FIRE RETARDANT MATTRESS CORE COVERING

FIELD OF THE INVENTION

The present invention relates generally to flame retardant fabrics used in bedding and sleep products, such as mattresses, and, more specifically, to stretchable and resilient, thermally-insulating covers for mattress cores.

BACKGROUND OF THE INVENTION

Each year, thousands of residential fires are caused in the United States by the ignition of mattresses and bedding, resulting in hundreds of deaths and hundreds of millions of dollars in property losses. Heightened awareness of fire prevention has led to the development of standards and regulations directed to reducing the likelihood that such fires will occur. One approach to reducing the likelihood of residential fires is to use flame-resistant fabrics as flame barriers in mattresses and bedding.

One type of conventional mattress comprises a foam core covered with a fire barrier fabric. Fiberglass core-spun yarns are often used in such fabrics, since they have good fire barrier properties. However, the yarns provide poor thermal insulation, and may permit the foam core to spontaneously ignite without being contacted by a flame. This poses a significant hazard to the public, since the commercial trend is to make mattresses with latex foams for comfort. Such foams can spontaneously ignite at temperatures as low as 450° F. Further, the glass fibers can cause skin irritation and itching, and broken fibers may present an inhalation hazard.

SUMMARY OF THE INVENTION

In an embodiment, a mattress core cap according to the present invention includes a flame-retardant thermally-insulating knitted fabric that is stretchable and resilient. In an embodiment, a mattress core covering according to the present invention is pre-formed to fit closely to the top, sides, and corners of a mattress core. In an embodiment, a mattress core covering according to the present invention is pre-formed to be applied to the top of a mattress core and pulled downward along the sides and corners of the mattress core, the mattress core covering having an elastic piping along its edges to retain the mattress core covering around the mattress core. In an embodiment, the fabric of the mattress core covering according to the present invention stretches to conform to the shape of the foam core as the core is compressed and relaxes in response to the sleeper's movements.

In one embodiment, optionally in combination with any embodiment described above or below, the present invention is a fitted mattress core covering comprising: (i) a non-woven fabric comprising a plurality of flame-retardant fibers; wherein the non-woven fabric is substantially free of fiberglass; and (ii) elastic piping located along an edge of the non-woven fabric; wherein the fitted mattress core covering is configured to fit over a mattress core such that the elastic piping extends underneath the mattress core when the fitted mattress core covering fits over the mattress core.

In another embodiment, optionally in combination with any embodiment described above or below, the non-woven fabric is free of fiberglass.

In another embodiment, optionally in combination with any embodiment described above or below, the flame-retardant fibers comprise at least one of cellulosic fiber incorporated with silica, cellulosic fiber incorporated with at least one flame-retardant chemical, polyaramids, elastanes, or polyesters.

In another embodiment, optionally in combination with any embodiment described above or below, the non-woven fabric further comprises elastic fibers.

In another embodiment, optionally in combination with any embodiment described above or below, the elastic fibers comprise at least one of polyurethanes or elastanes.

In another embodiment, optionally in combination with any embodiment described above or below, the flame-retardant fibers are present in 100% of the non-woven fabric.

In another embodiment, optionally in combination with any embodiment described above or below, the density of the flame-retardant fibers is 1.5 denier to 7 denier.

In another embodiment, optionally in combination with any embodiment described above or below, the weight of the flame-retardant fibers in the non-woven fabric is 2 ounces per square yard to 12 ounces per square yard.

In another embodiment, optionally in combination with any embodiment described above or below, the weight of the non-woven fabric is 50 grams per square meter to 300 grams per square meter.

In another embodiment, optionally in combination with any embodiment described above or below, the weight of the non-woven fabric is 100 grams per square meter to 200 grams per square meter.

In another embodiment, optionally in combination with any embodiment described above or below, the non-woven fabric further comprises a coating; wherein the coating comprises at least one of nanoclay or graphite.

In another embodiment, optionally in combination with any embodiment described above or below, the present invention is a fitted mattress core covering comprising: (i) a non-woven fabric comprising a plurality of flame-retardant fibers and a plurality of non-flame retardant fibers; wherein the non-woven fabric is substantially free of fiberglass; and (ii) elastic piping located along an edge of the non-woven fabric; wherein the fitted mattress core covering is configured to fit over a mattress core such that the elastic piping extends underneath the mattress core when the fitted mattress core covering fits over the mattress core.

In another embodiment, optionally in combination with any embodiment described above or below, the flame-retardant fibers comprise at least one of polyurethanes or elastanes.

In another embodiment, optionally in combination with any embodiment described above or below, the non-flame retardant fibers comprise at least one of cotton, bamboo, wool, cashmere, or silk.

In another embodiment, optionally in combination with any embodiment described above or below, the flame retardant fibers comprise 0.1% to 30% of polaramid fibers, based on a total weight of the flame retardant fibers and the non-flame retardant fibers.

In another embodiment, optionally in combination with any embodiment described above or below, the non-woven fabric is substantially free of thermoplastic and latex.

In another embodiment, optionally in combination with any embodiment described above or below, the present invention is a fitted mattress core covering comprising: (i) a stitch-bonded non-woven fabric comprising a plurality of flame-retardant fibers; wherein the stitch-bonded non-woven fabric is substantially free of fiberglass; and (ii) elastic piping located along an edge of the stitch-bonded non-woven fabric; wherein the fitted mattress core covering is configured to fit over a mattress core such that the elastic piping extends underneath the mattress core when the fitted mattress core covering fits over the mattress core.

In another embodiment, optionally in combination with any embodiment described above or below, the weight of the stitch-bonded non-woven fabric is 50 grams per square meter to 300 grams per square meter.

In another embodiment, optionally in combination with any embodiment described above or below, non-woven fibers comprise 70% to 80% of a total weight of the stitch-bonded non-woven fabric and yarn comprises 20% to 30% of the total weight of the stitch-bonded non-woven fabric.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings, which are presented for the purpose of illustration rather than being drawn to scale, and in which:

FIG. 1 is a cross-sectional view of a mattress including a mattress core covering fit over a mattress core according to an embodiment of the present invention;

FIG. 2 is a schematic orthogonal view of the mattress core of FIG. 1, with hidden edges of the mattress core shown in dashed lines;

FIG. 3 is a schematic top view of a sheet of fabric that is to be shaped into the mattress core covering of FIG. 1 to cover the mattress core of FIG. 1;

FIG. 4 is a schematic orthogonal view of the mattress core covering of FIG. 1 during a step of fitting the mattress core covering over the foam mattress core of FIG. 1, with hidden edges of the mattress core shown in dashed lines;

FIG. 5 is a schematic orthogonal view of the mattress core covering of FIG. 1 illustrating the mechanism of fitting the mattress core covering over the foam mattress core of FIG. 1, with hidden edges of the mattress core shown in dashed lines;

FIG. 6 is a schematic orthogonal view of the mattress core covering of FIG. 1 fitted to the mattress core of FIG. 1, with hidden edges of the mattress core and hidden features of the mattress core covering shown in dashed lines; and

FIG. 7 is a schematic bottom view of the mattress core and the mattress core covering of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

The following disclosure is presented to provide an illustration of the general principles of the present invention and is not meant to limit, in any way, the inventive concepts contained herein. All terms defined herein should be afforded their broadest possible interpretation, including any implied meanings as dictated by a reading of the specification as well as any words that a person having skill in the art and/or a dictionary, treatise, or similar authority would assign thereto.

Further, it should be noted that, as recited herein, the singular forms “a”, “an”, and “the” include the plural referents unless otherwise stated. Additionally, the terms “comprises”, “comprising”, “includes”, “including”, “has” and the like, when used herein specify that certain features are present in that embodiment, however, this phrase should not be interpreted to preclude the presence or addition of additional steps, operations, features, components, and/or groups thereof.

As used herein, the phrase “substantially free of” means less than 3 weight % based on a total weight of the fabric. As used herein, the phrase “free of” means less than 1 weight % based on a total weight of the fabric.

Unless otherwise specified, the term “%” corresponds to weight percent based on a total weight of the fabric.

In an exemplary embodiment, a mattress core covering according to the present invention includes a flame-retardant, thermally-insulating non-woven fabric that is stretchable and resilient. In another exemplary embodiment, a mattress core covering according to the present invention includes a flame-retardant, thermally-insulating knitted fabric that is stretchable and resilient. Exemplary embodiments of the non-woven fabric and knitted fabric are substantially free of or free of fiberglass or other components that fragment to form irritating or toxic particles.

Exemplary non-woven fabrics and knitted fabrics suitable for making a mattress core covering according to the present invention include flame-retardant fibers. Examples of suitable flame-retardant fibers include inherently flame-retardant cellulosic fibers, such as rayon with incorporated silica, cellulosic fibers with incorporated flame-retardant chemicals (e.g., phosphorous compounds), polyaramids (e.g., NOMEX® or KEVLAR®), elastanes (e.g., SPANDEX®, LYCRA®), and polyesters. In an embodiment, the exemplary non-woven fabric includes fibers made of elastic materials (e.g., polyurethanes or other elastanes). In an embodiment, the exemplary non-woven fabric includes crimped or textured fibers, such that the fibers are stretchable even if the fiber material is not elastic.

In some exemplary embodiments of the non-woven and knitted fabrics, 100% of the fibers are inherently flame-retardant cellulosic fibers. In other exemplary embodiments, the fabric is a blend of inherently flame-retardant cellulosic fibers with other flame-retardant and/or non-flame retardant fibers. In exemplary embodiments, the fabric is a blend of 5% to 95% inherently flame-retardant cellulosic fibers and 95% to 5% other flame-retardant and/or non-flame retardant fibers. In exemplary embodiments, the fabric is a blend of 15% to 85% inherently flame-retardant cellulosic fibers and 85% to 15% other flame-retardant and/or non-flame retardant fibers. In exemplary embodiments, the fabric is a blend of 25% to 75% inherently flame-retardant cellulosic fibers and 75% to 25% other flame-retardant and/or non-flame retardant fibers. In exemplary embodiments, the fabric is a blend of 35% to 65% inherently flame-retardant cellulosic fibers and 65% to 35% other flame-retardant and/or non-flame retardant fibers. In exemplary embodiments, the fabric is a blend of 45% to 55% inherently flame-retardant cellulosic fibers and 55% to 45% other flame-retardant and/or non-flame retardant fibers. In exemplary embodiments, the fabric is a blend of about 50% inherently flame-retardant cellulosic fibers and about 50% other flame-retardant and/or non-flame retardant fibers.

Exemplary blends include inherently flame-retardant cellulosic fibers with one or more of the following fiber types: polyaramids, polyesters, polyurethanes or other elastanes, acrylics, modacrylics, non-flame-retardant cellulosic fibers (e.g., cotton or bamboo), wool, cashmere, or silk. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyaramid fibers in the range of 0.1% to 30% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyaramid fibers in the range of 1% to 30% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyaramid fibers in the range of 10% to 30% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyaramid fibers in the range of 20% to 30% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyaramid fibers in the range of 0.1% to 20% of the total weight of the fibers. Further exemplary blends include inherently flame- retardant cellulosic fibers and one or more of polyaramid fibers in the range of 0.1% to 10% of the total weight of the fibers. In exemplary embodiments of the non-woven fabric and knitted fabric, the polyaramid fibers are present in the fabric at about 5% of the total weight of the fibers.

Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyester fibers in the range of 0.1% to 20% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyester fibers in the range of 1% to 20% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyester fibers in the range of 5% to 20% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyester fibers in the range of 10% to 20% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyester fibers in the range of 15% to 20% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyester fibers in the range of 0.1% to 15% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyester fibers in the range of 0.1% to 10% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyester fibers in the range of 0.1% to 5% of the total weight of the fibers.

Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of modacrylic fibers in the range of 10% to 50% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of modacrylic fibers in the range of 20% to 50% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of modacrylic fibers in the range of 30% to 50% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of modacrylic fibers in the range of 40% to 50% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of modacrylic fibers in the range of 0.1% to 40% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of modacrylic fibers in the range of 0.1% to 30% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of modacrylic fibers in the range of 0.1% to 20% of the total weight of the fibers. Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of modacrylic fibers in the range of 0.1% to 10% of the total weight of the fibers.

Further exemplary blends include inherently flame-retardant cellulosic fibers and one or more of polyaramid fibers in the range of 0.1% to 30% of the total weight of the fibers, one or more of polyester fibers in the range of 0.1° A to 20% of the total weight of the fibers, and one or more of modacrylic fibers in the range of 0.1% to 50% of the total weight of the fibers.

In exemplary embodiments of the non-woven fabric and knitted fabric, the materials of the fibers and blends are selected such that the fabric is both stretchable and resilient.

In exemplary embodiments, the aforementioned fibers and blends may be used in the non-woven fabric and in the yarns of the knitted fabric. In an exemplary embodiment, the non-woven fabric stretches in the machine direction (MD) of the fibers. In another exemplary embodiment, the non-woven fabric stretches in the machine direction of the fibers (MD) and in the cross-direction (CD). In an exemplary embodiment, the knitted fabric stretches in both the X and the Y directions.

In exemplary embodiments of the non-woven fabric, the weight of the fabric is in the range of 50 gram per square meter (gsm) to 300 gsm. In exemplary embodiments of the non-woven fabric, the weight of the fabric is in the range of 100 gsm to 300 gsm. In exemplary embodiments of the non-woven fabric, the weight of the fabric is in the range of 200 gsm to 300 gsm. In exemplary embodiments of the non-woven fabric, the weight of the fabric is in the range of 250 gsm to 300 gsm. In exemplary embodiments of the non-woven fabric, the weight of the fabric is in the range of 100 gsm to 250 gsm. In exemplary embodiments of the non-woven fabric, the weight of the fabric is in the range of 100 gsm to 200 gsm. In exemplary embodiments of the non-woven fabric, the weight of the fabric is in the range of 100 gsm to 150 gsm.

In exemplary embodiments of the non-woven fabric, the density of the fibers is in the range of 1.5 denier to 7 denier, and the weight of the fibers in the fabric is in the range of 2 ounces per square yard (osy) to 12 osy. In embodiments of the non-woven fabric, the density of the fibers is in the range of 3 denier to 7 denier. In embodiments of the non-woven fabric, the density of the fibers is in the range of 5 denier to 7 denier. In embodiments of the non-woven fabric, the density of the fibers is in the range of 1.5 denier to 5 denier. In embodiments of the non-woven fabric, the density of the fibers is in the range of 1.5 denier to 3 denier.

In yet other embodiments of the non-woven fabric, the weight of the fibers in the fabric is in the range of 4 osy to 12 osy. In yet other embodiments of the non-woven fabric, the weight of the fibers in the fabric is in the range of 6 osy to 12 osy. In yet other embodiments of the non-woven fabric, the weight of the fibers in the fabric is in the range of 8 osy to 12 osy. In yet other embodiments of the non-woven fabric, the weight of the fibers in the fabric is in the range of 10 osy to 12 osy. In yet other embodiments of the non-woven fabric, the weight of the fibers in the fabric is in the range of 2 osy to 10 osy. In yet other embodiments of the non-woven fabric, the weight of the fibers in the fabric is in the range of 2 osy to 8 osy. In yet other embodiments of the non-woven fabric, the weight of the fibers in the fabric is in the range of 2 osy to 6 osy. In yet other embodiments of the non-woven fabric, the weight of the fibers in the fabric is in the range of 2 osy to 4 osy.

In exemplary embodiments of the knitted fabric, densities of the yarns are in the range of 10 singles to 40 singles, and the weight of the yarns in the fabric is in the range of 2 osy to 12 osy. In yet other embodiments of the knitted fabric, the weight of the yarns in the fabric is in any of the weight ranges detailed above for the weight of the fibers in the fabric.

In an exemplary embodiment, the non-woven fabric is substantially free of or free of any binding materials, such as thermoplastics or latexes. In an exemplary embodiment, the fibers in the non-woven fabric are bonded by stitch-bonding or by needle-punching. In an exemplary stitch-bonded non-woven fabric, the yarn used to stitch-bond the fibers is a fire-retardant yarn that includes one or more of the fibers and blends described above. In exemplary embodiments, the spacing of the stitches in the stitch-bonded non-woven fabric is in the range of 12 yarns/inch to 28 yarns/inch. In exemplary embodiments, the spacing of the stitches in the stitch-bonded non-woven fabric is in the range of 18 yarns/inch to 28 yarns/inch. In exemplary embodiments, the spacing of the stitches in the stitch-bonded non-woven fabric is in the range of 20 yarns/inch to 28 yarns/inch. In exemplary embodiments, the spacing of the stitches in the stitch-bonded non-woven fabric is in the range of 12 yarns/inch to 24 yarns/inch. In exemplary embodiments, the spacing of the stitches in the stitch-bonded non-woven fabric is in the range of 12 yarns/inch to 18 yarns/inch. In exemplary embodiments, the spacing of the stitches in the stitch-bonded non-woven fabric is in the range of 16 yarns/inch to 20 yarns/inch. In an exemplary embodiment, the spacing of the stitches is about 18 yarns/inch.

In exemplary embodiments of the stitch-bonded non-woven fabric, the weight of the fabric is in the range of 50 gram per square meter (gsm) to 300 gsm, with the non-woven fibers accounting for about 70% to 80% of the total weight of the fabric, and the yarn used to stitch-bond the fabric accounting for about 20% to 30% of the total weight of the fabric. In exemplary embodiments of the stitch-bonded non-woven fabric, the weight of the fabric is in the range of 100 gsm to 300 gsm. In exemplary embodiments of the stitch-bonded non-woven fabric, the weight of the fabric is in the range of 200 gsm to 300 gsm. In exemplary embodiments of the stitch-bonded non-woven fabric, the weight of the fabric is in the range of 250 gsm to 300 gsm. In exemplary embodiments of the stitch-bonded non-woven fabric, the weight of the fabric is in the range of 100gsm to 250 gsm. In exemplary embodiments of the stitch-bonded non-woven fabric, the weight of the fabric is in the range of 100 gsm to 200 gsm. In exemplary embodiments of the stitch-bonded non-woven fabric, the weight of the fabric is in the range of 100 gsm to 150 gsm.

In other embodiments of the of the stitch-bonded non-woven fabric, the non-woven fibers accounting for about 60% to 90% of the total weight of the fabric and the yarn used to stitch-bond the fabric accounting for about 10% to 40% of the total weight of the fabric. In other embodiments of the of the stitch-bonded non-woven fabric, the non-woven fibers accounting for about 65% to 85% of the total weight of the fabric and the yarn used to stitch-bond the fabric accounting for about 15% to 35% of the total weight of the fabric. In other embodiments of the of the stitch-bonded non-woven fabric, the non-woven fibers accounting for about 75% to 85% of the total weight of the fabric and the yarn used to stitch-bond the fabric accounting for about 15% to 25% of the total weight of the fabric.

In an exemplary embodiment of the non-woven fabric, the fabric is a coated non-woven fabric (not shown), wherein the coating is applied to the fabric. In an exemplary embodiment of the coated non-woven fabric, the coating includes one or more flame-retardant chemicals. In an exemplary embodiment of the coated non-woven fabric, the coating includes a nanoclay. In an exemplary embodiment of the coated non-woven fabric, the coating includes graphite. In an exemplary embodiment of the present invention, the non-woven fabric does not have a coating; in other words, it is an uncoated fabric.

In an exemplary embodiment of the knitted fabric, the fabric is 100% yarn. In an exemplary embodiment of the knitted fabric, the fabric is a flat-knit fabric. In an exemplary embodiment of the knitted fabric, the fabric is a circular-knit fabric.

FIG. 1 is a cross-sectional view of a foam core mattress 30 according to an embodiment of the present invention. Referring to FIG. 1, the foam core mattress 30 includes a foam core 40, a mattress core covering 100, a ticking 200 over the cap 100, and a filler cloth 210 that completes the enclosure of the cap 100 and core 40. In an exemplary embodiment, the mattress core covering 100 includes a non-woven or knitted thermally-insulating, flame-retardant fabric 102 such as those discussed above, and an elastic piping 104 sewn to the fabric 102. In an exemplary embodiment, the mattress 30 does not include a filler cloth 210. In an exemplary embodiment, the mattress 30 does not include a filler cloth 210 or a mattress ticking 200.

In known methods of fabricating a cover for a foam core mattress, a sheet of flame-retardant fabric is fashioned into a tube or sock, and pulled over the foam core. The open ends of the tube or the open end of the sock are then sewn so that the fabric encloses the foam core. This method of applying the fabric to the foam core is labor-intensive and time-consuming because friction between the fabric and the surface of the foam core cause the fabric to resist being pulled across the surface of the core. A mattress core covering according to embodiments of the present invention allows the fabric to be quickly and easily applied to the foam core. An exemplary embodiment 100 of such a mattress core covering is described below.

FIG. 2 is a schematic orthogonal view of the mattress core 40 of FIG. 1, where hidden edges of the mattress core 40 are indicated by dashed lines. In the embodiment of FIG. 2, the mattress core 40 has a shape approximating that of a rectangular prism, although the mattress cores of other embodiments of the present invention may have other shapes. In an exemplary embodiment, the mattress core 40 is made of or includes a resilient foam. In an exemplary embodiment, the resilient foam is a polyurethane foam. In an exemplary embodiment, the resilient foam is a latex foam. In an exemplary embodiment, the resilient foam is a foam that conforms to the shape of a person lying on the mattress, and rebounds to its original shape when the weight of the person is removed from the mattress.

The mattress core 40 has a top (“sleeping”) surface 42, a bottom surface 44 opposite the top surface 42, a first end face 46, a second end face 48 opposite the first end face 46, a first side face 50, and a second side face 52 opposite the first side face 50. The top surface 42 is bounded by a first end edge 54, a second end edge 56 opposite the first end edge 54, a first side edge 58 extending from the first end edge 54 to the second end edge 56, and a second side edge 60 opposite the first side edge 58 and extending from the first end edge 54 to the second end edge 56. The bottom surface 44 is bounded by a third end edge 62 opposite the first end edge 54, a fourth end edge 64 opposite the second end edge 56, a third side edge 66 extending from the third end edge 62 to the fourth end edge 64, and a fourth side edge 68 opposite the third side edge 66 and extending from the third end edge 62 to the fourth end edge 64. The first end face 46 is bounded by the first end edge 54, the third end edge 62, a first corner edge 70 extending from the first end edge 54 to the third end edge 62, and a second corner edge 72 opposite the first corner edge 70 and extending from the first end edge 54 to the third end edge 62. The second end face 48 is bounded by the second end edge 56, the fourth end edge 64, a third corner edge 74 extending from the second end edge 56 to the fourth end edge 64, and a fourth corner edge 76 opposite the third corner edge 76 and extending from the second end edge 56 to the fourth end edge 64. The first side face 50 is bounded by the first side edge 58, the third side edge 66, the first corner edge 70, and the fourth corner edge 76. The second side face 52 is bounded by the second side edge 60, the fourth side edge 68, the second corner edge 72, and the third corner edge 74.

FIG. 3 is a schematic top view of the sheet of fabric 102 before it is shaped to form the mattress core covering 100. With reference to FIG. 3, in the illustrated embodiment, the sheet of fabric 102 is provided as a rectangular sheet 106, and the four corner pieces 108, 110, 112, 114, indicated by dashed lines, are cut away from the rectangular sheet 102 as part of the shaping of the mattress cover 100.

The rectangular sheet 106 of fabric 102 has a first edge 116, a second edge 118 opposite the first edge 116, a third edge 120 extending from the first edge 116 to the second edge 118, and a fourth edge 122 opposite the third edge 120 and extending from the first edge 116 to the second edge 118. The four corner pieces 108, 110, 112, 114 of the rectangular sheet 106 are cut away, leaving intersecting edges on the sheet 106 of fabric 102, as are described further herein. Cutting away corner piece 108 produces intersecting edges 124, 126, which intersect at point 128; cutting away corner piece 110 produces intersecting edges 130, 132, which intersect at point 134; cutting away corner piece 112 produces intersecting edges 136, 138, which intersect at point 140; and cutting away corner piece 114 produces intersecting edges 142, 144, which intersect at point 146. The lengths of the various intersecting edges referenced above are such that, if the sheet 106 were draped over the top surface 42 of the mattress core 40, the edges 116, 118, 120, 122 of the sheet 106 would extend beyond the bottom surface 44 of the mattress core 40 by a distance in the range of about 2-8 inches (i.e., the edges 116, 118, 120, 122 would be from 2-8 inches longer than the length of the corner edges 70, 72, 74, 76 of the mattress core 40).

Referring to FIGS. 3-7, in the shaping process, edge 124 is drawn to edge 126, and the edges 124, 126 are sewn to each other to create a first corner seam 148; edge 130 is drawn to edge 132, and the edges 130, 132 are sewn to each other to create a second corner seam 150; edge 136 is drawn to edge 138, and the edges 136, 138 are sewn to teach other to create a third corner seam 152; and edge 142 is drawn to edge 144, and the edges 142, 144 are sewn together to create a fourth corner seam 154. The corner seams 148, 150, 152, 154 are not shown in FIG. 3, but are shown in FIGS. 4-7. In an exemplary embodiment, the various intersecting edges referenced above are sewn as described above using a flame-retardant yarn or filament (not shown). In an embodiment, the yarn or filament includes one or more of the fire-retardant materials or blends described above with respect to the exemplary non-woven fabrics and knitted fabrics. In an embodiment, the yarn or filament includes a polyaramid.

Referring to FIGS. 1, 4, and 7, in an exemplary embodiment of the present invention, a continuous length of elastic piping 104 is sewn along the first edge 116, second edge 118, third edge 120, and fourth edge 122 of the sheet 106, subsequent to the creation of the corner seams 148, 150, 152, 154. In an exemplary embodiment, the piping 104 is sewn to form a closed loop of piping 104. In an exemplary embodiment, the piping is arranged to draw the first edge 116, second edge 118, third edge 120, and fourth edge 122 of the sheet 106 toward each other, yet is sufficiently elastic that it can be stretched to a circumference that allows the mattress cover cap 100 to be drawn over the top surface 42 of the mattress core 40. In an exemplary embodiment, the piping 104 is sewn to the sheet 106 of fabric 104 using a flame-retardant yarn or filament (not shown). In an exemplary embodiment, the yarn or filament includes one or more of the fire-retardant materials or blends described above with respect to the exemplary non-woven fabrics and knitted fabrics. In an exemplary embodiment, the yarn or filament includes a polyaramid.

FIG. 4 is a schematic orthogonal view of the exemplary mattress core covering 100 during a step of fitting the mattress core covering 100 over the foam mattress core 40 of FIG. 2. FIG. 5 is a schematic orthogonal view of the mattress core covering 100 of FIG. 4, illustrating a further step of fitting the mattress core covering over the foam mattress core 40, subsequent to the step illustrated in FIG. 4.

Referring to FIGS. 2 and 4, the exemplary mattress core covering 100 is applied to the top 42 of the mattress core 40 by approaching the mattress core 40 from above and stretching the piping 104 over the top surface 42, first end face 46, second end face 48, first side face 50, and second side face 52 of the mattress core 40. The first seam 148, second seam 150, third seam 152, and fourth seam 154 are roughly aligned respectively with the first corner edge 70, the second corner edge 72, the third corner edge 74, and the fourth corner edge 76 of the mattress core 40. Referring to FIG. 5, the piping 104 is then pulled below the bottom surface 44 of the mattress core 40. The resilience of the piping 104 causes it to contract and pull the first edge 116, second edge 118, third edge 120, and fourth edge 122 toward each other. As a result of the contraction of the piping 104, the mattress core covering 100 is pulled into a close fit with all of the faces 42, 44, 46, 48, 50, 52 of the mattress core 40. FIG. 6 is a schematic orthogonal view of the mattress core covering 100 of FIG. 4 fitted to the mattress core 40. The piping 104 proximate to the bottom surface 44 of the mattress core 40 is shown in dashed lines.

FIG. 7 is a schematic bottom view of the mattress core covering 100 fitted to the mattress core 40. FIG. 7 shows the bottom surface 44 of the mattress core 40, the mattress core covering 100 tucked against the bottom surface 44 of the mattress core 40, the first, second, third, and fourth seams 148, 150, 152, 154, and the piping of the mattress core covering 104, all in relation to the third and fourth side edges 66, 68 and third and fourth end edges 62, 64 of the mattress core 40.

The foregoing discussion of FIGS. 1-7 relates to an exemplary embodiment of the mattress core covering 100 that is adapted to a mattress core 40 that approximates the shape of a rectangular prism. The exemplary thermally-insulating, fire-retardant fabrics discussed above can be cut and sewn to cover cores having a broad range of shapes that are known in the art, in manners that will be understood by those having ordinary skill in the art. Thus, the exemplary mattress core covering 100 can be readily adapted to provide flame resistance in cushions, pillows, mattresses, and various resilient accessories that decorate or add functionality to household furnishings. Further, the foregoing discussion of FIGS. 1-7 relates to embodiments of the mattress core covering 100 that are fitted directly to a foam mattress core 40. The inventive concepts disclosed herein can readily be adapted to provide mattress core coverings that cover other types of cores, or that cover mattresses, pillows, cushions, and so forth, that are otherwise complete or partially complete. The mattress core covering of the present invention may also be used in situations where there are foam or fabric layers, or other materials, between the core and mattress core covering.

It should be understood that the embodiments described herein are merely exemplary in nature and that a person skilled in the art may make many variations and modifications thereto without departing from the scope of the present invention. All such variations and modifications, including those discussed above, are intended to be included within the scope of the invention as described herein.

FIRE RETARDANT MATTRESS CORE COVERING

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