Tunable spring mattress and method of making same

Abstract

A mattress includes a spring extending between first and second points to provide a first spring rate in a first direction. A polymer fiber structure is provided between the first and second points and adjoins the spring. The polymer fiber structure includes fibers interlinked with one another to provide the second spring rate in the first direction. An example method of manufacturing a mattress is provided that includes arranging springs to provide a mattress innerspring. A polymer fiber structure is introduced in a first state to the innerspring to provide an assembly. The assembly is further processed and the polymer fiber structure is simultaneously altered from the first state to a second state.

1 . A mattress comprising:
 an innerspring including a plurality of springs; and   a polymer fiber structure arranged at least partially inside one of the springs to provide a spring assembly, the spring assembly including an enclosure containing interlinked fibers.   
     
     
         2 . The mattress as recited in  claim 1 , wherein the enclosure is provided by a mesh. 
     
     
         3 . The mattress as recited in  claim 1 , wherein the interlinked fibers are polymer fibers. 
     
     
         4 . The mattress as recited in  claim 1 , wherein the enclosure at least partially encloses the spring, and at least some of the interlinked fibers are provided within the spring. 
     
     
         5 . The mattress as recited in  claim 1 , wherein the mattress includes a plurality of polymer fiber structures arranged at least partially inside a respective one of the plurality of springs to provide the mattress with a plurality of spring assemblies. 
     
     
         6 . The mattress as recited in  claim 5 , wherein each spring of the mattress is at least partially enclosed by a respective polymer fiber structure. 
     
     
         7 . The mattress as recited in  claim 1 , wherein the spring provides a first spring rate in a first direction, and wherein the polymer fiber structure provides a second spring rate different than the first spring rate in the first direction. 
     
     
         8 . The mattress as recited in  claim 7 , wherein the first direction is a height direction of the mattress. 
     
     
         9 . The mattress as recited in  claim 7 , wherein the polymer fiber structure includes fibers interlinked with one another at bond points to provide the second spring rate. 
     
     
         10 . The mattress as recited in  claim 1 , wherein the plurality of springs are metallic coil springs. 
     
     
         11 . The mattress as recited in  claim 10 , wherein the plurality of springs are stitched together with wiring. 
     
     
         12 . A method of forming a spring assembly, comprising:
 heating a spring assembly, the spring assembly including a spring and a polymer fiber structure arranged at least partially inside the spring, the polymer fiber structure initially including an enclosure containing a plurality of loose, unbonded fibers within the spring, wherein heating the spring assembly causes the fibers within the spring to become interlinked with one another.   
     
     
         13 . The method as recited in  claim 12 , wherein the enclosure is provided by a mesh. 
     
     
         14 . The method as recited in  claim 12 , wherein the fibers are polymer fibers. 
     
     
         15 . The method as recited in  claim 12 , wherein the spring provides a first spring rate in a first direction, and wherein the polymer fiber structure provides a second spring rate different than the first spring rate in the first direction. 
     
     
         16 . The method as recited in  claim 15 , wherein the first direction is a height direction. 
     
     
         17 . The method as recited in  claim 15 , wherein the polymer fiber structure includes fibers interlinked with one another at bond points to provide the second spring rate. 
     
     
         18 . The method as recited in  claim 12 , wherein the spring is a metallic coil spring.