Mattress constructions with densified fiber components

Abstract

Densified fiber structures are incorporated into mattress constructions and bedding Applications. In one embodiment, a mattress innerspring is combined with one or more densified fiber structures which fit with the innerspring and with other components of the mattress. An innerspring perimeter support made of densified fiber may encase the outer perimeter of the innerspring and provide structural side walls to the mattress. In another embodiment and application, the inner cavity of one or more coils of a mattress innerspring may be substantially filled with densified fiber. In yet another embodiment, the general space between the coils of the innerspring may be filled with densified fiber. In still another embodiment, a combination of densified fiber supports may be included in one mattress innerspring assembly, such as, for example, a densified fiber perimeter support with densified fiber filled innerspring coils, or a densified fiber perimeter support with densified fiber filled in the general space between the coils of the innerspring, or a densified fiber filled innerspring coils densified fiber in the general space between each innerspring coil. Additional densified fiber components for use in a mattress innerspring include an innerspring corner coil reinforcement member which is made of densified fiber and which fits around the coils located at each of the four corners of the innerspring.

1 . A mattress innerspring assembly comprising:
 a mattress innerspring having a plurality of interconnected coils in a generally rectangular array, each of the coils having a generally helical configuration with top ends of the coils in a common plane and bottom ends of the coils in a common plane;   an innerspring perimeter support which forms an exterior wall around the plurality of springs of the innerspring, the perimeter support being generally rectangular and having a top rail surface and a bottom rail surface opposite and parallel to the top rail surface, a right side rail surface and a left side rail surface opposite and parallel to the right side rail surface, the right and left side rail surfaces extending between the top and bottom rail surfaces, and   wherein the innerspring perimeter support is made of densified fiber.   
     
     
         2 . The mattress innerspring of  claim 1 , wherein the densified fiber contains polyester fiber. 
     
     
         3 . The mattress innerspring assembly of  claim 1 , wherein the densified fiber contains elastomeric fibers. 
     
     
         4 . The mattress innerspring assembly of  claim 1 , wherein a density of the innerspring perimeter support is in an approximate range of 1.0-2.0 lbs/ft 3 . 
     
     
         5 . The mattress innerspring assembly of  claim 1 , wherein a tear strength of the innerspring perimeter support is in an approximate range of 800-1200 N/m. 
     
     
         6 . The mattress innerspring assembly of  claim 1 , wherein a tensile strength of the innerspring perimeter support is an in approximate range of 100-200 kPa. 
     
     
         7 . The mattress innerspring assembly of  claim 1  further including four corner coil reinforcement members each of which substantially surround a spring located at a corner of the innerspring. 
     
     
         8 . A mattress innerspring assembly comprising:
 an innerspring having a plurality of springs connected together in an array wherein the springs are arranged in rows and columns, each spring having a body with a first end and a second end, the body of each spring being generally cylindrical and having a longitudinal axis and an outer diameter, the springs being spaced apart in the rows and columns and connected together in a spaced apart arrangement with each spring being spaced from each adjacent spring in the array;   wherein the generally cylindrical body of one or more springs is substantially filled with densified fiber.   
     
     
         9 . The mattress innerspring assembly of  claim 8 , wherein the densified fiber contains polyester fiber. 
     
     
         10 . The mattress innerspring assembly of  claim 8 , wherein the densified fiber contains elastomeric fibers. 
     
     
         11 . The mattress innerspring assembly of  claim 8 , wherein the density of the densified fiber is in an approximate range of 1.0-2.0 lbs/ft 3 . 
     
     
         12 . The mattress innerspring assembly of  claim 8 , wherein the tear strength of the densified fiber is in an approximate range of 800-1200 N/m. 
     
     
         13 . The mattress innerspring assembly of  claim 8 , wherein the tensile strength of the densified fiber is in an approximate range of 100-200 kPa. 
     
     
         14 . The mattress innerspring assembly of  claim 8  further including an innerspring perimeter support which comprises a substantially rectangular wall which encases an outside perimeter of the innerspring, wherein the innerspring perimeter support is made of densified fiber. 
     
     
         15 . The mattress innerspring assembly of  claim 8  further including one or more corner coil reinforcement members located about the outer diameter of at least one spring which is located at a corner of the innerspring. 
     
     
         16 . The mattress innerspring assembly of  claim 14  further including one or more corner coil reinforcement members located about the outer diameter of at least one spring which is located at a corner of the innerspring. 
     
     
         17 . The mattress innerspring assembly of  claim 8 , wherein all of the springs of the innerspring are substantially filled with densified fiber. 
     
     
         18 . The mattress innerspring assembly of  claim 17 , wherein at least two springs contain different blends of densified fiber. 
     
     
         19 . The mattress innerspring assembly of  claim 17 , wherein all of the springs contain the same blend of densified fiber. 
     
     
         20 . The mattress innerspring assembly of  claim 8 , wherein a general space between each spring of the innerspring is filled with densified fiber. 
     
     
         21 . The mattress innerspring assembly of  claim 1  further comprising one or more layers of padding material positioned over a support side of the innerspring, and upholstery which covers the innerspring assembly to form a mattress. 
     
     
         22 . A mattress innerspring assembly comprising:
 a mattress innerspring having a plurality of interconnected coils in a generally rectangular array, each of the coils having a generally helical configuration with top ends of the coils in a common plane and bottom ends of the coils in a common plane;   an innerspring perimeter support which forms an exterior wall around the plurality of springs of the innerspring, the perimeter support being generally rectangular and having a top rail surface and a bottom rail surface opposite and parallel to the top rail surface, a right side rail surface and a left side rail surface opposite and parallel to the right side rail surface, the right and left side rail surfaces extending between the top and bottom rail surfaces;   at least one spring insert located within the innerspring and proximate to one of the plurality of springs of the innerspring;   a substantially planar core which extends over a substantial area of the innerspring over ends of a plurality of springs of the innerspring, and   wherein the innerspring perimeter support, the at least one spring insert and the substantially planar core are made of densified fiber.   
     
     
         23 . A mattress innerspring assembly comprising:
 an innerspring having a plurality of helical springs connected together in an array of rows and columns;   a densified fiber perimeter support having four substantially rectangular side walls which border an outer perimeter of the innerspring and in contact with the helical springs located at the outer perimeter of the innerspring   at least one additional densified fiber component contained within the innerspring.   
     
     
         24 . The mattress innerspring assembly of  claim 23 , wherein the at least one additional densified fiber component is a corner coil reinforcement member. 
     
     
         25 . The mattress innerspring assembly of  claim 23 , wherein the at least one additional densified fiber component is a planar foam deck located beneath the innerspring. 
     
     
         26 . The mattress innerspring assembly of  claim 23 , wherein each of the helical springs of the innerspring are filled with densified fiber. 
     
     
         27 . A mattress comprising a core and at least one densified fiber component made by the process of densified fiber formation in contact with or surrounding the core, and an external cover which encloses the core and the at least one densified fiber component. 
     
     
         27 . The mattress innerspring assembly of  claim 23 , wherein one or more helical springs are filled with densified fiber.