Mattress innerspring structure having coaxial coil units

A spring structure for use in an innerspring structure of a mattress comprising:

• a row of non-pocketed outer coils, the row being formed from a single continuous piece of wire and containing outer coils interconnected by interconnection segments;
• a row of non-pocketed inner coils, the row being formed from a single continuous piece of wire and containing inner coils interconnected by interconnection segments;
• the row of inner coils being positioned together with said row of outer coils and the inner coils being positioned generally coaxially with the outer coils to form reinforced coil units which extend between top and bottom face surfaces of the spring structure;
• interconnection segments of each row being overlapped relative to one another proximate both of said top and bottom face surfaces;
• unitary, helically-shaped wire connectors wrapped around and engaging overlapped interconnection segments of the rows in both the top and bottom face surfaces of the spring structure and engaging both the row of inner coils and the row of outer coils to directly secure the rows of inner and outer coils together in an assembled relation to form the reinforced coil units, the reinforced coil units having generally equal firmness along their individual lengths for supporting the top and bottom face surfaces of the spring structure.

An innerspring structure for a mattress comprising:

• a plurality of adjacent non-pocketed outer coils extending generally parallel to one another between bottom and top face surfaces of an innerspring structure:
• a plurality of adjacent non-pocketed inner coils extending generally parallel to one another between the top and bottom face surfaces, the inner coils positioned generally coaxially with the outer coils, the inner and outer coils cooperatively forming reinforced coil units in the innerspring structure;
• unitary helically-shaped wire connectors wrapped around and engaging both the inner and outer coils of the coaxial units proximate both of the top and bottom face surfaces to directly secure the inner and outer coils together as reinforced units in the innerspring structure;
• the reinforced coaxial coil units providing generally equal firmness along their lengths in said innerspring structure for providing support at the top and bottom face surfaces of the innerspring structure.

A method of forming an innerspring structure for a mattress comprising:

• providing a row of non-pocketed inner coils and a row of non-pocketed outer coils, each row of coils formed from a single continuous piece of wire and containing coils interconnected by interconnection segments;
• positioning the row of inner coils together with said row of outer coil, the rows being positioned such that the inner coils are generally coaxial with the outer coils to form reinforced coil units which extend between top and bottom face surfaces of the innerspring structure;
• overlapping interconnection segments of one row with corresponding interconnection segments of the other row in both the top and bottom face surfaces;
• engaging and wrapping the overlapped segments of the rows with unitary, helically-shaped wire connectors in both the top and bottom face surfaces for engaging both the row of inner coils and the row of outer coils to directly secure the rows of inner and outer coils together in an assembled relation to form the reinforced coil units in the innerspring structure, the reinforced coil units having generally equal firmness along their individual lengths for supporting the top and bottom face surfaces of the innerspring structure.