Flame 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 stitch bonded non-woven batt is exposed to a temperature in a range of 160° 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 fabric, comprising
a contracted by heat-setting non-woven batt having flame retardant fibers
wherein the flame retardant fibers are selected from the group consisting of flame retardant rayon, polyaramids, a blend of inherently flame retardant cellulosic fibers and polyaramid fibers in a range of 1% to 30% by weight of a total weight of the non-woven batt, polyester fibers in a range of 1% to 20% by weight of a total weight of the non-woven batt, and modacrylic fibers in a range of 1% to 50% by weight of a total weight of the non-woven batt,
wherein the density of the flame retardant fibers is 1.5 denier to 7 denier,
wherein the non-woven batt is 60% to 90% by weight of a total weight of the fabric; and
a contracted by heat-setting elastic yarn stitch bonded to the non-woven batt,
wherein the elastic yarn includes filament polyester,
wherein a density of the elastic yarn is 75 denier to 100 denier,
wherein the elastic yarn is 10% to 40% by weight of the total weight of the fabric,
wherein the fabric includes stitches of the elastic yarn, and wherein spacing of the stiches is 15 yarns/inch to 28 yarns/inch, and
wherein the weight of the fabric is 300 grams per square meter (gsm) to 400 grams per square meter (gsm).
2. The fabric of claim 1 , further comprising a coating.
3. The fabric of claim 2 , wherein the coating includes a nanoclay.
4. The fabric of claim 1 , wherein the fabric is adapted for constructing a mattress core cover.
5. The fabric of claim 1 , wherein the fabric is stretchable and resilient in a machine direction of the fabric and a cross direction of the fabric.