Flame Resistant Knit Fabric

Abstract

A flame resistant knit fabric containing a first weft yarn set and a second weft yarn set. The first yarn set contains first flame resistant yarns which contain flame resistant rayon fibers. The second weft yarn set contains second weft yarns. The knit fabric is knitted 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. A flame resistant support article containing the flame resistant knit fabric as well as methods for making the knit fabric and support article are also disclosed.

What is claimed is: 
     
         1 . A flame resistant knit fabric comprising:
 a first weft yarn set, wherein the first weft yarn set comprises first flame resistant yarns, wherein the first flame resistant yarns comprise flame resistant rayon fibers, and;   a second weft yarn set, wherein 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 second weft yarns comprise a blend of flame resistant rayon fibers and polyester fibers. 
     
     
         3 . The flame resistant knit fabric of  claim 1 , wherein the second weft yarns comprise between about 50 and 85% by weight flame resistant rayon fibers. 
     
     
         4 . The flame resistant knit fabric of  claim 1 , wherein the first flame resistant yarns further comprise polyphenylene sulfide fibers. 
     
     
         5 . The flame resistant knit fabric of  claim 1 , wherein the flame resistant knit fabric comprises less than about 0.1% glass fibers. 
     
     
         6 . A flame resistant support article comprising:
 a support article comprising a resilient material; and   a knit flame resistant fabric at least partially surrounding the support article, wherein the knit flame resistant fabric comprises:
 a first weft yarn set, wherein the first weft yarn set comprises first flame resistant yarns, wherein the first flame resistant yarns comprise flame resistant rayon fibers, and; 
 a second weft yarn set, wherein 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. 
   
     
     
         7 . The flame resistant support article of  claim 6 , 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. 
     
     
         8 . The flame resistant support article of  claim 6 , wherein the knit fabric fully encapsulates the support article. 
     
     
         9 . The flame resistant support article of  claim 6 , wherein the support article is a mattress. 
     
     
         10 . The flame resistant support article of  claim 6 , wherein the support article passes the Consumer Product Safety Council CFR 1633 test. 
     
     
         11 . The flame resistant support article of  claim 6 , wherein the flame resistant knit fabric comprises less than about 0.1% glass fibers. 
     
     
         12 . A flame resistant knit fabric comprising:
 a first weft yarn set, wherein the first weft yarn set comprises first flame resistant yarns, wherein the first flame resistant yarns comprise partially oxidized polyacrylonitrile fibers and polyoxadiazole fibers, and;   a second weft yarn set, wherein 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.   
     
     
         13 . The flame resistant knit fabric of  claim 12 , wherein the second weft yarns comprise a blend of flame resistant rayon fibers and polyester fibers. 
     
     
         14 . The flame resistant knit fabric of  claim 12 , wherein the flame resistant knit fabric comprises less than about 0.1% glass fibers. 
     
     
         15 . A flame resistant support article comprising:
 a support article comprising a resilient material; and   a flame resistant knit fabric at least partially surrounding the support article, wherein the flame resistant knit fabric comprises:
 a first weft yarn set, wherein the first weft yarn set comprises first flame resistant yarns, wherein the first flame resistant yarns comprise partially oxidized polyacrylonitrile fibers and polyoxadiazole fibers, and; 
 a second weft yarn set, wherein 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. 
   
     
     
         16 . The flame resistant support article of  claim 15 , 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. 
     
     
         17 . The flame resistant support article of  claim 15 , wherein the knit fabric fully encapsulates the support article. 
     
     
         18 . The flame resistant support article of  claim 15 , wherein the support article is a mattress. 
     
     
         19 . The flame resistant support article of  claim 15 , wherein the support article passes the Consumer Product Safety Council CFR 1633 test. 
     
     
         20 . The flame resistant support article of  claim 15 , wherein the flame resistant knit fabric comprises less than about 0.1% glass fibers.