US2012255128A1PendingUtilityA1

Enhanced Knit Fabric Fire Barrier for Mattresses

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Individually held — no corporate assignee on recordPriority: Apr 7, 2011Filed: Apr 5, 2012Published: Oct 11, 2012
Est. expiryApr 7, 2031(~4.7 yrs left)· nominal 20-yr term from priority
Inventors:Ronald Sytz
D10B 2403/0114D10B 2403/021A47C 31/001D04B 15/06A47C 27/008D04B 1/04D10B 2503/06
42
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Claims

Abstract

An enhanced knit fabric fire barrier for mattresses and method for making same, the fabric barrier including a looped terry knitted fabric with a jersey side and a looped terry side; the jersey side including a fire retardant yarn and a melting yarn; the looped terry side including a fire retardant yarn; the loops in the jersey side are very high loops between about 4 mm and about 8 mm which char to provide a fire barrier for latex and highly volatile foams in mattresses. Also a double knit construction and method for making same, the fabric providing improved performance with the addition of a fire retardant yarn on the outside of the loops. Also, an enhanced fire-resistant full-foam mattress.

Claims

exact text as granted — not AI-modified
1 . A fire bather knit fabric with non-woven properties, the fabric comprising:
 a circular single knit fabric having 4-way stretch and recovery, and further including a jersey side and a looped terry side;   wherein the jersey side includes a fire retardant yarn and a melting yarn;   wherein the looped terry side includes a fire retardant yarn; and   wherein the loops in the jersey side are between about 4 mm and about 8 mm;   
       thereby providing a fire barrier fabric that provides 4-way stretch and recovery. 
     
     
         2 . The fabric of  claim 1 , wherein the loops are between about 5 mm and about 6 mm. 
     
     
         3 . The fabric of  claim 1 , wherein the loops are between about 6 mm and about 8 mm. 
     
     
         4 . The fabric of  claim 1 , wherein the melting yarn includes nylon, polyester and combinations thereof. 
     
     
         5 . The fabric of  claim 1 , wherein the fire retardant yarn is selected from the group consisting of modacryl, flame resistant rayon, flame retardant viscose, meta-aramid, para-aramid, fiberglass, melamine, poly-benzimidazole, oxidized polyacrylonitrile, novoloid, pre-oxidized and carbon fibers, wool, and combinations thereof. 
     
     
         6 . The fabric of  claim 1 , wherein the melting yarn is between about 5% and about 20% of a total fabric composition of the circular knit fabric. 
     
     
         7 . The fabric of  claim 6 , wherein melting yarn is about 10% of the total fabric composition. 
     
     
         8 . A fire-resistant mattress comprising:
 a mattress enclosed by a knit fabric fire barrier, the knit fabric fire barrier comprising:   a circular single knit fabric having 4-way stretch and recovery, and further including with a jersey side and a looped terry side;   wherein the jersey side includes a fire retardant yarn and a melting yarn;   wherein the looped terry side includes a fire retardant yarn; and   wherein the loops in the jersey side are between about 4 mm and about 8 mm;   
       thereby providing a mattress with a fire-resistant covering that provides 4-way stretch and recovery. 
     
     
         9 . The mattress of  claim 8 , wherein the loops are between about 5 mm and about 6 mm. 
     
     
         10 . The mattress of  claim 8 , wherein the loops are between about 6 mm and about 8 mm. 
     
     
         11 . The mattress of  claim 8 , wherein the melting yarn includes nylon, polyester and combinations thereof. 
     
     
         12 . The mattress of  claim 8 , wherein the melting yarn is selected from the group consisting of modacryl, flame resistant rayon, flame retardant viscose, meta-aramid, para-aramid, fiberglass, melamine, poly-benzimidazole, oxidized polyacrylonitrile, novoloid, pre-oxidized and carbon fibers, wool, and combinations thereof. 
     
     
         13 . The mattress of  claim 8 , wherein the melting yarn is between about 5% and about 20% of the total fabric compositions. 
     
     
         14 . The mattress of  claim 13 , wherein melting yarn is about 10% of the total fabric composition. 
     
     
         15 . The mattress of  claim 8 , wherein the mattress is selected from the group consisting of full-foam, full-latex and latex-foam mattresses. 
     
     
         16 . A method for making a knit fabric fire barrier comprising:
 providing a circular single knit terry machine having a sinker, constructed and configured for knitting a circular single knit fabric having 4-way stretch and recovery, and further including a jersey side and a looped terry side;   providing a fire retardant yarn and a melting yarn for a jersey side;   providing a fire retardant yarn for a looped terry side;   knitting a circular single knit fabric having 4-way stretch and recovery, and further including with a jersey side and a looped terry side;   thereby providing a fire-resistant fabric that provides 4-way stretch and recovery.   
     
     
         17 . The method of  claim 16 , wherein the sinker has a height between about 4 and about 8 mm. 
     
     
         18 . The method of  claim 16 , wherein the sinker has a height of about 5 mm. 
     
     
         19 . A method for making a double-knit fabric fire barrier, comprising:
 providing a circular double knit machine, constructed and configured for knitting a circular double knit fabric having 4-way stretch and recovery; the machine having a tuck stitch setting, a first feed, second feed and a third feed; wherein the first feed is on the on the cylinder side of the double knit machine, wherein the second feed is on the dial side of the double knit machine, and wherein the third feed feeds the middle yarn of the double knit fabric;   providing a fire retardant yarn and a melting yarn for the first feed;   providing a fire retardant yarn for the second feed; and   providing the middle yarn for the third feed;   setting the tuck stitch setting to between about 2 and about 8 mm;   knitting the double knit fabric;   thereby providing a fire-resistant fabric that provides 4-way stretch and recovery.   
     
     
         20 . The method of  claim 19 , wherein the middle yarn is a fire retardant yarn. 
     
     
         21 . The method of  claim 19 , wherein the fire retardant yarns are selected from the group consisting of modacryl, flame resistant rayon, flame retardant viscose, meta-aramid, para-aramid, fiberglass, melamine, poly-benzimidazole, oxidized polyacrylonitrile, novoloid, pre-oxidized and carbon fibers, wool, and combinations thereof. 
     
     
         22 . The method of  claim 19 , wherein the melting yarn is between about 5% and about 20% of a total fabric composition of the circular knit fabric. 
     
     
         23 . The method of  claim 19 , wherein melting yarn is about 10% of the total fabric composition. 
     
     
         24 . The method of  claim 19 , wherein the tuck stitch setting is between about 6 mm and about 8 mm. 
     
     
         25 . The method of  claim 19 , wherein the tuck stitch setting is about 8 mm. 
     
     
         26 . A fire bather knit fabric with non-woven properties, the fabric comprising:
 a double knit fabric having 4-way stretch and recovery, the fabric having a first side, a second side, and a middle;   wherein the first side includes a fire retardant yarn and a melting yarn;   wherein the second side includes a fire retardant yarn; and   wherein the middle includes a middle yarn; and   wherein the fabric further includes tuck stitches that are between about 2 mm and about 8 mm;   
       thereby providing a fire barrier fabric that provides 4-way stretch and recovery. 
     
     
         27 . The fabric of  claim 25 , wherein the tuck stitches are between about 6 mm and about 8 mm. 
     
     
         28 . The fabric of  claim 25 , wherein the tuck stitches are about 8 mm. 
     
     
         29 . The fabric of  claim 25 , wherein the melting yarn includes nylon, polyester and combinations thereof. 
     
     
         30 . The fabric of  claim 25 , wherein the fire retardant yarn is selected from the group consisting of modacryl, flame resistant rayon, flame retardant viscose, meta-aramid, para-aramid, fiberglass, melamine, poly-benzimidazole, oxidized polyacrylonitrile, novoloid, pre-oxidized and carbon fibers, wool, and combinations thereof. 
     
     
         31 . The fabric of  claim 25  wherein the melting yarn is between about 5% and about 20% of a total fabric composition of the circular knit fabric. 
     
     
         32 . The fabric of  claim 25 , wherein melting yarn is about 10% of the total fabric composition. 
     
     
         33 . A fire-resistant mattress comprising:
 a mattress enclosed by a knit fabric fire barrier, the knit fabric fire barrier comprising:   a double knit fabric having 4-way stretch and recovery, the fabric having a first side, a second side, a middle;   wherein the first side includes a fire retardant yarn and a melting yarn;   wherein the second side includes a fire retardant yarn; and   wherein the middle includes a middle yarn; and   wherein the fabric further includes tuck stitches between about 2 mm and about 8 mm;   
       thereby providing a fire resistant mattress with a knit fabric fire barrier that provides 4-way stretch and recovery.

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