Abstract: Improved batts for sleeping bags, insulated apparel, bedding, and other uses are made from a tow of crimped continuous filaments by a machine and process which spreads, extends, and wraps the tow into an endless flat-tube structure with desired uniformity, balanced tensile strength, dimensional stability, stretchability, and high loft.

Abstract: The present invention relates to a fibrous pad structure having a variable density. The continuous strip-shaped webs are sliced and rubbed to form one or more continuous strip-shaped webs that are separated from each other by a constant distance. The strip-shaped webs can also be spread and lapped onto a continuous smooth fibrous web in a regular arrangement. The combined fibrous webs are corrugated and shaped into a vertical porous fibrous pad. Such a fibrous pad has a different density distribution in the transversal cross section and a continuous corrugated structure in the mechanical direction. The density of the combined fibrous pad in accordance with the present application can be adjusted according to the uses of the fibrous pad. The mechanical properties of the products made from the fibrous pad thus are adjustable to meet the requirements of different uses of the product.