the inner cover closed on all sides. 
     
     
         19 . The method of  claim 15 , wherein sewing the inner cover closed on all sides comprises sewing the inner cover closed with a flame-retardant thread. 
     
     
         20 . The method of  claim 15 , wherein covering the inner core with the inner cover includes placing the inner core within the inner cover that includes an opening with a flap, and folding the flap to thereby cover an entirety of the inner core with the inner cover.