Heat and flame-resistant materials and upholstered articles incorporating same

An upholstered article, comprising:

• a core;
• and
• barrier material completely surrounding the core that is configured to prevent combustion of the core in accordance with testing protocol set forth in Technical Bulletins 603, 117, and/or 129 of the State of California Department of Consumer Affairs (TB-603, TB-117, TB-129), wherein the barrier material comprises:
• flame and heat-resistant material comprising cellulosic fibers and having a basis weight of less than or equal to about 9 ounces per square yard, wherein the flame and heat-resistant material is configured to prevent combustion of the core when the upholstered article is impinged with a gas flame;
• and
• intumescent material applied as a liquid and dried and that is configured to swell and char in the presence of a flame so as to form a barrier to the flame and to heat generated by the flame, wherein the intumescent material is selected from the group consisting of melamine, pentaerythritol, vermiculite, fluorocarbon, graphite, bentonite, clay, phosphated melamine, borated melamine, sugars, and polyols;
• wherein the barrier material has a char strength of greater than or equal to 2 Newtons, and wherein a temperature on one side of the barrier material is prevented from reaching and exceeding 350° C. after about 50 seconds of flame exposure on an opposite side of the barrier material.

An upholstered article, comprising:

• a core;
• and
• barrier material completely surrounding the core that is configured to prevent combustion of the core in accordance with testing protocol set forth in Technical Bulletins 603, 117, and/or 129 of The State of California Department of Consumer Affairs (TB-603, TB-117, TB-129), wherein the barrier material comprises:
• flame and heat-resistant material comprising cellulosie fibers and having a basis weight of less than or equal to about 9 ounces per square yard, wherein the flame and heat-resistant material is configured to prevent combustion of the core when the upholstered article is impinged with a gas flame;
• and
• intumescent material applied as a liquid and dried and that is configured to swell and char in the presence of a flame so as to form a barrier to the flame and to heat generated by the flame, wherein the intumescent material comprises polymer binder and graphite treated with acid so as to expand at least about 10 times an original volume of the graphite;
• wherein the barrier material has a char strength of greater than or equal to 2 Newtons, and wherein a temperature on one side of the barrier material is prevented from reaching and exceeding 350° C. after about 50 seconds of flame exposure on an opposite side of the barrier material.