Abstract: The invention relates to an inherently flame resistant (FR) stitchbonded nonwoven fabric for mattresses, boxsprings, upholstered furniture, top-of-the-bed, office panel, transportation seating or any end use application where a FR textile material is desired. Two of the preferred forms of this invention include: 100% cotton. 100% rayon, 100% lyocell, cotton/non-FR fiber blends, rayon/non-FR fiber blends or lyocell/non-FR fiber blend battings that are stitchbonded with flame resistant fiberglass core-spun yarn. 100% cotton, 100% rayon, 100% lyocell, cotton/non-FR fiber blends, rayon/non-FR fiber blends or lyocell/non-FR fiber blend battings that are stitchbonded with FR spun yarn.

Abstract: The invention relates to the use of a flame resistant three-layer double-knit or woven fabric, also know as a matelasse fabric. The top layer is of standard non-flame resistant face yarn, the middle layer is of flame resistant filler yarn and the bottom layer is of flame resistant core wrap spun yarn. This flame resistant matelasse fabric can be used to protect a mattress, foundation, mattress pad, pillow, comforter, upholstery cushion, pillow, office panel, transportation seat or any other article requiring flame resistant protection. In this invention, a matelasse fabric is formed by circular double knitting or weaving a flame resistant core spun yarn into the bottom portion of the fabric, utilizing a heavy cotton count flame resistant filler yarns for the middle layer and using conventional non-flame resistant yarns for the top layer.

Abstract: The invention relates to the use of a flame resistant (FR) three-layer double-knit fabric, also know as a matelasse fabric. The top layer is of standard non-FR face yarn, the middle layer is of a FR filler spun yarn and the bottom layer is of a FR spun yarn or FR filament yarn. This FR matelasse fabric can be used to protect a mattress, foundation, upholstery cushion, pillow, office panel, transportation seat or any other article requiring FR protection. In this invention, a matelasse fabric is formed by circular double knitting a FR spun or FR filament yarn into the bottom portion of the fabric, utilizing a heavy cotton count FR filler spun yarn for the middle layer and using conventional non-FR yarns for the top layer.

Abstract: The invention relates to the use of a flame resistant knit tube, made with either a seamless or seamed circular knit or a seamed or tubular warp knit fabric, used to protect a mattress, foundation, upholstery cushion, pillow, office panel, transportation seat or any other article requiring flame resistant protection. In this invention, a tubular knit fabric is formed utilizing flame resistant yam and then optionally heat-set to prevent curling during subsequent cutting and processing. Heat-setting the knit fabric is especially preferred for circular knit constructions to prevent curling in subsequent processing. The knit tube is then cut to the length of the article to be flame protected, allowing enough additional length to sew a pocket closure on one end and a standard closure on the other end. First, one end of the tubular knit sock is sewn with a pocket closure seam, using a flame resistant thread or a suitable substitute.

Abstract: Nonwoven wet-lay flame barrier of the invention comprises a blend of water dispersible fibers, that are inherently fire resistant and nonshrinking to direct flame, along with water dispersible fibers extruded from polymers made with halogenated monomers and optionally including fiberglass and wood pulp, being together thermally bonded with a binder resin in a wet-lay manufacturing process to provide a relatively thin, but dense, durable flame barrier with excellent tensile, and durability properties in the end use application. The wet-lay flame barrier of this invention also allows for the manufacture of open flame resistant composite articles, while also permitting the continued use of conventional non-flame retardant dress cover fabrics, conventional non-flame retardant fiberfills and conventional non-flame retardant polyurethane foams.