Mattress having a flammable core and a nonwoven cellulose flame retardant fabric

Abstract

The present invention concerns a mattress having a flammable core and a cellulosic flame-retardant (FR) nonwoven fabric that at least partially encloses the flammable core. The nonwoven fabric comprises from about 65 to about 85 weight percent (wt. %) cellulosic flame retardant fibers, and from about 15 to about 35 weight percent of low melt binder (bicomponent fiber or low-melting fiber), the nonwoven fabric prepared from these components, has a basis weight of about 5 to about 20 oz./sq. yd. and is capable of passing stringent flame-resistant tests. The mattress from this construction passes the California Test Bulletin 129 and/or 603 stringent conditions for mattresses used in public or residential places.

1 ) A mattress having a flammable core and a flame retardant nonwoven fabric at least partially enclosing said flammable core, said nonwoven fabric produced from about 65 to about 85 weight percent cellulosic flame retardant fibers, and from about 15 to about 35 weight percent low melt binder fiber, said nonwoven fabric having a basis weight of about 5-20 oz./sq. yd.  
   
   
       2 ) The mattress of  claim 1 , wherein said cellulosic flame retardant fibers are either inherent or post treated fibers, or both.  
   
   
       3 ) The mattress of  claim 2 , wherein said cellulosic flame retardant fibers are inherent fibers.  
   
   
       4 ) The mattress of  claim 2 , wherein said cellulosic flame retardant fibers are post treated cellulosic fibers.  
   
   
       5 ) The mattress of  claim 4 , wherein said cellulosic flame retardant fibers are post treated with a non-halogenated phosphate flame retardant composition.  
   
   
       6 ) The mattress of  claim 1 , wherein said cellulosic flame retardant fibers are either rayon, cotton, jute, hemp, flax, kenaf, cellulose acetate, or a mixture of 2 or more of these fibers.  
   
   
       7 ) The mattress of  claim 1 , wherein said low melt binder fibers are bicomponent fibers.  
   
   
       8 ) The mattress of  claim 1 , optionally including other synthetic or natural fibers.  
   
   
       9 ) The mattress of  claim 8 , wherein said synthetic or natural fibers are either flame retardant or not.  
   
   
       10 ) The mattress of  claim 8 , wherein said synthetic or natural fibers comprise up to 20 weight percent of said nonwoven fabric.  
   
   
       11 ) The mattress of  claim 1 , wherein said mattress passes the standards of California TB 603 in that less than 25 MJ of total heat release at 10 minutes after burner ignition, and less than 200 kW of heat release rate at 30 minutes after burner ignition.  
   
   
       12 ) The mattress of  claim 1 , wherein said cellulosic flame retardant fibers are present in a range form about 70 to about 80 weight percent of the fabric.  
   
   
       13 ) The mattress of  claim 1  wherein said basis weight ranges from 6 to 11 oz. per sq. yd.  
   
   
       14 ) The mattress of  claim 1 , wherein said cellulosic flame retardant fibers are rayon fibers post treated with a non-halogen, phosphorus flame retardant composition.