Abstract: A structured fiber product is constructed with fibers oriented primarily in a vertical direction. Fibers made from recycled materials are combined with binder fibers which have a lower transition temperature than the recycled fibers. A three dimensional web is formed from the fibers oriented in a horizontal direction. The web is heated to bind the fibers and cooled to fix the web in a predetermined thickness. Sections of the web are stacked while maintaining substantially parallel orientation of the fibers in the horizontal direction, heated to bind the fibers and cooled to fix a predetermined thickness of the structured fiber product. The structured fiber product is rotated so that the fibers are oriented in the vertical direction. One or more slabs of the structured fiber product with vertically oriented fibers may be configured to form a resilient structure such as a mattress core.

Abstract: A structured fiber product is constructed with fibers oriented primarily in a vertical direction. Fibers made from recycled materials are combined with binder fibers which have a lower transition temperature than the recycled fibers. A three dimensional web is formed from the fibers oriented in a horizontal direction. The web is heated to bind the fibers and cooled to fix the web in a predetermined thickness. Sections of the web are stacked while maintaining substantially parallel orientation of the fibers in the horizontal direction, heated to bind the fibers and cooled to fix a predetermined thickness of the structured fiber product. The structured fiber product is rotated so that the fibers are oriented in the vertical direction. One or more slabs of the structured fiber product with vertically oriented fibers may be configured to form a resilient structure such as a mattress core.

Abstract: Disclosed is a process for making fire resistant materials, such as fabrics or barriers, comprising the steps of selecting cellulosic fibers and optionally synthetic fibers; feeding a machinery serving to make the nonwoven material with the fibers, and treating the fibers at least one time with at least one fire retardant chemical compound while the machinery is making the non-woven material for obtaining the requested fire resistant nonwoven material. Preferably, an aqueous solution containing the fire retardant chemical compounds is spread on the nonwoven web before, during and/or after the web is heated up during a thermo bonding step of the process. The process is environmentally friendly and allows for higher impregnation of the fibers with fire retardant chemicals.