Drop-in seat spring unit assembly

A method for making a seating structure comprising:

• constructing a generally rectangular frame portion of the seating structure;
• securing a plurality of individual bottom grids of a spring assembly to said frame portion with mechanical fasteners, each said bottom grid comprising a plurality of longitudinal and transverse wires and a border wire extending around a periphery of said bottom grid, each said transverse wire terminating at an intersection with said border wire, pairs of adjacent said longitudinal wires combining with pairs of adjacent said transverse wires to define bottom grid cells, each said bottom grid cell having a pair of opposed upwardly directed depressions in one of said pairs of adjacent transverse wires and said pairs of adjacent longitudinal wires;
• attaching a bottom turn of a spring to selected ones of said bottom grid cells without benefit of additional mechanical fasteners by engaging each of said upwardly directed depressions with one of a pair of detents in said bottom turn of said spring;
• and
• attaching a top grid to a top turn of each said spring without benefit of additional mechanical fasteners, said top grid comprising a plurality of longitudinal and transverse wires and a border wire extending around a periphery of said top grid, pairs of adjacent said longitudinal wires combining with pairs of adjacent said transverse wires to define top grid cells, each said top grid cell being generally vertically aligned with a corresponding said bottom grid cell, each said top grid cell having a pair of opposed downwardly directed depressions in one of said pairs of adjacent transverse wires and said pairs of adjacent longitudinal wires, said top grid being attached to each said spring by engaging each of said downwardly directed depressions with one of a pair of detents in said top turn of said spring, wherein said plurality of said bottom grids are attached to said top grid via said springs to form said spring assembly.

A method of assembling a spring assembly adapted to be dropped into and to form a seating structure, said method comprising:

• attaching a bottom turn of a spring to selected cells in one of a plurality of individual bottom grids without benefit of additional mechanical fasteners, each said bottom grid comprising a plurality of longitudinal and transverse wires and a border wire extending around a periphery of said bottom grid, each said transverse wire terminating at an intersection with said border wire, pairs of adjacent said longitudinal wires combining with pairs of adjacent said transverse wires to define said bottom grid cells, each said bottom grid cell having a pair of opposed upwardly directed depressions in one of said pairs of adjacent transverse wires and said pairs of adjacent longitudinal wires, said bottom turn being attached to said selected bottom grid cells by engaging each of said upwardly directed depressions with one of a pair of detents in said bottom turn of said spring;
• and
• attaching a top grid to a top turn of each said spring without benefit of additional mechanical fasteners, said top grid comprising a plurality of longitudinal and transverse wires and a border wire extending around a periphery of said top grid, pairs of adjacent said longitudinal wires combining with pairs of adjacent said transverse wires to define top grid cells, each said top grid cell being generally vertically aligned with a corresponding said bottom grid cell, each said top grid cell having a pair of opposed downwardly directed depressions in one of said pairs of adjacent transverse wires and said pairs of adjacent longitudinal wires, said top grid being attached to each said spring by engaging each of said downwardly directed depressions with one of a pair of detents in said top turn of said spring, wherein said plurality of said bottom grids are attached to said top grid via said springs to form said spring assembly.

A method for making a seating structure comprising:

• constructing a frame portion of the seating structure;
• securing a plurality of individual bottom grids of a spring assembly to said frame portion, each said bottom grid comprising a plurality of longitudinal and transverse wires and a border wire extending around a periphery of said bottom grid, each said transverse wire terminating at an intersection with said border wire, pairs of adjacent said longitudinal wires combining with pairs of adjacent said transverse wires to define bottom grid cells;
• attaching a bottom turn of a spring to selected ones of said bottom grid cells without benefit of additional mechanical fasteners;
• and
• attaching a top grid to a top turn of each said spring, said top grid comprising a plurality of longitudinal and transverse wires and a border wire extending around a periphery of said top grid, pairs of adjacent said longitudinal wires combining with pairs of adjacent said transverse wires to define top grid cells, each said top grid cell being generally vertically aligned with a corresponding said bottom grid cell, wherein said plurality of said bottom grids are attached to said top grid via said springs to form said spring assembly.

A method for making a seating structure comprising:

• constructing a frame portion of the seating structure;
• securing a plurality of individual bottom grids of a spring assembly to said frame portion, each said bottom grid comprising a plurality of transverse wires and a border wire extending around a periphery of said bottom grid, each said transverse wire terminating at an intersection with said border wire, pairs of said transverse wires combining with portions of said border wire to define bottom grid cells;
• attaching a bottom turn of a spring to selected ones of said bottom grid cells without benefit of additional mechanical fasteners;
• and
• attaching a top grid to a top turn of each said spring without benefit of additional mechanical fasteners.

A method for making a seating structure comprising:

• constructing a frame portion of the seating structure;
• securing a plurality of individual bottom grids of a spring assembly to said frame portion, each said bottom grid comprising a plurality of transverse wires and a border wire extending around a periphery of said bottom grid, each said transverse wire terminating at an intersection with said border wire, pairs of adjacent said transverse wires combining with portions of said border wire to define bottom grid cells;
• attaching a bottom turn of a spring to selected ones of said bottom grid cells without benefit of additional mechanical fasteners;
• attaching a top grid to a top turn of each said spring without benefit of additional mechanical fasteners by manually tying twine to said top turn of each said spring, said top grid comprising a plurality of lateral, longitudinal and diagonal sections of said twine;
• and
• tying said twine to each said top turn of each said spring at eight locations on each said top turn.

A spring assembly for use in a seating structure, the spring assembly comprising:

• a plurality of individual bottom grids, each said bottom grid comprising a plurality of transverse wires and a border wire extending around a periphery of said bottom grid, each said transverse wire terminating at an intersection with said border wire, pairs of said transverse wires combining with portions of said border wire to define bottom grid cells;
• a bottom turn of each of a plurality of springs attached to selected ones of said bottom grid cells;
• and
• a top grid attached to a top turn of each said spring.

A spring assembly for use in a seating structure, the spring assembly comprising:

• a plurality of individual bottom grids, each said bottom grid comprising a plurality of transverse wires and a border wire extending around a periphery of said bottom grid, each said transverse wire terminating at an intersection with said border wire, pairs of said transverse wires combining with portions of said border wire to define bottom grid cells;
• a bottom turn of each of a plurality of springs attached to selected ones of said bottom grid cells without benefit of mechanical fasteners;
• a top grid attached to a top turn of each said spring without benefit of mechanical fasteners, said top grid comprising a plurality of transverse, longitudinal and diagonal sections of twine tied to said top turn of each said spring at eight locations on each said top turn, wherein top grid is attached to the seating structure;
• and
• each said bottom grid having a plurality of springs attached thereto and one of said plurality of springs attached to each said bottom grid is shorter than the other of said plurality of springs.

A seating structure comprising:

• a frame portion;
• a spring assembly attached to said frame portion, said spring assembly further comprising:
• (a) a plurality of individual bottom grids, each said bottom grid comprising a plurality of transverse wires and a border wire extending around a periphery of said bottom grid, each said transverse wire terminating at an intersection with said border wire, pairs of said transverse wires combining with portions of said border wire to define bottom grid cells;
• (b) a bottom turn of each of a plurality of springs attached to selected ones of said bottom grid cells without benefit of mechanical fasteners;
• and
• (c) a top grid attached to a top turn of each said spring without benefit of mechanical fasteners, said top grid comprising a plurality of lateral, longitudinal and diagonal sections of twine tied to said top turn of each said spring at eight locations on each said top turn, wherein said top grid is attached to the frame portion.