U.S. patent application number 13/440775 was filed with the patent office on 2012-10-11 for enhanced knit fabric fire barrier for mattresses.
Invention is credited to Ronald M. Sytz.
Application Number | 20120255128 13/440775 |
Document ID | / |
Family ID | 46964956 |
Filed Date | 2012-10-11 |
United States Patent
Application |
20120255128 |
Kind Code |
A1 |
Sytz; Ronald M. |
October 11, 2012 |
Enhanced Knit Fabric Fire Barrier for Mattresses
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.
Inventors: |
Sytz; Ronald M.; (Gastonia,
NC) |
Family ID: |
46964956 |
Appl. No.: |
13/440775 |
Filed: |
April 5, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61473140 |
Apr 7, 2011 |
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Current U.S.
Class: |
5/698 ; 66/13;
66/191; 66/202; 66/215; 66/80; 66/9R |
Current CPC
Class: |
A47C 31/001 20130101;
D10B 2403/0114 20130101; D04B 1/04 20130101; A47C 27/008 20130101;
D04B 15/06 20130101; D10B 2403/021 20130101; D10B 2503/06
20130101 |
Class at
Publication: |
5/698 ; 66/191;
66/202; 66/9.R; 66/13; 66/80; 66/215 |
International
Class: |
A47C 17/00 20060101
A47C017/00; D04B 13/00 20060101 D04B013/00; D04B 9/00 20060101
D04B009/00; D04B 15/00 20060101 D04B015/00; D04B 9/14 20060101
D04B009/14; D04B 1/04 20060101 D04B001/04 |
Claims
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.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This non-provisional utility patent application claims the
benefit of prior filed U.S. provisional application Ser. No.
61/473,140 filed Apr. 7, 2011, which is incorporated herein by
reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to knitted fabric and more
specifically to a fire barrier fabric used specifically for
covering mattresses or furniture.
[0004] 2. Description of the Prior Art
[0005] Current residential mattresses use products like
polyurethane foam and latex on the sleep surfaces to improve the
comfort of the mattresses. Current studies show that consistent
support of the body from head to toe provides a better sleep
condition. Therefore it is important that mattress shapes to the
body. As an example to this, most new comfort beds that are foam,
latex or a combination of these products including traditional
springs, use a knitted fabric as the mattress ticking in place of
the older style woven ticking fabric. The knitted ticking fabric
has 4-way stretch and allows the mattress to shape to the body
providing continuous support. Therefore it is most important to
allow all the fabrics that are covering the foam, latex, etcetera
to have stretch and continuously move without deterioration in the
ability to shape to the users in order to provide the best sleeping
surface.
[0006] The U.S. Consumer Product Safety Commission approved a
federal mattress flammability standard to take effect Jul. 1, 2007.
This is referred to as 16 CFR 1633 requirement for all mattresses.
Compliance to this requirement was the criteria that through the
test procedure a matters maintain a heat release rate of less than
200 kW during the first 30 minutes of the test and also that the
Total Heat Release be less than 15MJ in the first 10 minutes of the
test.
[0007] With the newer foam and latex mattresses, the challenge of
meeting these requirements becomes tougher. Polyurethane foam,
latex and other products are more flammable than the conventional
spring mattresses. This provides a challenge to the manufacturer as
many of these more flammable sleep surfaces also contain air
pockets and produces very challenging opportunities.
[0008] Mattress manufacturers have begun to use different products
to meet the 16 CFR 1633 standard. Some of these products include
knitted socks or fabric covers using inherently fire retardant
yarns made of fibers used but not limited to, include fibers of
Modacrylic, flame resistant rayon, flame retardant viscose,
meta-aramid, para-aramid, fiberglass, melamine, poly-benzimidazole,
oxidized polyacrylonitrile, novoloid, pre-oxidized and carbon
fibers, wool, and flame retardant treated cotton and fibers yet to
be developed. Also used are knitted socks with topically treated
fabric like but not limited to flame retardant treated cotton
fabrics. Other solutions include non-woven fabrics with inherently
fire retardant fibers, used but not limited to, include fibers of
Modacrylic, flame resistant rayon, flame retardant viscose,
meta-aramid, para-aramid, fiberglass, melamine, poly-benzimidazole,
oxidized polyacrylonitrile, novoloid, pre-oxidized and carbon
fibers, wool, and flame retardant treated cotton and fibers yet to
be developed. Also used are topically treated non-woven fabrics.
Topical treatment of fibers for yarn and fabric and topical
treatment of fabrics may include but not limited to treatments both
durable and non-durable like ammonium bromide, ammonium chloride,
boric acid, borax, phosphate, sulfamate, esters, halogenated
organic compounds, antimony oxides and many more topical treatments
to make fibers, yarns, fabrics, knit, woven or non-woven to have
fire retardant properties.
[0009] The non-woven products are less expensive to manufacture
than the knitted fabrics. Because of manufacturing cost it is much
less expensive to produce a non-woven fabric, and therefore this
solution has been the preferred solution for spring coil type
mattresses. The preferred solution for polyurethane foam mattresses
has been the knitted fabric solution. The knitted fabric solution
provides a FR fabric that has 4-way stretch and allows the
mattresses to perfectly shape to the body of the user. Some
manufacturers have used the non-woven solution on their least
expensive mattresses. This solution looses the opportunity to shape
to the body. The non-woven fabric is rigid and does not have
stretch. If it does get stretched, there is no recovery of the
fabric and the stretch area is now deformed.
[0010] The benefit of using the non-woven as the FR barrier is that
you can make the weight of the non-woven much greater with a small
increase in cost. This increase in weight provides better FR
protection yet also reduces the comfort and feel of the bed. Every
increase in weight and thickness of the non-woven FR barrier
significantly reduces the feel of the mattresses.
[0011] The current use of highly volatile sleep surfaces like latex
produces more challenges to provide FR protection to meet the 16
CFR 1633 standard. Latex mattresses are particularly hard to pass
due to the holes and pockets that are made in the latex to provide
better shaping of the bed to the user. These holes and pockets
provide more oxygen to fuel the fire. Also, a drafting effect of
the air through the holes creates a torch effect when on fire. This
torch effect hard to control and increases the amount of heat
released during the 16 CFR 1633 test.
[0012] Latex and other volatile foams on all or part of a mattress
create a difficult obstacle to pass the 16 CFR 1633 test.
[0013] Mattress manufacturers have been using non-woven FR barriers
to achieve a positive pass of the 16 CFR 1633 test. The non-woven
FR barrier works because the fibers within the non-woven product
are extremely intertwined and create a blanket effect during the
burn test. This blanket effect blocks the flow of the air out of
the latex holes. Yet because of the intertwining of the fibers, the
non-woven fabric has no stretch and recovery.
[0014] Another embodiment of the non-woven fabric is to make it
thicker and have the fibers less intertwined. The problem with this
embodiment is that the non-woven fabric may stretch some but it
will not recover. Therefore if the non-woven fabric is stretched,
it stays stretched and creates a puckered area. To make this
product more usable, some solutions are to sandwich the non-woven
between two stretchable knit fabrics during a quilting process. The
quilting process limits the area of the puckered area and assists
to bring the shape back closer to the original, but never exactly
to the original shape.
[0015] Some mattresses manufactures have used multiple layers of
the knitted sock fabrics, mostly with limited success. The knitted
sock fabrics open during the burn test and expose an underlying
layer. Most of the time the underlying layer is the latex and
therefore these embodiments do not pass the 16 CFR 1633 test. Due
to the inconsistency in results, most manufacturers have decided
not to use this solution.
[0016] Prior art patents and patent applications include:
[0017] U.S. Pat. No. 7,546,853 issued to Rock, et al. Jun. 16, 2009
and United States Patent Application 20090126057 for Advanced
engineered garment, teaches an under body armor hybrid fabric
garment has first and second fabric portions. The first fabric
portion, configured to cover an upper torso region of a user's body
left exposed by the body armor and extending into a second body
transition region covered by the body armor, is formed of low or no
stretch fabric. The second fabric element, configured to cover a
lower torso region of the user's body underneath the body armor, is
formed of stretchable fabric.
[0018] United States Patent Application 20100088818 filed by Rock;
Moshe; et al. Apr. 15, 2010 for Coverings For Viscoelastic Foam
Mattresses teaches covers for mattresses having a reclining surface
of viscoelastic foam have a fabric body with a first surface
disposed in engagement with the reclining surface; an opposite,
second surface disposed for engagement by a person reclining upon
the cover; and at least one air flow region defined by the fabric
body for enhanced circulation of air between the reclining surface
of viscoelastic foam and an opposed skin surface of the person
reclining upon the cover. The circular knit fabric body comprises a
flame retardant material.
[0019] U.S. Pat. No. 7,743,476 issued to Rock, et al. Jun. 29, 2010
and United States Patent Application 20100242148 and 20080189824
for Engineered fabric articles teaches methods for forming unitary
fabric elements for use in engineered thermal fabric articles,
including thermal fabric garments, thermal fabric home textiles,
and thermal fabric upholstery covers, and for forming these
articles, having predetermined discrete regions of contrasting
insulative capacity positioned about the thermal fabric article in
correlation to insulative requirements of a user's body. In one
implementation, loop yarn in first regions is formed to a first
pile height, and loop yarn in other regions is formed to another,
different, relatively greater pile height. In another
implementation, loop yarn having a first shrinkage performance is
formed in first regions to a predetermined loop height, and loop
yarn having another, different shrinkage performance is formed in
other regions; the loops are cut and finished to a common pile
height and the web is exposed to heat to cause loop yarn to shrink
to one or more different pile heights.
[0020] United States Patent Application 20050097652 filed by Rock,
Moshe; et al. May 12, 2005 for Multi-layer flame retardant fabric
teaches a composite velour fabric garment includes a laminate
consisting of an outer woven shell layer, an inner thermal layer of
knit construction, and an intermediate layer disposed between and
laminated to each of the shell layer and the thermal layer. The
outer woven shell layer contains spandex in at least a weft
direction for stretch and recovery in a width direction. The knit
construction of the inner thermal layer provides stretch in at
least a width direction, in harmony with the shell layer, and the
inner thermal layer has a raised surface facing inwardly, away from
the shell layer. The intermediate layer has controlled air
permeability, including zero air permeability.
[0021] United States Patent Application 20050115001 Horst,
Gerd-Hermann Jun. 2, 2005 for Protective cover for bedding or
bedding equipped with protective cover, teaches a bedding article
which includes a core and a flame-resistant protective cover
surrounding and enclosing the core.
[0022] United States Patent Application 20040060120 Murphy,
Harrison Robert; et al. Apr. 1, 2004 for Composite fire barrier and
thermal insulation fabric for mattresses and mattress foundations
teaches an open flame resistant article composed of filling
materials and a fire barrier fabric including a fire barrier layer
and a thermally insulating layer at least partially enclosing the
filling materials.
[0023] U.S. Pat. No. 6,823,548 issued to Murphy, et al. Nov. 30,
2004 and United States Patent Applications 20040060120 and
20040060119 for Composite fire barrier and thermal insulation
fabric for mattresses and mattress foundations teaches a composite
fire barrier fabric including a fire barrier layer and a thermally
insulating layer at least partially encloses the core of an open
flame resistant mattress. The fire barrier layer and thermally
insulating layer are composed of at least one flame-retardant
fiber, and not necessarily the same flame retardant fiber.
[0024] United States Patent Application 20070004302 filed by
McKinnon; et al. Jan. 4, 2007 for Flame resistant matelasse fabrics
utilizing spun and filament flame resistant yarns teaches the use
of a flame resistant (FR) three-layer double-knit fabric, also
known 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.
[0025] U.S. Pat. Nos. 6,782,590, 6,828,003, RE40,314, and RE41,574
and related United States Patent Applications 20030003264 and
20040083768 by Rock, et al. Aug. 31, 2004 for Velour fabric
articles having flame retardance and improved dynamic insulation
performance teach a velour fabric article consisting of a fabric
body having a technical face formed by a filament stitch yarn and a
technical back formed by a loop yarn. The filament stitch yarn
includes a heat sensitive material, e.g. a hot melt material or a
heat shrinkable material, and/or an elastomeric material, such as
spandex. The loop yarn includes flame retardant material, such as
M-Aramide fiber. The fabric body has a velour surface formed at one
or both of the technical back and the technical face. Raised fibers
of at least one of the technical face and the technical back may be
entangled, including in and/or through interstices of the fabric
body, toward the other of the technical face and the technical
back, e.g., by a hydroentanglement process applied after finishing.
The fabric body has permeability of about 90 ft.sup.3/ft.sup.2/min,
or less, under a pressure difference of 1/2 inch of water across
the fabric body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a photograph of a sinker according to the present
invention.
[0027] FIG. 2 is a photograph of a standard sinker overlaying a
sinker according to the present invention.
[0028] FIG. 3 is a photograph of a terry loop construction
according to the present invention.
[0029] FIG. 4 is a photograph of circular terry knitting machine
according to the present invention.
[0030] FIG. 5 is a photograph of an enhanced knit fabric fire
bather according to the present invention.
[0031] FIG. 6 is a photograph of an enhanced knit fabric fire
bather according to the present invention after burning.
[0032] FIG. 7 is a photograph of the loop side of an enhanced knit
fabric fire bather according to the present invention.
[0033] FIG. 8 is a photograph of the loop side of an enhanced knit
fabric fire barrier according to the present invention after
burning.
[0034] FIG. 9 is a photograph of a side view of an enhanced knit
fabric fire barrier according to the present invention after
burning.
[0035] FIG. 10 shows a knitting sequence of fabric construction
[0036] FIG. 11 is a view of completed knitting repeat of fabric
construction.
DETAILED DESCRIPTION
[0037] Referring now to the drawings in general, the illustrations
are for the purpose of describing a preferred embodiment of the
invention and are not intended to limit the invention thereto.
[0038] The present invention provides knitted fabrics and more
specifically a fire barrier fabric used specifically for covering
mattresses and/or furniture that require passing a certified burn
test related to the product's use to ensure consumer or user safety
based upon regulations in the US. It is known to provide cushioning
materials like polyurethane foam and latex to provide a softer feel
for products, typically because the use of foam and latex allow
products to shape to the user's body for providing a more
comfortable and supportive feel. However, foam and latex are
inherently flammable due to their components. Thus, it is important
to design a fire barrier product that does not reduce the comfort
of the foam and latex, while not compromising on the safety factor
ensured by government standards or regulations. It is also
important to develop a stretchable product that shapes to the
user's body. Notably, if a non-stretchable product is used as a
barrier, then the bed does not shape to the user's body and only
deflects from the heaviest place on the user's body with respect to
the bed, and the balance of the bed is angled from this deflection.
So then, it would be beneficial to address shortcomings of the
prior art by providing a stretchable knit construction for a fire
barrier mattress and/or cover that enhances the shape, support and
feel of the bed yet also that passes the US regulation as set forth
in 16 CFR 1633 and the test described therein. The 16 CFR 1633 test
is difficult to pass when a mattress includes highly volatile latex
and foam, as in the prior art. All of the current stretchable knit
products do not provide for a positive pass of the 16 CFR 1633 test
because of the light weight of the products. Thus, the present
invention of a stretchable knit fabric that improves the barrier
performance during the 16 CFR 1633 test and allows the comfort of
foam and or latex to be enjoyed by a user is necessary, since it is
not provided to date.
[0039] The present invention provides for an enhanced knit fabric
fire barrier for mattresses, 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; thereby
providing a fire barrier for latex and highly volatile foams in
mattresses. In embodiments of the present invention, the very high
loops are between about 4 mm and about 8 mm. These very high loops
are preferably between about 5 mm and about 6 mm. More preferably,
the very high loops are between about 6 mm and about 8 mm.
[0040] The melting yarn is preferably nylon, polyester and
combinations thereof, although any melting yarn that can be used in
comfort fabrics can be used. Preferably, the melting yarn is
between about 5% and about 20% of the total fabric compositions.
More preferably, the melting yarn is about 10% of the total fabric
composition.
[0041] Typically, in prior art full Latex beds, there are 10-12
inches of Latex incorporated, which makes them highly flammable.
For these types of beds and similar ones, an enhanced barrier
according to the present invention is combined with multilayer
ticking fabric that is integrally knitted with a fire retardant
yarn to provide a fire barrier and fire and/or flame resistance.
Thus, the present invention provides a fire barrier for Latex,
Visco foam and other highly volatile foams. In embodiments
according to the present invention, a fabric cover is provided that
is knitted and that provides four-way stretch. It includes very
high loops as set forth in the foregoing that provide ventilation
during normal use and create fire-retardant blanket when they char,
similar to non-wovens. The melting yarn plugs char holes when it
melts, thus preventing air from feeding flame.
[0042] Furthermore, the present invention is directed to and
provides a fire barrier solution for Latex and highly volatile
foams that have previously not been able to be solved with a
knitted fabric cover. Specifically, a knitted fabric cover is
provided that has 4-way stretch and allows the mattress to fully
shape to the body of an individual in a bed having the knitted
fabric cover thereon. The knitted fabric cover of the present
invention by knitting a looped terry knitted fabric with a specific
fire retardant and resistant yarn on the jersey side of the fabric
that contains a fire resistant yarn or fiber like fiberglass,
aramid, carbon or any other fabric that is resistant to degrading
in the presences of fire. The looped terry side of the fabric
contains fire retardant fibers such as modacrylic, fire retardant
viscose rayon, treated fibers and other fibers that provide a
retardant effect in the presence of fire. By way of contrast to the
prior art and importantly according to the present invention, the
terry loop side of the fabric must be created with very high loops
creating in effect an intertwine of loops and fibers.
[0043] During a 16 CFR 1633 test, the fire resistant yarns on one
side of the fabric maintain the structure of the fabric, thus
keeping the fabric from opening up even as the flames have burned
into the barrier. Also, the loop side of the fabric has fire
retardant fibers; importantly, as these fibers burn during the
test, the fibers form a char layer creating a blanketing effect to
the barrier and blocking the fire from the highly volatile latex
and foam. This char blanket blocks the air from flowing out of the
latex and keeps the intensity of the flames very low. And,
surprisingly and importantly, it allows the product to pass the 16
CFR 1633 test. The 16 CFR 1633, and the 16 CFR 1633 test referred
to herein are hereby incorporated by reference in their entirety,
preferably for the version of the regulation in effect at the time
of the present invention filing date.
[0044] Notably, most terry loop machines known in the prior art
cannot make a loop high enough with sinkers provided by the
manufacturer to create a thick loop area that creates the blanket
affect when charred. To solve this problem, a special sinker was
developed to create a higher than normal loop. Most sinkers
provided with terry loop machines provide loops that are measured
in mm, with typical loop heights are from 1 mm to 3.5 mm. To create
a loop high enough to develop the intertwining of loops and fibers,
the sinkers were manufactured to create loops of 4 mm to 8 mm. In
the current embodiment, a sinker of 5 mm was specially designed. So
the present invention is further embodied as a product by process
using this specially designed sinker.
[0045] In one embodiment, the present invention is manufactured
using a circular single knit terry machine that was retrofitted to
allow it to knit a specially designed sinker, as set forth
hereinabove, and multiple yarns. The uniqueness of the fabric
created by this process with this sinker and multiple yarns on such
a machine is to create a loop height long enough to allow two
benefits to happen: one benefit of a longer loop means more yarn,
more fire retardant fiber in the yarn to be present in the fabric.
The competitive product, a non-woven, can lay additional fiber on
the non-woven at a lower manufacturing cost to add additional fire
retardant fiber, yet this continues to limit any opportunity of the
non-woven to stretch. In order for the invention fabric to have the
stretch, recovery and benefits of complimenting the flex and shape
ability of a latex mattress, a circular single knit terry machine
is used. A circular single knit has natural 4-way stretch. For the
invention according to the preferred embodiments, the terry loop
that is made on the circular single knit terry machine is increased
to provide additional fire retardant fiber. The second benefit of
the increased loop size is that after the fibers burn and retard
the growth of the flame, they create a thicker char layer of
fibers. The thicker layer of the charred fibers reduces the amount
of air flow allowed through the burned barrier. The reduction of
air flow by the charred fibers reduces the quick spreading and
increased heat generated from the burning mattress.
[0046] The present invention is manufactured using a circular
single knit terry machine, as shown in FIG. 4, wherein the standard
sinker heights (typical range from 1.2 mm-3.4 mm) are replaced with
a specially-manufactured 5.0 mm height sinker. Sinkers with heights
between about 4 mm and about 8 mm are also provided for in the
present invention. FIG. 1 shows the specially-designed sinker next
to a standard height sinker. The specially-designed sinker is a 5
mm high sinker. The standard height sinker is a 3.2 mm sinker. The
manufacturers of knitting elements do not offer a sinker higher
than 4.0 mm because knitting machines are not built to allow
sinkers greater than 4.0 mm. The 5.0 mm sinker is used to create
the extra length of the loop height. FIG. 2 shows the 3.2 mm sinker
overlaying the 5.0 mm sinker. It is important to specially design
the sinker so that it would not hit other parts of the knitting
elements. Reviewing FIGS. 1 and 2, the areas of the sinker that
make the jersey and the area of the sinker that make the loop are
illustrated. The area of the sinker to make the jersey part of the
fabric is identical between each sinker. In the special designed
sinker, it is shown how the height of the sinker was increased to
produce the higher loop. It is also important to design the sinker
to allow it to move around the machine and not hit the carriers.
The back side of the sinker was cut to an angle to allow this.
[0047] The carriers, which are guides to thread the yarns into the
correct positions, are also adjusted to allow these sinkers to
function. Due to the higher profile of the 5.0 mm sinker, the
carriers are modified such that they are positioned to guide the
yarns into the proper position, while not obstructing the movement
of the sinkers around the machine. Importantly, this repositioning
keeps the sinkers from hitting the carriers and breaking and
damaging the machine.
[0048] Once the machine is properly measured, indicated and set,
the yarns are threaded into the machine. As shown in FIG. 3, two
yarns are used on the jersey side of the fabric. One yarn has a
fiber that does not melt or burn, this could be a fiberglass fiber
or para-aramid or such. In the embodiment produced the yarn used
was a 1/99 fiberglass that was air jet spun with modacrylic FR
fibers wrapped around the modacrylic. Plaited with this yarn into
the jersey side of the fabric was a 1/70 polyester yarn. These two
yarns make up the flat jersey side of the fabric. The role and
function of the 1/70 polyester yarn is to support the fiberglass
yarn during the knitting process to reduce the chance of defects
like holes to be produced. The most important benefit of the
polyester yarn is to melt and mix with the charred modacrylic
fibers and coagulate and produce a simulated shield to block the
flame from reaching the latex or foam or more importantly reducing
the air flow.
[0049] The terry loop yarn is knitted into the same feeding
positions. In terry loop construction, the loop yarn knits with the
jersey stitches, but the terry machine causes the sinker loop of
just the terry yarn to be extended much longer than the sinker loop
of the jersey yarns. Based on the sinker height used, the terry
loop can be changed from very low (almost non-existent) to longer.
A sinker made to produce loops longer than 4.0 mm is not normal.
Part suppliers do not manufacture and inventory a sinker that
produces a very high loop height similar to a 5.0 sinker.
Preferably, the loop yarn is made from flame retardant fibers like
modacrylic, FR Rayon etc. This can be 100% FR fibers or a blend
with other fibers. In the example embodiment a blend of 75%
modacrylic and 25% cotton was used. The percent of FR fibers can be
increased or decreased based on the amount of fire retardant
needed. Also, in another example embodiment includes an additional
fiber that will burn and melt into the blend, such as polyester or
nylon. The percentage is low, such that the thermoplastic fiber
does not drip and add much fuel to the flame. The benefit of the
melting fiber would be to mix with the charred fibers and produce a
shield barrier.
[0050] These large loops intertwining together create an effect
similar to non-woven solutions, as shown in FIGS. 5 and 7. The
invention specifically was created to simulate a non-wovens effect,
yet with a knitted fabric that stretched and recovered. In
addition, the fabric must not fall apart when burned; so then fire
resistant fibers are used. Also, these intertwined high loops
create a blanketing effect that block flames and reduces air flow
when the fibers become charred and mix with the melted polyester
fiber, as shown in FIGS. 6, 8 and 9.
[0051] Another benefit of the enhanced knit fabric barrier is that
in addition to stretching and recovering, the fabric allows air to
flow through it, having adequate permeability to ensure comfort and
breathability of the fabric, as well as insulation. Latex and visco
foam beds best provide a cooling or warming sensation when air is
allowed to flow through the channels in the Latex or foam and
consequently, the barrier and ticking fabric needs to permit air
flow. A knit fabric allows air to flow through it when it is in its
natural unburned state. These factors have provided a longstanding
and unmet need in the art for a knitted barrier fabric, as opposed
to a non-woven barrier.
[0052] Another aspect of the invention is to include a small amount
of a fiber that melts during the testing of the 16 CFR 1633 burn
test. This fiber melts during the burning of the bed, and it is
then absorbed into the charring fibers, thereby plugging holes in
them and creating a more significant barrier between the fire and
the volatile latex or visco foam. This barrier reduces the air flow
into and out of the latex or foam and significantly reduces the
heat release and chimney effect of the burning bed. Polyester,
nylon, and similar fibers and combinations thereof are used for
this purpose.
[0053] The melting fiber can either be included in the jersey side
or the loop side or both. It can be knitted in with the fire
resistant yarn, twisted in the fire resistant yarn, and/or blended
in the fire retardant yarn. It is important to minimize the amount
of this fiber because it is also fuel for the flame. Therefore the
amount should be between 5% and 20% of the total fabric
compositions, more specifically approximately 10% of the present
embodiment.
[0054] The enhanced knit fabric barrier according to the present
invention can be used to allow partially Latex and Visco Foam beds
to pass the 16 CFR 1633 test. Because there is between 2-4 inches
of the Latex or volatile foam on the top of the beds as opposed to
10-12 inches of Latex in a full Latex bed, the Barrier can be used
over the core without any other knitted ticking fabric.
[0055] In full-Latex or full-foam beds of 10-12 inches of latex or
foam, it becomes necessary to use a multilayer ticking fabric that
is integrally knitted with a fire retardant yarn. An example
ticking is shown in US Patent Application 20090149101 for Fire
barrier fabric for use with articles, which is incorporated herein
by reference in its entirety.
[0056] The combination of the Enhanced Barrier and the multilayer
ticking fabric that is integrally knitted with a fire retardant
yarn provides enough protection to allow the most extreme test of
mattresses to pass the 16 CFR 1633 test.
[0057] In evaluating embodiments of the present invention, testing
of a bed with 10 inches of Latex and 2 inches of polyurethane
mattress core was performed. The testing included a 3-trial test of
beds made with the enhanced knit barrier according to the present
invention and a TioTec.RTM. multilayer ticking fabric that is
integrally knitted with a fire retardant yarn. The testing outcomes
provided that the embodiments of the present invention had passing
results three (3) consecutive times.
[0058] For the 16 CFR 1633 as of the date of the present invention,
which is incorporated herein by reference in its entirety for the
version as of this date of filing, the Heat Release rate must not
exceed 200 kW and the Total Heat Release in the first 10 minutes
must be less than 15 MJ. Surprisingly, the Heat Release rate
results were 81, 64, and 68 kW, well below the allowable maximum of
200 kW. Also surprisingly, the total Heat Release in the First 10
minutes results were 7.2, 6.3, and 3.0 MJ. Again, this is well
below the allowable maximum of 15 MJ. These results show the
enhanced performance of the present invention.
[0059] Thus, a fire barrier knit fabric with non-woven properties
according to the present invention includes 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.
[0060] The loops may be between about 5 mm and about 6 mm or
between about 6 mm and about 8 mm. The melting yarn includes nylon,
polyester and combinations thereof. The fabric of claim 1, 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.
[0061] A fire-resistant mattress according to the present invention
includes a mattress enclosed by a knit fabric fire barrier, the
knit fabric fire barrier including 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. The mattress may be full-foam,
full-latex and latex-foam mattresses.
[0062] A method for making a knit fabric fire barrier according to
the present invention includes the steps of: providing a circular
single knit terry machine having a 5.0 mm 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.
[0063] Double-Knit Fabric
[0064] Double-knit fabric structures are also considered within the
scope of the present invention and provided as embodiments herein.
As illustrated in the figures, specifically FIGS. 10 and 11, for
Feed 2 on the dial side of the 3-dimensional double knit, the same
yarn that is used in the ticking with the integrated barrier can be
used. Knitting this yarn to the outside of the 3-dimensional double
knit creates the same effect of a terry fabric layered with another
layer of a fire barrier or also with a ticking with an integrated
barrier. The amount of fire retardant materials is equal and an
insulating space in the middle of the 3-dimensional double knit is
provided that equals the space created with the ticking with
integrated fire barrier lays on top of the terry knit.
[0065] Much of the mattress market prefers to develop solutions
such that a ticking fabric without an integrated fire barrier can
be used, so it was determined that a need to invent a enhanced fire
barrier fabric that would have enough protection that the enhanced
barrier alone could be used along with a normal ticking fabric that
did not have a integrated fire barrier component. Thus, the present
invention also provides for an enhanced knit fabric fire barrier
for mattresses comprising of a 3-dimensional double knit fabric.
During testing of other fire barrier fabrics utilizing a
single-knit terry fire barrier fabric, it was determined that along
with the terry fabric, another layer of fire barrier or a ticking
fabric with an integrated fire barrier would improve performance in
the 16 CFR 1633 test.
[0066] The present invention provides for a fire barrier for latex,
visco foam and other highly volatile foams. The present invention
provides for one fabric that is a cover for the mattress core that
is knitted and provides four-way stretch. The 3-dimensional double
knit provides for ventilation of the mattress through the fire
barrier into and out of the mattress core. This ventilation
provides comfort to the sleeping surface during normal use yet
creates a fire retardant blanket when the burned, charring and the
melting yarn plugs the holes with the charred fibers and preventing
air from feeding the flame.
[0067] The present invention is directed to and provides for an
enhanced fire barrier solution for latex and highly volatile foams
that have previously not been able to be solved with a knitted
fabric cover. Specifically a knitted fabric cover that has 4-way
stretch and allows the mattress to fully shape to the body of the
individual in the bed. The invention was developed by knitting a
3-dimensional double knit fabric with a specific fire retardant and
resistant yarn on the outsides of the fabric that contains a fire
resistant yarn or fiber like fiberglass, aramid, carbon or any
other yarn or fiber that is resistant to degrading in the presence
of fire. These yarns may also contain fire retardant fibers such as
modacrylic, fire retardant viscose rayon, treated fire retardant
fibers and other fibers that provide a retardant effect in the
presence of fire.
[0068] The middle of the 3-dimensional double knit enhanced bather
can be made of different fibers to provide different levels of
protection. In one embodiment yarns blending modacrylic and cotton
were used that provided a lower level of performance. In another
embodiment yarns blended of modacrylic and fiberglass were used to
provide a higher level of performance. Any fibers can be used, both
fire retardant and normal cellulosic fibers like but not limited to
cotton, rayon, hemp, bamboo, that burn and char, or they can be
blended with other fibers that provide fire retardant and fire
resistant properties and can be used in the middle of the
3-dimensional double knit. This includes and is not limited to
modacrylic, fire retardant viscose rayon, fiberglass, aramid,
carbon, treated fibers and all other fibers that provide retardant
and resistance in the presence of fire.
[0069] In the present invention of the 3-dimensional double knit
enhance fire barrier, a terry fabric including the melting yarn is
knit and combined with a layer of additional fire retardant yarn
that creates the same effect as layering the terry fabric
underneath a ticking fabric with a integrated fire barrier
component.
[0070] As shown in FIGS. 10 and 11, for Feed 1 on the bottom layer
of the 3-dimensional double knit, a fire retardant yarn and a
melting yarn are knit on the cylinder side of the double knit
machine. The melting yarn is preferably nylon, polyester or
combinations thereof, although any melting yarn that can be used in
comfort fabrics can be used. Preferably, the melting yarn is
between 1% and 15% of the fabric composition. More preferably the
melting yarn is about 4% of the total fabric composition. This
combination of yarns provides for the melting yarn to mix with the
charred fibers of the fire retardant yarn and plug the holes of the
knit structure.
[0071] As shown in FIGS. 10 and 11, for Feed 3 in the middle of the
3-dimensional double knit, fire retardant yarns are used to assist
in retarding the growth of the fire and create an area of
insulation between the outside and the volatile latex or foam core.
These yarns are knit in a pattern that creates the same effect of
the terry fabric. The yarns are tucked between the cylinder of the
machine and the dial and create loops that are tied to both the
cylinder side of the fabric and the dial side of the fabric. These
tucks/loops hold the dial side of the fabric away from the cylinder
side, creating a space between the fabrics. This design simulates
the same effect created when the terry fabric was used with the
integrated fire barrier ticking fabric. The distance from the
cylinder side of the fabric to the dial side of the fabric is the
tuck stitch setting, which is adjustable by raising or lowering
parts of the knitting machine to create different tuck stitch
heights and thus different thicknesses of fabric. The thickness of
the fabric is thus determined by the tuck stitch setting, which is
the distance from the cylinder side to the dial side of the fabric.
The greater the tuck stitch setting, the greater the tuck stitch
height and thus the better the fire retardant/resistant protection
provided. The tuck stitch setting is preferably set such that the
tuck stitches are between about 2 and about 8 mm. More preferably,
the tuck stitch setting is such that a tuck stitch height of
between about 6 mm and about 8 mm is produced. Even more
preferably, the tuck stitch setting is such that a tuck stitch
height of about 8 mm is produced.
[0072] The important result of this invention is that a single
fabric is created that performs to pass the 16 CFR 1633 and allows
the manufacturer to use any ticking fabric, and not require one
with an integrated barrier.
[0073] In addition to the ability to use any ticking fabric the
present invention also allow for the ease of installing one fabric
that stretches and recovers to benefit the comfort of latex or
foam.
[0074] During a 16 CFR 1633 test, the fire resistant yarns on both
sides of the 3-dimensional double knit maintained the structure of
the fabric keeping the fabric from opening up even as the flames
have burned into the bather.
[0075] As the fire retardant fibers burn and char they mix with the
melting yarn and create a blanket reducing the exposure to the
highly volatile latex or foam core. This char blanket blocks the
air from flowing out of the latex and keeps the intensity of the
flames very low. This allows the product to pass the 16 CFR 1633
test.
[0076] Certain modifications and improvements will occur to those
skilled in the art upon a reading of the foregoing description. The
above-mentioned examples are provided to serve the purpose of
clarifying the aspects of the invention and it will be apparent to
one skilled in the art that they do not serve to limit the scope of
the invention. All modifications and improvements have been deleted
herein for the sake of conciseness and readability but are properly
within the scope of the present invention.
* * * * *