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 quilted composite comprising ticking, a first fire blocker, and cushioning material,   b) a pillow for said mattress, and   c) a gusset covering a joint between the mattress body and the pillow,   wherein, the gusset includes a quilted composite comprising ticking, a second fire blocker that has at least 50% higher basis weight than the first fire blocker, and cushioning material.   
   
   
       2 . The fire blocked mattress of  claim 1  wherein the pillow is also fire blocked. 
   
   
       3 . The fire blocked mattress of  claim 2  wherein the pillow is fire blocked with the first fire blocker. 
   
   
       4 . The fire blocked mattress of  claim 1  wherein the gusset is attached to the mattress body and pillow by sewing. 
   
   
       5 . The fire blocked mattress of  claim 1  wherein the first or second fire blocker is a nonwoven fabric. 
   
   
       6 . 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 a quilted composite comprising ticking, a first fire blocker, and cushioning material,   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 comprises a quilted composite comprising ticking, a second fire blocker having at least 50% higher basis weight than the first fire blocker found in the mattress side border, and cushioning material.   
   
   
       7 . The fire blocked mattress of  claim 6  wherein the pillow is also fire blocked. 
   
   
       8 . The fire blocked mattress of  claim 6  wherein the gusset is attached to the mattress body and pillow by sewing 
   
   
       9 . The fire blocked mattress of  claim 6  wherein the fire blocking comprises a nonwoven fabric. 
   
   
       10 . 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 a joint between the mattress body and the pillow, comprising the steps of:
 a) incorporating a quilted composite comprising ticking, a first fire blocker, and cushioning material into the mattress side border, and   b) incorporating a quilted composite comprising ticking, a second fire blocker, and cushioning material into the gusset,   wherein, the second fire blocker has at least 50% higher basis weight than the first fire blocker.   
   
   
       11 . The process of  claim 10  wherein the top panel of the pillow is also fire blocked with either the first or second fire blocker. 
   
   
       12 . The process of  claim 10  wherein the first or second fire blocker is a nonwoven fabric. 
   
   
       13 . 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 a joint between the mattress body and the pillow, comprising the steps of:
 a) incorporating a quilted composite comprising ticking, a single layer of a fire blocker fabric, and cushioning material into the mattress side border and   b) incorporating a quilted composite comprising ticking, a plurality of layers of a fire blocker fabric having at least 50% higher basis weight than the fire blocker fabric of a cushioning material into the gusset.   
   
   
       14 . The process of  claim 13 , wherein each layer of the fire blocker fabric used in the border and the gusset are the same fabric.