Fire resistant fabric composite, process for fire-blocking a mattress and mattress set, and a mattress and mattress set fire-blocked thereby

A mattress resistant to an open flame comprising a fabric composite containing in order:

• (a) sacrificial outer ticking,
• (b) sacrificial cushioning material, and
• (c) fire-blocking fabric,
• the fire-blocking fabric being a single layer of nonwoven fabric comprising at least 0.5 ounces per square yard (17 grams per square meter) of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air to 700 C at a rate of 20 degrees C. per minute, and at least 0.5 ounces per square yarn (17 grams per square meter) of a heat-resistant fiber.
• with the provisos:
• (i) only a single layer is employed in the fireblocking fabric of (c) and
• (ii) only a single layer of fabric is employed for fireblocking the mattress.

A mattress set resistant to an open flame comprising a mattress and a mattress foundation:

• the mattress comprising a fabric composite and a mattress core, the fabric composite comprising in order:
• (a) sacrificial outer ticking,
• (b) sacrificial cushioning material, and
• (c) a single layer nonwoven fire-blocking fabric,
• the mattress foundation comprising a single layer nonwoven fire-blocking fabric and a support structure,
• wherein the mattress set has a peak heat release rate of less than 150 kilowatts within 30 minutes and a total heat release of less than 25 megajoules in the first 10 minutes when tested according to Technical Bulletin 603 of the State of California.
• with the provisos:
• (iii) only a single layer is employed in the fireblocking fabric of (c) and
• (iv) only a single layer of fabric is employed for fireblocking the mattress.

A process for fire-blocking a mattress while retaining the aesthetics of the mattress cushioning material, the mattress having, in order, ticking, cushioning material, and a mattress core, the process comprising:

• (a) incorporating into the mattress a fire-blocking fabric between the cushioning material and the mattress core,
• (b) the fire-blocking fabric being a single layer of nonwoven fabric comprising at least 0.5 ounce per square yard (17 grams per square meter) of a cellulose fiber that retains at least 10 percent of its fiber weight when heated in air to 700 C at a rate of 20 degrees C. per minute and at least 0.5 ounces per square yard (17 grams per square meter) of a heat-resistant fiber.
• with the provisos:
• (v) only a single layer is employed in the fireblocking fabric set forth in (a) and (b) and
• (vi) only a single layer of fabric is employed for fireblocking the mattress.