Patent ID: 7125465

Claim:
A method of forming a resilient structure for supporting a load comprising: providing a first fiber batt strip having first and second surfaces defining a thickness of the first fiber batt strip, the first surface adapted to support the load, and a third surface extending between the first and second surfaces; and heating a first coil spring having a first centerline to provide a heated first coil spring; providing relative motion between the heated first coil spring and the first fiber batt strip to move the heated first coil spring in a direction substantially perpendicular to the first centerline and through the third surface and to a desired location within the first fiber batt strip while maintaining the longitudinal centerline of the first coil spring substantially perpendicular to the first and second surfaces; providing a second fiber batt strip having fourth and fifth surfaces defining a thickness of the second fiber batt strip, the fourth surface adapted to support the load, and a sixth surface extending between the fourth and fifth surfaces of the second fiber batt strip; heating a second coil spring having a second centerline to provide a heated second coil spring; providing relative motion between the second coil spring and the second fiber batt strip to move the heated second coil spring in a direction substantially perpendicular to the second centerline and against and through the sixth surface and to a desired location within the second fiber batt strip while maintaining the longitudinal centerline of the second coil spring substantially perpendicular to the fourth and fifth surfaces of the second fiber batt strip; and joining the first fiber batt strip and the second fiber batt strip to form a unitary resilient structure.