Mattress cover and related method

Abstract

A flame-retardant mattress cover, including a back layer; an inlay layer, where the inlay layer has an inherently flame-retardant material; and a face layer, where the back layer is configured to be closer to a mattress core covered by the flame-retardant mattress cover than the inlay layer and the face layer, where the inlay layer is between the back layer and the face layer.

1 . A flame-retardant mattress cover, comprising:
 a back layer;   an inlay layer,
 wherein the inlay layer comprises an inherently flame-retardant material; and 
   a face layer,
 wherein the back layer is configured to be closer to a mattress core covered by the flame-retardant mattress cover than the inlay layer and the face layer, 
 wherein the inlay layer is between the back layer and the face layer. 
   
     
     
         2 . The flame-retardant mattress cover of  claim 1 , wherein the inherently flame-retardant material comprises at least one of a cellulosic yarn or a rayon yarn. 
     
     
         3 . The flame-retardant mattress cover of  claim 1 , wherein the inherently flame-retardant material comprises at least one of a continuous flame-retardant viscose staple fiber (FRVSF) or a micro-flame-retardant-viscose (micro-FRV) yarn. 
     
     
         4 . The flame-retardant mattress cover of  claim 1 , wherein the inherently flame-retardant material has a limiting oxygen index (LOI) from 14 to 45. 
     
     
         5 . The flame-retardant mattress cover of  claim 1 , wherein at least one of the face layer and the back layer comprises at least one of a knit fabric material or a woven fabric material. 
     
     
         6 . The flame-retardant mattress cover of  claim 1 , wherein the inlay layer comprises a number of loose yarns. 
     
     
         7 . The flame-retardant mattress cover of  claim 1 , wherein the inlay layer excludes a polyester yarn. 
     
     
         8 . A mattress assembly, comprising:
 a mattress core; and   a flame-retardant mattress cover that covers the mattress core, the flame-retardant mattress cover comprising:
 a back layer; 
 an inlay layer,
 wherein the inlay layer comprises an inherently flame-retardant material; and 
 
 a face layer,
 wherein the back layer is closer to the mattress core than the inlay layer and the face layer, 
 wherein the inlay layer is between the back layer and the face layer. 
 
   
     
     
         9 . The mattress assembly of  claim 8 , wherein the inherently flame-retardant material comprises at least one of a cellulosic yarn or a rayon yarn. 
     
     
         10 . The mattress assembly of  claim 8 , wherein the inherently flame-retardant material comprises at least one of a continuous flame-retardant viscose staple fiber (FRVSF) or a micro-flame-retardant-viscose (micro-FRV) yarn. 
     
     
         11 . The mattress assembly of  claim 8 , wherein the inherently flame-retardant material has a limiting oxygen index (LOI) from 14 to 45. 
     
     
         12 . The mattress assembly of  claim 8 , wherein at least one of the face layer and the back layer comprises at least one of a knit fabric material or a woven fabric material. 
     
     
         13 . The mattress assembly of  claim 8 , wherein the inlay layer comprises a number of loose yarns. 
     
     
         14 . The mattress assembly of  claim 8 , wherein the inlay layer excludes a polyester yarn. 
     
     
         15 . The mattress assembly of  claim 8 , wherein the mattress core comprises foam. 
     
     
         16 . The mattress assembly of  claim 8 , wherein the back layer contacts the mattress core. 
     
     
         17 . A method, comprising:
 obtaining an inherently flame-retardant material;   processing the inherently flame-retardant material, thereby to form a inlay layer of a mattress cover;   obtaining a back layer; and   obtaining a face layer;   disposing the inlay layer between the back layer and the face layer, thereby to form a flame-retardant mattress cover.   
     
     
         18 . The method of  claim 17 , wherein the processing comprises processing the inherently flame-retardant material with at least one of heat, water, or air. 
     
     
         19 . The method of  claim 17 , wherein the processing comprises processing the inherently flame-retardant material with at least two of heat, water, or air. 
     
     
         20 . The method of  claim 17 , wherein the inherently flame-retardant material comprises at least one of a continuous flame-retardant viscose staple fiber (FRVSF), a viscose filament yarn (VFY), or a micro-flame-retardant-viscose (micro-FRV) yarn, and wherein the processing comprises water texturing the inherently flame-retardant material.