Method of forming densified fiber batt with coil springs interlocked therein

A method of making a resilient structure comprising the steps of:

• forming a core of moderately densified heat bonded fiber batt having dual-polymer fibers each having a high-melt polymer core surrounded by a low melt outer sheath;
• forming a plurality of hollows in the core with stamping dies;
• placing a coil spring in each of the hollows;
• covering the coil springs with at least one additional layer of moderately densified fiber batting of dual-polymer fibers;
• heating the core and said at least one additional layer with the coil springs located therein;
• and
• allowing the core and said at least one additional layer to cure to interlock the coil springs therein wherein the hollow forming step further comprises:
• conveying the core along a production line;
• 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 lines;
• and
• die stamping hollows into the additional layer;
• and wherein the covering step further comprises inverting the additional layer and placing the additional layer on the core with the hollows in the additional layer aligned with the hollows in the core, with the coil springs enclosed within the hollows.

A method of forming a resilient structure comprising the steps of:

• inserting a guide element into a densified fiber batt core at a strategic position, the densified fiber batt core containing low melt fibers;
• heating the guide element to heat the densified fiber batt core and melt a portion of the low melt fibers surrounding the guide element, the guide element having a shape similar to a coil spring;
• removing the guide element from the densified fiber batt core;
• thereafter locating a coil spring into the fiber batt core at the strategic position;
• and
• allowing the densified fiber batt core and said coil spring to cure to interlock said coil spring with the low melt fibers and hold the coil spring within the densified fiber batt core at the strategic position.