Mattress with flame barrier cap and related method

A mattress comprising:

• a resilient foam core;
• and a flame barrier cap disposed over the core, wherein the flame barrier cap comprises a top panel of flame resistant fabric disposed in overlying relation to a substantially planar upper surface of the core, the flame barrier cap further comprising a stitch-bonded flame resistant skirting disposed in overlying relation to sides of the core perpendicular to the upper surface, wherein the skirting comprises at least one length of stitch-bonded fabric including a first plurality of elastomeric stitching yarns disposed in stitched relation through a flame retardant fleece substrate in a plurality of substantially parallel adjacent stitch lines running in a machine direction of the stitch-bonded fabric wherein the fleece substrate comprises a blend of flame retardant fibers comprising flame retardant silica rayon fiber, and wherein the skirting further comprises a gripping power zone extending inboard from a distal free edge of the skirting adapted to grip the underside of the core, and an attachment zone disposed along a proximal edge of the skirting fabric adjacent the top panel, at least one of the gripping power zone and the attachment zone comprising the first plurality of elastomeric stitching yarns in a chain stitch pattern in combination with at least a second plurality of elastomeric stitching yarns having a linear density greater than the first plurality of elastomeric stitching yarns and wherein the second plurality of elastomeric stitching yarns are stitched along common stitch lines with the first plurality of elastomeric stitching yarns, the second plurality of elastomeric stitching yarns being stitched in a pattern with elongated float segments having a length in the range of 0.24 to 1 inch between stitches within the stitch lines.