Patent ID: 6077378
Filing Date: 2000-06-20
Classification: A47C,B29C,B29L,Y10T

Abstract:
A method of forming a resilient structure comprising the steps of:locating a coil spring in a desired position in a densified, heat bonded, low melt fiber batt core, the fiber batt core having a desired resiliency and including low melt fibers;heating one of the densified fiber batt core and said coil spring to melt a portion of the low melt fibers surrounding a substantial length of said coil spring; andallowing the densified fiber batt core and said coil spring to cure to interlock the low melt fibers over the substantial length of said coil spring and hold the coil spring within the densified fiber batt core at the desired position, the substantial length of said coil spring functioning as a part of the fiber batt core when compressed and released, thereby enhancing the desired resiliency of the fiber batt core at the location of the spring wherein the locating step further comprises forming a plurality of hollows in the densified fiber batt core with stamping dies; and placing a coil spring in each of the hollows and wherein the forming step further comprises conveying the core along a production line; and die stamping the hollows into the core as it is conveyed along the production line via dies mounted on an endless conveyor oriented parallel with the production line.