Mattress with customized density

Abstract

An exemplary aspect of the present disclosure relates to a mattress and a method for manufacturing a mattress. The method includes, among other things, providing a batt of polymer fibers with a reduced dimension, forming a topper layer of polymer fibers having a lower surface corresponding to the reduced dimension in the batt, and arranging the topper layer relative to the batt such that the lower surface of the topper layer mates with the reduced dimension in the batt.

What is claimed is: 
     
         1 . A method for manufacturing a mattress, comprising:
 forming a batt of polymer fibers, the batt having at least one location with a reduced dimension;   forming a topper layer of polymer fibers having a surface corresponding to the reduced dimension in the batt; and   arranging the topper layer relative to the batt such that the surface of the topper layer mates with the reduced dimension in the batt.   
     
     
         2 . The method as recited in  claim 1 , wherein the reduced dimension provides the batt with a first height at a center point between opposed lateral sides and a second height at the lateral sides, the first height less than the second height. 
     
     
         3 . The method as recited in  claim 2 , wherein the batt has a consistent density throughout. 
     
     
         4 . The method as recited in  claim 2 , wherein the reduced dimension is provided by a pre-impression, and wherein the batt has a first density at the first height and a second density at the second height, the first density greater than the second density. 
     
     
         5 . The method as recited in  claim 4 , wherein the first density is within a range of 1.1-3.0 times greater than the second density. 
     
     
         6 . The method as recited in  claim 5 , wherein the first density is about  2 . 5  times greater than the second density. 
     
     
         7 . The method as recited in  claim 1 , wherein the topper layer is provided by a three-dimensional netted polymer structure. 
     
     
         8 . The method as recited in  claim 7 , wherein the three-dimensional netted polymer structure includes a plurality of randomly entangled polymer filaments, the polymer filaments being partially thermally bonded together. 
     
     
         9 . The method as recited in  claim 1 , wherein the topper layer has a first height at a center point between opposed lateral sides and a second height at the lateral sides, the first height greater than the second height. 
     
     
         10 . The method as recited in  claim 9 , wherein the topper layer has a first density at the first height and a second density at the second height, the first density greater than the second density. 
     
     
         11 . The method as recited in  claim 1 , wherein the density of the topper layer varies along at least one of a width and a length. 
     
     
         12 . The method as recited in  claim 1 , wherein an upper surface of the topper layer is parallel to a lower surface of the batt, and wherein a lower surface of the topper layer is contoured to correspond to the reduced dimension in the batt. 
     
     
         13 . The method as recited in  claim 1 , further comprising:
 forming a first topper layer of polymer fibers having a surface corresponding to the reduced dimension in the batt;   forming a second topper layer of polymer fibers having a surface corresponding to the reduced dimension in the batt; and   arranging the first topper layer adjacent an upper surface of the batt and the second topper layer adjacent the lower surface of the batt such that the surfaces of the first and second topper layers mate with the reduced dimension in the batt.   
     
     
         14 . A method for manufacturing a mattress, comprising:
 extruding loose polymer fibers;   heating the extruded polymer fibers; and   providing the extruded polymer fibers with a reduced dimension at at least one location.   
     
     
         15 . The method as recited in  claim 14 , wherein the reduced dimension provides the extruded polymer fibers with a first height at a center point between opposed lateral sides and a second height at the lateral sides, the first height less than the second height. 
     
     
         16 . The method as recited in  claim 15 , wherein the extruded polymer fibers have a first density at the first height and a second density at the second height, the first density greater than the second density. 
     
     
         17 . The method as recited in  claim 14 , further comprising:
 mating a topper layer with the extruded polymer fibers, the topper layer having a contour corresponding to the reduced dimension.   
     
     
         18 . The method as recited in  claim 17 , further comprising:
 separating the topper layer from the extruded polymer fibers; and   separately recycling the topper layer and the extruded polymer fibers.   
     
     
         19 . A mattress, comprising:
 a batt of polymer fibers, the batt having an upper surface, a lower surface, and opposed lateral sides, wherein the upper surface has a contour providing the batt with a reduced dimension, the reduced dimension providing the batt with a first height at a center point between the opposed lateral sides and a second height at the lateral sides, the first height less than the second height; and   a topper layer of polymer fibers having an upper surface, a lower surface, and opposed lateral sides, the lower surface having a contour corresponding to the reduced dimension in the batt, the topper layer arranged relative to the batt such that the lower surface of the topper layer mates with the reduced dimension in the batt.   
     
     
         20 . The mattress as recited in  claim 19 , wherein:
 the topper layer has a first height at a center point between opposed lateral sides and a second height at the lateral sides, the first height greater than the second height; and   the topper layer has a first density at the first height and a second density at the second height, the first density greater than the second density.