Flame resistant knit fabric

Abstract

A flame resistant knit fabric having a first weft yarn set and a second weft yarn set. The first weft yarn set contains flame resistant yarns and the second weft yarn set contains second weft yarns. The knit fabric is knit such that the first weft yarns are interlinked with one another by a plurality of knit stitches, the second weft yarns are interlinked with one another by a plurality of knit stitches, and the first weft yarns are not interlinked with the second weft yarns.

What is claimed is: 
     
         1 . A flame resistant knit fabric comprising a first weft yarn set and a second weft yarn set, wherein the first weft yarn set comprises flame resistant yarns and the second weft yarn set comprises second weft yarns, wherein the knit fabric is knit such that the first weft yarns are interlinked with one another by a plurality of knit stitches, the second weft yarns are interlinked with one another by a plurality of knit stitches, and the first weft yarns are not interlinked with the second weft yarns. 
     
     
         2 . The flame resistant knit fabric of  claim 1 , wherein the first weft yarn set has a repeating stitch pattern comprising a knit stitch on a first needle and a welt on a second needle. 
     
     
         3 . The flame resistant knit fabric of  claim 2 , wherein the second weft yarn set has a repeating stitch pattern comprising a welt on a first needle and a knit stitch on a second needle. 
     
     
         4 . The flame resistant knit fabric of  claim 3 , wherein the knit stitches of the first weft yarn are in the same wale as the welts of the second weft yarn. 
     
     
         5 . The flame resistant knit fabric of  claim 1 , wherein the flame resistant yarns comprise continuous filament silica. 
     
     
         6 . The flame resistant knit fabric of  claim 1 , wherein the second weft yarns comprise an alternating arrangement of A yarns and B yarns, wherein the A yarns comprise a mixture of polyester and flame resistant rayon fibers, and wherein the B yarns comprise a mixture of modacrylic and cotton fibers. 
     
     
         7 . The flame resistant knit fabric of  claim 1 , wherein the flame resistant knit fabric has an upper surface and a lower surface, wherein the majority of the upper surface comprises the first weft yarns and the majority of the lower surface comprises the second weft yarns. 
     
     
         8 . A flame resistant support article comprising:
 a support article comprising a resilient material; and   a knit fabric at least partially surrounding the support article, wherein the knit fabric comprises a first weft yarn set and a second weft yarn set, wherein the first weft yarn set comprises a flame resistant yarns and the second weft yarn set comprises second weft yarns, wherein the knit fabric is knit such that the first weft yarns are interlinked with one another by a plurality of knit stitches, the second weft yarns are interlinked with one another by a plurality of knit stitches, and the first weft yarns are not interlinked with the second weft yarns.   
     
     
         9 . The flame resistant support article of  claim 8 , wherein the first weft yarn set has a repeating stitch pattern comprising a knit stitch on a first needle and a welt on a second needle, wherein the second weft yarn set has a repeating stitch pattern comprising a welt on a first needle and a knit stitch on a second needle, and wherein the knit stitches of the first weft yarn are in the same wale as the welts of the second weft yarn. 
     
     
         10 . The flame resistant support article of  claim 8 , wherein the knit fabric fully encapsulates the support article. 
     
     
         11 . The flame resistant support article of  claim 8 , wherein the support article is a mattress. 
     
     
         12 . The flame resistant support article of  claim 8 , wherein the article is selected from the group consisting of a cushion, pillow, office panel, and seat. 
     
     
         13 . The flame resistant support article of  claim 8 , wherein the first weft yarn set has a repeating stitch pattern comprising a knit stitch on a first needle, a welt on a second needle and a welt on a third needle. 
     
     
         14 . The flame resistant support article of  claim 8 , wherein the second weft yarns comprise an alternating arrangement of A yarns and B yarns, wherein the A yarns comprise a mixture of polyester and flame resistant rayon fibers, and wherein the B yarns comprise a mixture of modacrylic and cotton fibers. 
     
     
         15 . The flame resistant support article of  claim 8 , wherein the flame resistant knit fabric has an upper surface and a lower surface, wherein the majority of the upper surface comprises the first weft yarns and the majority of the lower surface comprises the second weft yarns.