Fire retardant mattress core cap and method of making same
A fabric made by the method of providing a non-woven batt having flame retardant fibers, stitch bonding the non-woven batt with an elastic yarn, and heat setting the stitch bonded, non-woven batt. The stich bonded non-woven batt is exposed to a temperature in a range of 65° C. to 200° C. for a period in a range of 30 seconds to 120 seconds. In an embodiment, the fabric is adapted for use as a mattress core cover
1. A method for making a fabric, comprising the steps of:
providing a non-woven batt having flame retardant fibers;
stitch bonding the non-woven batt with an elastic yarn;
heat treating the stitch bonded, non-woven batt and contracting the elastic yarn and the non-woven batt by exposing the stich bonded non-woven batt to a temperature in a range of 160° C. to 200° C. for a time period in a range of 30 seconds to 120 seconds.
2. The method of claim 1 , wherein the flame retardant fibers include flame retardant rayon.
3. The method of claim 1 , wherein the flame retardant fibers include polyaramids.
4. The method of claim 3 , wherein the flame retardant fibers are a blend of inherently flame retardant cellulosic fibers and polyaramid fibers.
5. The method of claim 4 , wherein the blend of inherently flame retardant cellulosic fibers and polyaramid fibers are in a range of 1% to 30% by weight of the total weight of the non-woven batt.
6. The method of claim 4 , wherein the flame retardant fibers include polyester fibers.
7. The method of claim 6 , wherein the polyester fibers are in a range of 1% to 20% of the total weight of the non-woven batt.
8. The method of claim 6 , wherein the flame retardant fibers include modacrylic fibers.
9. The method of claim 8 , wherein the modacrylic fibers are in a range of 1% to 50% of the total weight of the non-woven batt.
10. The method of claim 1 , wherein the density of the flame retardant fibers of the non-woven batt is in a range of 1.5 denier to 7 denier.
11. The method of claim 1 , wherein the non-woven batt is from 60% to 90% by weight of a total weight of the fabric.
12. The method of claim 1 , wherein the elastic yarn includes filament polyester.
13. The method of claim 1 , wherein a density of the elastic yarn is in a range of 75 denier to 300 denier.
14. The method of claim 11 , wherein the elastic yarn is from 10% to 40% by weight of the total weight of the fabric.
15. The method of claim 1 , wherein the step of stitch bonding the non-woven batt includes creating stitches with the elastic yarn, and wherein the spacing of the stiches is in a range from 10 yarns/inch to 28 yarns/inch.
16. The method of claim 1 , wherein the weight of the fabric is in a range of 50 grams per square meter (gsm) to 400 grams per square meter (gsm).
17. The method of claim 1 , further comprising the step of coating the heat set, stitch bonded, non-woven fabric with a coating.
18. The method of claim 17 , wherein the coating includes a nanoclay.