A flame-retardant fabric comprises a textile substrate having a layer of a nanoclay material extending along a surface of the textile substrate and integrated with the textile substrate.

A non-flip mattress with top side and bottom side and depending edges; wherein the bottom side is covered with a flame-resistant, highly needled, double-sided-calendered, needlepunch nonwoven fabric that passes 16 CFR 1633. The nonwoven fabric is a double-calendered, 80/20 polyester/flame-resistant rayon blend needled with a minimum of 190 punches per cm.sup.2 and with increased tensile strength.

Some embodiments of the invention include a modular foam bed comprising a foam base layer having a length and a width; a foam edge support having a length that is substantially the same as the length of the foam base layer and a width that is substantially the same as the width of the foam base layer, the foam edge support comprising a cavity; a first support layer sized and configured to be disposed within the cavity of the foam edge support; a second support layer sized and configured to be disposed within the cavity of the first foam edge support adjacent with the first support layer; and a foam top layer having a length that is substantially the same as the length of the foam base layer and a width that is substantially the same as the width of the foam base layer.

A mattress cover includes a first, face layer, a second, back layer, and third, inlay layer between the face layer and the back layer. The inlay layer is composed of a flame-retardant material. The face layer is attached to the back layer. The inlay layer is not attached to the face layer and the back layer.

The present invention relates to a flame-retardant nonwoven fabric for a mattress, and a flame-retardant nonwoven fabric for mattresses comprising flame-retardant rayon (FR-Rayon) staple fibers of 20 to 50% by weight; modacrylic staple fibers of 30 to 60% by weight; polyimide (PI) staple fibers of 10 to 30% by weight; and low melting polyester (LM PET) staple fibers of 5 to 20% by weight provides enhanced flame retarding and mechanical properties.

The present application provides a cushion having a core layer and a quilt support/comfort layer. The core layer may comprise innersprings, foams, air cells, or combinations thereof. The support/comfort layer comprises a sleep layer that simulates a conventional quilted fabric layer. The sleep layer includes a thick, comfort fabric and a backing fabric, which backing fabric may be the same as the thick, comfort fabric. The sleep layer is formed by coupling the thick, comfort fabric to the backing fabric to form a plurality of individual pockets in which micro spring coils are placed. The micro spring coils have less uncompressed height than conventional innerspring coils. The sleep layer coupling is formed by spot coupling without using a metal needle to stitch the layers together. In other words, the spot coupling may comprise an adhesive or weld.

A foundation for a mattress is formed from a foam block and may also have supports that extend across the foam block's bottom side. The supports can be manufactured with the foam block or may be provided in a kit or separately sourced. The foam block is rigid enough to support a mattress and is compressible so it has a compressed configuration and an expanded configuration and its bottom side may have channels for the supports. In the compressed configuration, the foundation may be folded into a compact form and vacuum-sealed in a plastic membrane which easies in storage, shipping, and delivery of the foundation. When the foundation is delivered to its place of use, the compressed foundation can be removed from its packaging, allowing the foam block to return to its expanded configuration and placed onto a standard bed frame with the supports providing crosswise support across the frame.

The present invention, in embodiments, is a fitted mattress core covering having a non-woven fabric comprising a plurality of flame-retardant fibers and elastic piping located along an edge of the non-woven fabric. The non-woven fabric, in embodiments, is substantially free of fiberglass, and 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.

A foundation for a mattress is formed from one or more single-layer, unitary foam blocks with supports that extend across each foam block's bottom side. The supports provide lateral or longitudinal crosswise support across a bed frame and can be directly attached to the foam block or may be provided in a kit or separately sourced. Legs can be attached to the crosswise supports. The foam block is rigid enough to support a mattress and is compressible so it has a compressed configuration and an expanded configuration, and its bottom side may have channels for the supports. In the compressed configuration, the foundation may be folded and vacuum-sealed in a plastic membrane which provides benefits for storing, shipping, and delivering the foundation. When the foundation is delivered to its place of use, the compressed foundation is removed from its packaging, allowing the foam block to return to its expanded configuration.

A method of producing a flame resistant ticking includes laminating a flame resistant substrate to a decorative fabric, wherein the substrate is configured to release a chemical vapor that reduces the rate of propagation of a flame along the decorative fabric when the decorative fabric is exposed to flame. The substrate is laminated in direct contact with the inside surface of the decorative fabric. In some embodiments, the laminated ticking is configured to release less than 15 MJ of heat in the first ten minutes when exposed to a flame in accordance with the testing protocol set forth in 16 CFR 1633. Upholstered articles, such as mattresses, mattress foundations, and articles of furniture, may incorporate the flame resistant ticking layer.