Textile woven and knit fabrics with enhanced flame retardancy and comfort for bedclothing products

Abstract

Textile woven and knit fabrics with inherent flame resistant properties for use in household filled bedclothing applications, such as mattress ticking. In one embodiment, the yarn used to weave or knit the fabric comprises from about 25 to about 60 weight % modacrylic fiber and from about 40 to about 75 weight % cellulosic fiber. In another embodiment, the yarns used to knit the fabrics can comprise from about 25 to about 75 weight % modacrylic fiber, from about 20 to about 50 weight % of cellulosic fibers, and from about 5 to about 55 weight % of other materials such as polyester fibers/filaments and/or glass filaments. Preferably, the woven fabrics have a spun yarn count from about 20/1 ecc to about 40/1 ecc, while the knit fabrics have a spun yarn count from 10/1 ecc to 30/1 ecc for the face side layer, a yarn count of 4/1 ecc to 10/1 ecc as well as 4/2 ecc to 10/2 ecc for the filling layer, and a yarn count of 20/1 ecc to 40/1 ecc (more preferably 30/1 ecc to 40/1 ecc) as well as a filament yarn count of 100 denier to 300 denier for the back side layer. The textile woven fabric may be suitable for filled bedclothing products such as comforters, bed spreads, pillow and mattress covers, and pillow and mattress pad ticking. The textile knit fabric may be suitable for mattress ticking applications.

1 . A textile fabric comprising: 
 a yarn comprising a modacrylic fiber in an amount of from about 25 to about 60 weight % of the yarn, and a cellulosic fiber in an amount of from about 40 to about 75 weight % of the yarn;    wherein the fabric is woven.    
   
   
       2 . The fabric of  claim 1 , wherein the modacrylic fiber is present in an amount of from about 35 to about 50 weight % of the yarn, and the cellulosic fiber is present in an amount of from about 50 to about 70 weight % of the yarn.  
   
   
       3 . The fabric of  claim 1 , wherein the modacrylic fiber is present in an amount of 35 weight % of the yarn, and the cellulosic fiber is present in an amount of 65 weight % of the yarn.  
   
   
       4 . The fabric of  claim 3 , wherein the modacrylic fiber comprises a polymer including halogenated monomers which generate oxygen depleting gases during thermal decomposition, and the cellulosic fiber comprises cotton.  
   
   
       5 . The fabric of  claim 1 , wherein the fabric has a spun yarn count of from about 20/1 ecc to about 40/1 ecc.  
   
   
       6 . The fabric of  claim 1 , wherein the fabric has a spun yarn count of about 35/1 ecc.  
   
   
       7 . The fabric of  claim 1 , wherein the fabric has a weight of from about 50 g/m 2  to about 400 g/m 2 .  
   
   
       8 . A filled bedclothing product including the fabric of  claim 1 .  
   
   
       9 . The filled bedclothing product of  claim 8 , wherein the filled bedclothing product is selected from the group consisting of a comforter, a bed spread, a pillow cover, a mattress cover, a pillow ticking, and a mattress ticking.  
   
   
       10 . A textile fabric comprising: 
 a yarn comprising a modacrylic fiber in an amount of from about 25 to about 60 weight % of the yarn, and a cellulosic fiber in an amount of from about 40 to about 75 weight % of the yarn;    wherein the fabric is knitted.    
   
   
       11 . The fabric of  claim 10 , wherein the modacrylic fiber is present in an amount of from about 30 to about 50 weight % of the yarn, and the cellulosic fiber is present in an amount of from about 50 to about 70 weight % of the yarn.  
   
   
       12 . The fabric of  claim 10 , wherein the modacrylic fiber is present in an amount of 35 weight % of the yarn, and the cellulosic fiber is present in an amount of 65 weight % of the yarn.  
   
   
       13 . The fabric of  claim 12 , wherein the modacrylic fiber comprises a polymer including halogenated monomers which generate oxygen depleting gases during thermal decomposition, and the cellulosic fiber comprises cotton.  
   
   
       14 . The fabric of  claim 10 , wherein the fabric has a spun yarn count for a face side layer of about 16/1 ecc, for a filling layer of about 6/1 ecc, and for a back face layer of about 36/1 ecc.  
   
   
       15 . The fabric of  claim 10 , wherein the fabric has a weight of from about 5 oz. sq. yd. to about 15 oz. sq. yd.  
   
   
       16 . A mattress tick including the fabric of  claim 10 .  
   
   
       17 . A textile fabric comprising: 
 a yarn comprising a modacrylic fiber in an amount of from about 25 to about 75 weight % of the yarn, a cellulosic fiber in an amount of from about 20 to about 50 weight % of the yarn, and a polyester fiber or filament in an amount of from about 5 to about 55 weight % of the yarn;    wherein the fabric is knitted.    
   
   
       18 . The fabric of  claim 17 , wherein the modacrylic fiber comprises a polymer including halogenated monomers which generate oxygen depleting gases during thermal decomposition, and the cellulosic fiber comprises cotton.  
   
   
       19 . The fabric of  claim 17 , wherein the fabric has a spun yarn count for a face side layer of about 16/1 ecc, for a filling layer of about 6/1 ecc, and for a back face layer of about 36/1 ecc.  
   
   
       20 . A mattress tick including the fabric of  claim 17.