Composite fire barrier and thermal insulation fabric for mattresses and mattress foundations

Abstract

An open flame resistant article is composed of filling materials and a fire barrier fabric including a fire barrier layer and a thermally insulating layer at least partially enclosing the filling materials. Open flame resistance of the article is determined under the California Technical Bulletin #603 test protocol.

1 . An open flame resistant mattress comprising a fire barrier fabric at least partially enclosing a core of said mattress, said fire barrier fabric comprising a fire barrier layer and a thermally insulating layer, said fire barrier layer and thermally insulating layer independently comprising at least one char-forming flame-retardant fiber.  
     
     
         2 . An open flame resistant mattress according to  claim 1 , wherein said mattress resists an open flame under conditions of a full-scale open flame test.  
     
     
         3 . An open flame resistant mattress according to  claim 2 , wherein said full-scale open flame test is California TB 603.  
     
     
         4 . A method for reducing flammability of an article comprising filling materials, said method comprising at least partially enclosing the filling materials with a fire barrier fabric comprising a fire barrier layer and a thermally insulating layer, said fire barrier layer and thermally insulating layer independently comprising at least one char-forming flame-retardant fiber, whereby flammability of the article is reduced.  
     
     
         5 . A method according to  claim 4 , wherein said article is selected from mattresses, mattress foundations, upholstered furniture, transportation seating systems, health care seating systems and fire-protective apparel.  
     
     
         6 . A method according to  claim 4 , wherein said article is a mattress or mattress foundation.  
     
     
         7 . A method according to  claim 4 , wherein flammability of said article is determined according to a fire safety test protocol.  
     
     
         8 . An open flame resistant article comprising filling materials, said article comprising a fire barrier fabric at least partially enclosing the filling materials, said fire barrier fabric comprising a fire barrier layer and a thermally insulating layer, said fire barrier layer and thermally insulating layer independently comprising at least one char-forming flame-retardant fiber.  
     
     
         9 . An open flame resistant article according to  claim 8 , wherein open flame resistance of said article is determined in accordance with California TB 117.  
     
     
         10 . An open flame resistant article according to  claim 8 , wherein at least one of said fire barrier layer and said thermally insulating layer comprises at least one structure-providing char-forming flame-retardant fiber.  
     
     
         11 . An open flame resistant article according to  claim 8 , wherein said at least one char-forming flame-retardant fiber is selected from para-aramid fibers, meta-aramid fibers, fiberglass, melamine fibers, poly-benzimidazole fibers, polyacrylonitrile fibers, novoloid fibers, pre-oxidized fibers, carbon fibers, modacrylic fibers, flame-resistant rayon fibers, flame-retardant viscose fibers, wool fibers, and flame-retardant treated cotton fibers.  
     
     
         12 . An open flame resistant article according to  claim 8 , wherein said at least one char-forming flame-retardant fiber is selected from para-aramid fibers, modacrylic fibers, flame-retardant viscose fibers, fiberglass and blends thereof.  
     
     
         13 . An open flame resistant article according to  claim 8 , wherein said at least one char-forming flame-retardant fiber comprises para-aramid fibers.  
     
     
         14 . An open flame resistant article according to  claim 8 , wherein said at least one char-forming flame-retardant fiber comprises a blend of para-aramid and modacrylic fibers.  
     
     
         15 . An open flame resistant article according to  claim 8 , wherein said at least one char-forming flame-retardant fiber comprises a blend of para-aramid and flame-retardant viscose fibers.  
     
     
         16 . An open flame resistant article according to  claim 8 , wherein said thermally insulating layer comprises a blend of flame-retardant viscose and modacrylic fibers.  
     
     
         17 . An open flame resistant article according to  claim 10 , wherein said at least one structure-providing char-forming flame-retardant fiber is selected from para-aramid fibers, meta-aramid fibers, fiberglass, melamine fibers, poly-benzimidazole fibers, polyacrylonitrile fibers, novoloid fibers, pre-oxidized fibers, and carbon fibers.  
     
     
         18 . An open flame resistant article according to  claim 10 , wherein said at least one structure-providing char-forming flame-retardant fiber is selected from para-aramid fibers, fiberglass and blends thereof.