Pillow-top mattress comprising a fire blocked gusset

Abstract

This invention relates to an improved gusset for use in fire-blocking a pillow-top mattress. This gusset provides additional fire blocking to provide a pillow-top mattress with improved performance when tested according to Technical Bulletin 603 of the State of California.

1 . A fire blocked pillow-top mattress, comprising: 
 a) a mattress body having a border comprising a first fire blocker,    b) a pillow for said mattress, and    c) a gusset covering the joint between the mattress body and the pillow,    wherein the gusset includes a second fire blocker that has a higher basis weight than the first fire blocker.    
   
   
       2 . The fire blocked mattress of  claim 1  wherein the second fire blocker has at least 20% higher basis weight than the first fire blocker.  
   
   
       3 . The fire blocked mattress of  claim 1  wherein the second fire blocker has at least 50% higher basis weight than the first fire blocker.  
   
   
       4 . The fire blocked mattress of  claim 1  wherein the pillow is also fire blocked.  
   
   
       5 . The fire blocked mattress of  claim 4  wherein the pillow is fire blocked with the first fire blocker.  
   
   
       6 . The fire blocked mattress of  claim 1  wherein the gusset is attached to the mattress body and pillow by sewing.  
   
   
       7 . The fire blocked mattress of  claim 1  wherein the first or second fire blocker is a nonwoven fabric.  
   
   
       8 . A fire blocked pillow-top mattress, comprising: 
 a) a mattress body having a seam connecting a panel of the mattress body and a side border, the side border having fire blocking,    b) a pillow having a seamed outer edge,    the pillow having a contact point with the mattress panel inboard from the side border of the mattress,    the seamed outer edge of the pillow also extending outboard above such contact point,    wherein the area extending from the seam of the mattress body across the mattress panel to the pillow contact point and up the underside of the pillow surface to the seamed outer edge of the pillow has more fire blocking than that found in the mattress side border.    
   
   
       9 . The fire blocked mattress of  claim 8  wherein the pillow is also fire blocked.  
   
   
       10 . The fire blocked mattress of  claim 8  wherein the gusset is attached to the mattress body and pillow by sewing  
   
   
       11 . The fire blocked mattress of  claim 8  wherein the fire blocking comprises a nonwoven fabric.  
   
   
       12 . A process for fire blocking a pillow-top mattress comprising a mattress body having a side border and a pillow having a top panel, with a gusset covering the joint between the mattress body and the pillow, comprising the steps of: 
 a) incorporating a first fire blocker into the mattress side border, and    b) incorporating a second fire blocker into gusset,    wherein the second fire blocker has a higher basis weight than the first fire blocker.    
   
   
       13 . The process of  claim 12  wherein the top panel of the pillow is also fire blocked with either the first or second fire blocker.  
   
   
       14 . The process of  claim 12  wherein the first or second fire blocker is a nonwoven fabric.  
   
   
       15 . A process for fire blocking a pillow-top mattress comprising a mattress body having a side border and a pillow having a top panel, with a gusset covering the joint between the mattress body and the pillow, comprising the steps of: 
 a) incorporating a single layer of a fire blocker fabric into the mattress side border and    b) incorporating a plurality of layers of a fire blocker fabric into the gusset.    
   
   
       16 . The process of  claim 15 , wherein each layer of the fire blocker fabric used in the border and the gusset are the same fabric.