Abstract: A multi-density batt having a plurality of overlaid thermoplastic fiber web layers. Each of the web layers comprise a homogeneous blend of matrix fibers and binder fibers. The binder fibers have a relatively low predetermined melting temperature and the matrix fibers have a relatively high predetermined melting temperature. The binder fibers and matrix fibers are heat-fused together. The batt has a width defining a cross direction and a length defining a machine direction. At least one integrally-formed, relatively thick, high density region extends in both the cross direction and machine direction of the batt. At least one integrally-formed relatively thin, low density region extends in both the cross direction and machine direction. The batt can be used to form a cushion, such as a seat cushion.

Abstract: A multi-density batt having a plurality of overlaid thermoplastic fiber web layers. Each of the web layers comprise a homogeneous blend of matrix fibers and binder fibers. The binder fibers have a relatively low predetermined melting temperature and the matrix fibers have a relatively high predetermined melting temperature. The binder fibers and matrix fibers are heat-fused together. The batt has a width defining a cross direction and a length defining a machine direction. At least one integrally-formed, relatively thick, high density region extends in both the cross direction and machine direction of the batt. At least one integrally-formed relatively thin, low density region extends in both the cross direction and machine direction. The batt can be used to form a cushion, such as a seat cushion.

Abstract: A dual layer, dual density batt having a first batt layer comprising at least first and second staple polymer fiber constituents forming a homogeneous intermixture of the fibers, at least some of the fibers in the first or second fiber constituents having a relatively low predetermined melting temperature and the remainder of the fiber in the first or second fiber constituents having a relatively high predetermined melting temperature and a second batt layer comprising at least first and second staple polymer fiber constituents forming a homogeneous intermixture of the fibers. At least some of the fibers in the first or second fiber constituents have a relatively low predetermined melting temperature and the remainder of the fiber in the first or second fiber constituents have a relatively high predetermined melting temperature.

Abstract: A method of forming a vacuum bonded non-woven batt includes the steps of blending at least first and second staple polymer fiber constituents. One of the fiber constituents has a relatively low predetermined melting temperature and the other a relatively high melting temperature. The intermixture is formed either into a relatively thick single layer web or a relatively thin web which is then formed into a relatively thick multilayer web structure. The web structure is positioned on a rotating, air permeable drum and a vacuum is used to substantially reduce the thickness and increase the density of the web structure. The web structure is heated to a temperature at or above the relatively low melting temperature of the first fiber constituent and below the melting temperature of the second fiber constituent while under vacuum to release the plastic memory of the fibers of the first fiber constituent in their compressed configuration.

Abstract: A dense, resilient, non-woven staple polymer fiber batt is formed of either of a plurality of overlayed, relatively thin webs or at least one relatively thick web. The web or webs comprise at least first and second staple polymer fiber constituents blended to form a homogenous mixture. The first fiber constituent has a relatively low melting temperature and the second fiber constituent has a relatively high melting temperature. The fibers of the first fiber constituent are fused by heat to themselves and to fibers of a second fiber constituent to interconnect the fibers while in a vacuum-compressed state. The heat is sufficient to melt the fibers of the first fiber constituent but not high enough to melt the fibers of the second fiber constituent.