Abstract: A resilient structure such as a seat cushion, mattress, furniture back or the like has enhanced resiliency and support at strategic locations due to the use of coil springs interlocked and held within a densified heat bonded low melt fiber batt used as the core or cover of the resilient structure. The densified fiber batt core includes low melt fibers which, when heated to the melting point and then cooled, intersect and interlock with the coil springs. The coil springs function as an integral part of the fiber batt, eliminating the need for lattice wires and the like to interlock the springs in the structure. The invention also increases the capability of manufacturing resilient structures in a wide variety of shapes and sizes.

Abstract: A generally rectangular box spring assembly of the disclosure includes a wire grid supported on a lower frame by center coil springs and by formed wire springs at the edge of the assembly. The formed wire springs provide relatively firm edge support while the coil springs provide softer center support. Each of the formed wire springs includes at least one fishmouth section extending upwardly from an associated frame member for connection to the grid. The formed wire springs preferably include a pair of the fishmouth sections which are interconnected by a connecting portion. The grid may be secured to the connecting portion of the formed wire springs or to a border wire that is itself secured to the fishmouth sections of these springs. The center coil springs are preferably of a conical shape with their smaller ends secured to laterally extending frame slats and with their larger ends clipped to the wire grid.