Method for producing a variable density, corrugated resin-bonded or thermo-bonded fiberfill and the structure produced thereby

摘要

A corrugated fiberfill structure is provided including at least one fibrous web folded to form a plurality of pleats having alternating crests and bases, each of the pleats having a pair of legs in which each of the legs has a first leg surface and a second leg surface, the first leg surface of one leg being in intimate contact with the first leg surface of an adjoining leg of the pleat and the second leg surface of the one leg being in intimate contact with the second leg surface of one adjoining leg of an adjacent pleat over a portion of each leg. At least some crests define a first structural surface and at least some bases define a second structural surface, with the distance between the first and second structural surfaces defining the thickness of the structure. The pleats of the structure are so arranged across the thickness that the density of the structure varies between the first and second structural surfaces. A method for forming a corrugated bonded fiberfill structure having pleats, a first surface defined by crests of at least some of the pleats and a second surface defined by bases of at least some of the pleats is also provided which includes lapping at least one fibrous web formed from first fibers and second fibers in alternating directions to form alternating laps; folding the fibrous web to form a corrugated fibrous web having variations in density between the first and second surfaces; and bonding the pleats of the corrugated fibrous web. <IMAGE>