SYNTHETIC OR NATURAL FIBER MATTRESS WITH ENHANCED COMPRESSION RESISTANCE

摘要

A structured fiber product is constructed with fibers oriented primarily in a vertical direction. Fibers made from recycled materials are combined with binder fibers which have a lower transition temperature than the recycled fibers. A three dimensional web is formed from the fibers oriented in a horizontal direction. The web is heated to bind the fibers and cooled to fix the web in a predetermined thickness. Sections of the web are stacked while maintaining substantially parallel orientation of the fibers in the horizontal direction, heated to bind the fibers and cooled to fix a predetermined thickness of the structured fiber product. The structured fiber product is rotated so that the fibers are oriented in the vertical direction. One or more slabs of the structured fiber product with vertically oriented fibers may be configured to form a resilient structure such as a mattress core.

主权项

1. A method of forming a resilient structure, comprising:
aligning a blend of fibers comprising a first fiber type and a second fiber type to generate a plurality of webs of aligned fibers, the aligned fibers aligned in the parallel with the webs, wherein the first fiber type has a lower transition temperature than the second fiber type; stacking the webs of aligned fibers to generate a structured fiber product, wherein the stacking maintains alignment of the aligned fibers among the plurality of webs; heating the structured fiber product to a temperature above a transition temperature of the first fiber type and below a transition temperature of the second fiber type; compressing the heated structured fiber product to a predetermined thickness while the temperature of the heated structured fiber product is above the transition temperature of the first fiber type and below the transition temperature of the second fiber type; and cooling the heated structured fiber product to below the transition temperature of the first fiber type while the heated structured fiber product is compressed to the predetermined thickness to generate a fixed thickness structured fiber product, wherein the fibers are aligned in a direction perpendicular to the thickness of the structured fiber product.