Abstract:
A high loft fiber batt is formed from a blend comprising charred thermoplastic fibers and about 10-15 percent by volume polyester binder fibers, wherein the fiber batt is suitable for use as a fire barrier layer. Another embodiment of a high loft fiber batt is formed from a blend of at least 15 percent by volume charred thermoplastic fibers, at least 15 percent by volume polyester carrier fibers, and about 10-15 percent by volume polyester binder fibers. Still another embodiment of a high loft fiber batt comprises a blend of about equal amounts by volume of charred thermoplastic fibers and polyester carrier fibers, wherein the fiber batt is suitable for use as a fire barrier layer. These high loft fiber batts may be used as a fire barrier layer in various different products, including seating and insulation for vehicles and aircraft, bedding, upholstery and furniture.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a Continuation-In-Part of U.S. patent application Ser. No. 10/968,318, filed Oct. 18, 2004, which is based on and claims priority to U.S. patent application Ser. No. 10/221,638, filed Jan. 7, 2003, now U.S. Pat. No. 7,147,734, which is based upon International Patent Application PCT US01/07831, filed Mar. 13, 2001, which, in turn, is based on and claims priority to U.S. Patent Application Ser. No. 60/188,979, entitled Bi-Lofted Fire Combustion Modified Batt filed on Mar. 13, 2000. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       REFERENCE TO A MICROFICHE APPENDIX 
       [0003]    Not applicable. 
       FIELD OF THE INVENTION 
       [0004]    Disclosed herein are fire combustion modified batts and methods for forming such batts. More particularly, the fire combustion modified batts disclosed herein comprise a blend of nonwoven fibers and charred thermoplastic fibers, such as oxidized polyacrylonitrile (PAN) or FR rayon fibers. The methods include forming a blend of the nonwoven fibers and charred thermoplastic fibers into a web. The charred thermoplastic fibers are fire resistant, and when blended with nonwoven fibers, are relatively easily processed into a batt. A second blend of nonwoven fibers can be formed into a web and layered with the web of charred thermoplastic fibers and nonwoven fibers to form the batt. The fibers of the batt are bonded together with heat, resin or other suitable bonding means and are compressed and cooled to set the batt. The fire combustion modified batt is useful as a fire barrier layer and filling in bedding, upholstery and vehicle and aircraft seats, as insulators for apparel, appliances, walls, aircraft walls, vehicle walls and ducting, as barriers to separate control systems from a heat source, and as components in fire safety gear such as race driver suits, oven and welding mitts, and the like. 
       BACKGROUND 
       [0005]    Fire retardant barriers are desirable for a wide variety of applications. Products for household and public occupancies such as health care facilities, convalescent care homes, college dormitories, residence halls, hotels, motels and correctional institutions are sometimes governed by regulations which require certain fire resistant characteristics, particularly in bedding and upholstery. Fire barrier components are also needed in apparel, fire safety gear, vehicle and aircraft seating and walls, as insulators for appliances, walls, ducting, as barriers to separate sensitive controls from a heat source and other similar applications where fire safety is a concern. Effective fire barriers minimize the amount and rate of heat released from the barrier upon contact with fire. The rate of beat released is an indication of the intensity of the fire generated from the fire barrier material as well as how quickly the fire spreads. Slowing the spread of fire advantageously increases the amount of response time for a fire victim to safely escape and a fire department to successfully extinguish the fire. 
         [0006]    In the bedding, upholstery and other industries, foams and nonwoven fibers are used in mattresses, sofas, chairs, and seat cushions, backs and arms. Traditionally, urethane foam has been combined with other types of cushioning materials such as cotton batting, latex rubber, and various nonwoven fibers in order to impart desirable comfort, loft and durability characteristics to a finished product. However, urethane foam is extremely flammable and must be chemically treated or coated to impart fire resistant properties to the foam. Alternatively, neoprene foam is used in bedding and upholstery products as it is relatively fire resistant. Both neoprene foam and urethane foam which have been treated for fire resistancy are relatively expensive. 
         [0007]    Synthetic and natural nonwoven fibers also have demonstrated usefulness in the construction of mattresses and upholstery. Such fibers are inherently lightweight and therefore easy to ship, store and manipulate during processing. When subjected to open flame, many synthetic fibers, particularly polymer fibers and specifically dry polyester fibers, tend to melt and drip rather than burn. In addition, polymer fibers can be coated for fire resistance. For example, polymer fibers which have been treated for fire resistance are identified in the industry under the names Trevira FR, Kevlar and Nomex and are considered to be non-flammable. 
         [0008]    Correctional institutions typically use three types of cushion cores for mattresses. The cushion cores include foam, densified synthetic nonwoven fiber which has a density of about 1.5 pounds per cubic foot or greater, and cotton batting. Left untreated, cotton fibers are extremely flammable and burn rapidly. Cotton can, however, be chemically treated, typically with boric acid, to impart fire resistant properties to the cotton. Correctional institutions with heightened fire safety concerns may require their mattresses to meet certain fire safety standards. In these cases, the cushion cores are comprised of neoprene foam or cotton batting which has been treated with boric acid. However, cotton is extremely moisture absorbent. Thus, mattresses comprised of cotton are difficult to maintain in a hygienic condition. Furthermore, cotton mattresses are relatively heavy. 
         [0009]    Oxidized polyacrylonitrile (PAN) fibers, while fire resistant, are difficult to process into batts for use as a barrier layer or filling, particularly in bedding and upholstery applications. The fibers are relatively low in weight and specific gravity making traditional carding methods for forming batts difficult. In addition, oxidized PAN fibers are so-called dead fibers as they have relatively little resilience and loft and are incompressible. In certain applications, in particular for bedding and upholstery, a oxidized PAN fiber batt may be unsuitable where comfort and loft are desired. Oxidized PAN fibers are also black in color and thus may be unsuitable in applications which require a light color beneath a light decorative upholstery or mattress layer. 
       SUMMARY 
       [0010]    Through significant time and effort, it has been found that the difficulties associated with providing a fire barrier layer could be avoided by the method and batt of the present invention. As will be appreciated by one skilled in the art, the novel method and batt are applicable to a wide variety of products, including as barrier layers and filling materials in bedding and upholstery, as wraps for and replacements of cushion and arms in furniture, vehicle and aircraft seats, as insulators for apparel, appliances, walls, vehicle walls, aircraft walls, ducts and to separate sensitive controls from a heat source, and as components in fire safety gear such as oven or welding mitts, and the like. 
         [0011]    In one aspect, a high loft fiber batt disclosed herein is formed from a blend comprising charred thermoplastic fibers and about 10-15 percent by volume polyester binder fibers, wherein the fiber batt is suitable for use as a fire barrier layer. In an embodiment, the blend of the fiber batt comprises at least 15 percent by volume of the charred thermoplastic fibers. The blend may further comprise at least 15 percent by volume polyester carrier fibers. In an embodiment, the blend comprises about equal amounts by volume of the charred thermoplastic fibers and the polyester carrier fibers. The charred thermoplastic fibers may be selected from the group consisting of oxidized polyacrylonitrile fibers and FR rayon fibers. 
         [0012]    In another aspect, a high loft fiber batt disclosed herein is formed from a blend of at least 15 percent by volume charred thermoplastic fibers, at least 15 percent by volume polyester carrier fibers, and about 10-15 percent by volume polyester binder fibers. In an embodiment, blend forming the fiber batt comprises about equal amounts by volume of the charred thermoplastic fibers and the polyester carrier fibers. The charred thermoplastic fibers may be selected from the group consisting of oxidized polyacrylonitrile fibers and FR rayon fibers. 
         [0013]    In yet another aspect, a high loft fiber batt disclosed herein comprises a blend of about equal amounts by volume of charred thermoplastic fibers and polyester carrier fibers, wherein the fiber batt is suitable for use as a fire barrier layer. In an embodiment, the blend further comprises about 10-15 percent by volume polyester binder fibers. 
         [0014]    Many different products may use the fiber batt as a fire barrier layer thereof. In various embodiments, the products may be selected from the group consisting of vehicle seating, aircraft seating, vehicle wall insulation, aircraft wall insulation, bedding, upholstery and furniture. An aircraft or a vehicle may also use the fiber batt as a fire barrier layer thereof. 
         [0015]    The method of forming the fiber batts disclosed herein comprises blending carrier and binder nonwoven fibers and charred thermoplastic fibers, such as oxidized polyacrylonitrile (PAN) fibers or FR rayon fibers, to form a substantially homogeneous blend of the fibers. The binder fibers have a relatively low melting point and the carrier fibers have a relatively high melting point. While the homogeneous mixture can be any of a number of suitable blends, in one embodiment, the binder fiber can be anywhere in the range of about 5 percent to 50 percent by volume of the blend. The relative percent volume of charred thermoplastic fibers to carrier fibers in the remaining blend volume ranges anywhere from 15 percent to 85 percent. In a preferred embodiment, the relative volume of charred thermoplastic fibers to carrier fibers is about 50 percent to 50 percent. Thus, for a blend having 10 percent by volume of binder fibers and a 50 to 50 percent relative volume of charred thermoplastic fibers to carrier fibers, the volume of charred thermoplastic fibers and carrier fibers in the blend is 45 percent each. 
         [0016]    The blended fibers are formed into a batt by using a garnett machine, cross layers, an air layer or any other suitable batt forming apparatus. In a garnett and cross laying process, the blend of fibers are formed into a web for transporting along a conveyor moving in the machine direction. Successive web layers are layered in the cross direction onto the conveyor in an progressive overlapping relationship by moving one or more reciprocating cross-lappers carrying the web back and forth between a first side of the conveyor and an opposing second side. 
         [0017]    The batt is positioned on an air permeable support and a vacuum is applied through the air permeable support and batt from a first side of the batt to an opposing second side of the batt. The vacuum pressure is sufficient to substantially compress the web into a desired thickness or loft and at a desired density. In an alternative embodiment, the batt is compressed between opposing counter rotating rollers proximate the machine direction and spaced apart a predetermined distance to reduce the thickness and increase the density of the batt. Heat is applied to the web structure at a temperature sufficient to soften the binder fibers but low enough to avoid melting the carrier fibers. The plastic memory of the softened binder fibers is released in their compressed configuration and the fibers fuse to themselves and to the other web fibers to form a batt having interconnected and fused fibers. The batt is cooled in its compressed state to reset the plastic memory of the binder fibers and form a thermal bonded batt having a density and thickness substantially the same as induced in the batt by the vacuum pressure or compression. 
         [0018]    In products which require additional loft, compressibility, resilience and comfort or a light color beneath decorative upholstery, a mattress quilt or other covering for aesthetic purposes, an additional web comprising nonwoven fibers which are light in color can be formed. A surface of the nonwoven web is disposed to a surface of the blended charring fiber web to form a batt which is heated, compressed and cooled together. Alternatively, the charring fiber web and the nonwoven web can be heated, compressed and cooled separately and then disposed together to form the batt. 
         [0019]    The thermal bonded batt has a wide variety of applications in products, depending on its charring fiber content and the density of the batt. For example, a batt having a density of less than 1.5 pounds per cubic foot, defined herein as a high loft batt, can be used as a fire barrier layer in mattresses and border panels of mattresses and as a wrap for or an additional layer to cushion seats, backs and arms in furniture, vehicle and aircraft seats. Such high loft batts may also be used in applications such as insulation for aircraft walls and vehicle walls, and otherwise used in aircraft and vehicle applications. In mattresses and seats having a light colored decorative covering, the batt comprising a layer of nonwoven fibers would be positioned with the light colored nonwoven layer proximate the decorative covering to shield it from the dark color charring PAN fibers. The thermally bonded high loft batt is also suitable as an insulation lining in apparel and fire safety gear such as, for example, in fire fighter jackets and oven mitts for welding or industrial furnace purposes. Further, the high loft batt is suitable as a fire barrier air filter and as an insulator for appliances such as hot water tanks and furnaces. Wall insulation and insulation in recreational vehicle wall cavities are also suitable applications of the high loft batt. 
         [0020]    Batts formed from the method of the present invention having a density of about 1.5 pounds per cubic foot or greater, defined herein as densified, are suitable as a replacement to cushion backs, seats and arms in furniture, vehicle and aircraft seats. The densified batts are also suitable in toppers and filling in mattresses, as well as replacements for mattress cores, such as, for example, the foam or inner springs in mattresses, particularly for use in public occupancies and correctional institutions. Additionally, densified batts are suitable for insulation lining in apparel and safety gear such as race driver suits, and as insulation for walls, furnace wall insulation, and ducting insulation. Densified batts are particularly suitable for sound deadening and thermal transfer applications. 
         [0021]    In yet another embodiment of the method of the present invention, a resin is used to bond carrier fibers and charred thermoplastic fibers to form a fire combustion modified batt of the resent invention. In this embodiment, carrier fibers having a relatively high melting point are blended with the charred thermoplastic fibers to form a homogeneous mixture. While the homogeneous mixture can be any of a number of suitable blends, the charred thermoplastic fibers can be in the range of about 15 percent to 100 percent by volume of the batt and, accordingly, the volume of carrier fibers would be from 85 percent to a negligible amount. Thus, for a blend having 85 percent charred thermoplastic fibers, the volume of carrier fibers would be about 15 percent. The blended charring and carrier fibers can be formed into a web generally according to the garnett method for forming the thermally bonded web described herein. An air laying machine can also be used. Generally, the fibers are introduced into an air stream which carries the fibers to an air permeable support such as a perforated drum which is rotating. Accumulation of the fibers onto the drum surface results in a web formation. A vacuum is applied through the web from one side of the web to the other and through said air permeable support sufficient to reduce the thickness and increase the density of the web throughout the thickness of the web to form a batt. The batt is saturated with a heat curable resin which can additionally comprise fire resistant properties to enhance the fire resistance of the batt. Heat is applied at a temperature sufficient to cure the resin and fuse the fibers to form a batt having a density and thickness substantially the same as during the heating step. For products requiring additional loft, compressibility, resilience and comfort or a light color, a web comprising nonwoven fibers can be formed. A surface of the nonwoven web is disposed to a surface of the charring fiber web to form a batt which is saturated with a resin and heated to cure the resin. Alternatively, the charring fiber web and the nonwoven web can be separately saturated with resin, heat cured and then bonded together by suitable bonding applications. In addition, a relatively thin layer of a nonwoven fiber which is light in color can be bonded to the resin bonded batt for aesthetic purposes where loft, compression and comfort is not required. 
         [0022]    While the resin bonded batt can be high loft, preferably it is a densified batt having a density of about 1.5 pounds per cubic foot or greater. Preferably, the batt is relatively thin, having a thickness in the range of approximately ⅛ inch to approximately 1 inch. The resin bonded densified batt can be used as a fire barrier layer in a mattress, such as for example, directly below the ticking, under the quilt backing, under the quilt panels or borders and above the inner springs. Other suitable applications include as dust covers in mattresses and furniture. The densified resin bonded batt is also suitable as a wrap for cushion seats, backs and arms and for deck padding for furniture and curtain backing material. Further applications include wraps for hot water tanks and furnaces and fire and heat shields in building and vehicle walls. 
         [0023]    While heat and resin bonding methods are discuss, other methods for bonding the fibers of the web to form the batt of the present invention are suitable, such as, for example, needle punching, hydro-entangling and mechanical bonding, and are within in the scope of the present invention. 
         [0024]    The invention is more particularly shown and described in the accompanying drawings and materials included herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    For a more complete understanding of the present invention, and for further details and advantages thereof, reference is now made to the following Detailed Description of the Drawings taken in conjunction with the accompanying drawings, in which: 
           [0026]      FIG. 1  provides a schematic flow chart of a method according to an embodiment of the present invention. 
           [0027]      FIG. 2  provides a schematic top plan view of the processing line for forming a batt according to an embodiment of the method of the present invention. 
           [0028]      FIG. 3A  provides a schematic side view of a thermal bonding apparatus according to an embodiment of the method of the present invention. 
           [0029]      FIG. 3B  provides a schematic side view of another embodiment of a thermal bonding apparatus according to the method of the present invention. 
           [0030]      FIG. 4  provides a perspective top view of an embodiment of a batt formed from the method of the present invention. 
           [0031]      FIG. 5  provides a perspective top view of another embodiment of a batt formed from the method of the present invention. 
           [0032]      FIG. 6  provides a schematic flow chart of a method according to another embodiment of the present invention. 
           [0033]      FIG. 7  provides a perspective top view of further embodiment of a batt formed from the method of the present invention. 
           [0034]      FIG. 8A  is a side cut away view of a traditional mattress. 
           [0035]      FIG. 8B  is a side cut away view of a mattress comprising embodiments of batts formed from the method of the present invention. 
           [0036]      FIG. 9  is a side view of a mattress border comprising an embodiment of a batt formed from the method of the present invention. 
       
    
    
     NOTATION AND NOMENCLATURE 
       [0037]    Certain terms are used throughout the following description and claims to refer to particular components thereof. This document does not intend to distinguish between components that differ in name but not in function. 
         [0038]    In the detailed description and the claims that follow, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. 
         [0039]    The term “inherent-type FR fibers” generally refers to those fibers that resist combustion as a result of an essential characteristic of the fiber. 
         [0040]    The term “non-inherent-type FR fibers” generally refers to those fibers that are generally considered to be non-FR but have been treated with a suitable fire retardant chemical to render the fibers flame resistant. 
         [0041]    The term “charred thermoplastic fibers” generally refers to FR fibers that carbonize into a charred fiber but will maintain a stable physical structure when exposed to flame. Both inherent-type FR fibers and non-inherent-type FR fibers may be charred thermoplastic fibers. 
         [0042]    The term “FR rayon” generally refers to inherent-type FR rayon fibers or non-inherent-type FR rayon fibers. 
       DETAILED DESCRIPTION 
       [0043]    The method for forming a fire combustion modified batt of the present invention comprises a process for bonding web fibers together to form a batt. The bonding processes discussed herein include a thermal bonding process and a resin saturated curing process. However, other methods may be suitable for bonding web fibers together to form a fire combustion modified batt and thus are within the scope of the invention. For example, needle punching, hydro entangling and mechanical bonds are suitable. 
         [0044]    Turning first to the thermal bonding process which is representatively and schematically illustrated in  FIG. 1 , the method comprises the step of blending nonwoven fibers and charred thermoplastic fibers, such as oxidized polyacrylonitrile (PAN) fibers or FR rayon fibers, to form a first web blend. For purposes of illustrating the process and not by way of limitation, the charred thermoplastic fibers of the present invention may be oxidized PAN fibers, such as those marketed under the product name Pyron® by Zoltek Corporation. The oxidized polyacrylonitrile (PAN) fibers are produced from an acrylic precursor. Specifically, the Pyron® brand oxidized PAN fiber is a stabilized form of polyacrylonitrile (PAN) fiber. The stabilization is an oxidation process that converts the polyacrylonitrile (PAN) fiber from a thermoplastic state to a thermoset state. 
         [0045]    The discussion herein illustrates generally the method for forming, and the composition of a particular type of charred thermoplastic fibers, specifically, oxidized PAN fibers, but is not a limitation to the scope of the invention. Other methods and compositions may be suitable for the present invention as would be understood by one skilled in the art. Generally, several types of acrylic polymers with variations in their composition have been used for the production of oxidized PAN fibers. The exact composition of a particular acrylic precursor varies widely. Generally, however, the composition contains a minimum of 85% acrylonitrile and a maximum of 15%, but preferably no more than 8%, comonomers such as methyl methacrylate, methyl acrylate, vinyl acetate, vinyl chloride, and other monovinyl compounds. 
         [0046]    In addition to acrylic as a precursor for the production of carbon fibers, rayon and pitches are also used. The details of the conversion processes used for different precursors are not the same, although their essential features are similar. Generally, the processes involve a stabilizing treatment to prevent melting or fusion of the fiber, a carbonizing treatment to eliminate the non-carbon elements and a high temperature graphitizing treatment to enhance the mechanical properties of the final carbon fiber. 
         [0047]    In the case of PAN fibers, stabilization is carried out by controlled heating of the precursor fiber in an oxidizing atmosphere, for example, in air in the temperature range of about 180° C. to 300° C. The heating rate is usually 1-2° C./minute. However, other temperature ranges and heating rates may be appropriate. Shrinkage can be minimized by stretching the fibers along their axis during the low-temperature stabilization treatment Stretching also produces oxidized PAN fibers with a high degree of preferred orientation along the fiber axis. The stabilization process produces changes in chemical structure of the acrylic precursor such that the product becomes thermally stable to subsequent high temperature treatments. During this process, the fibers change in color to black. The black fibers are carbonized in an inert atmosphere at high temperatures, for example at 1000 to 1500° C. with a slow heating rate to avoid damage to the molecular order of the fiber. The fibers are given a graphitizing treatment at high temperatures for example, above 2000° C. to 3000° C., to improve the texture of the fiber and to enhance the Young&#39;s modulus. The strength and the modulus of the fibers can also be improved by hot stretching. 
         [0048]    Generally, the physical characteristics of oxidized PAN fibers are its black color, a moisture content of about 4 to 9 percent, an average fiber diameter of about 11 to 14 microns, a fiber tensile strength of about 180 to 300 Mpa, a fiber elongation of about 18 to 28 percent, a fiber density of about 1.36 to 1.38 g/cc and a fiber length of about 4 to 15 cm. In addition, in the case of Pyron®, the oxidized PAN fibers are thermally stable up to 600° F. The physical and chemical properties may vary depending on the specific manufacturing process. 
         [0049]    The nonwoven fibers of the first blend for the present invention include carrier fibers and binder fibers. The fibers can be natural or synthetic. For example, thermoplastic polymer fibers such as polyester are suitable synthetic fibers. Other fibers can be used depending upon the precise processing limitations imposed and the characteristics of the batt which are desired at the end of the process. For purposes of illustrating the process and combustion modified batt and not by way of limitation, the carrier fiber is KoSa Type 209, 6 to 15 denier, 2 to 3 inches in length, round hollow cross section polyester fiber. Alternatively, the carrier fiber is KoSa Type 295, 6 to 15 denier, ⅕ to 4 inches in length, pentalobal cross section polyester fiber. Other nonwoven fibers are suitable as carrier fibers for the present invention and are within the scope of this invention. 
         [0050]    The binder fiber has a relatively low predetermined melting temperature as compared with the carrier fiber. As used herein, however, the term melting does not necessarily refer only to the actual transformation of the solid polyester binder fibers into liquid form. Rather, it refers to a gradual transformation of the fibers or, in the case of a bicomponent sheath/core fiber, the sheath of the fiber, over a range of temperatures within which the polyester becomes sufficiently soft and tacky to cling to other fibers within which it comes in contact, including other binder fibers having its same characteristics and, as described above, adjacent polyester fibers having a higher melting temperature. It is an inherent characteristic of thermoplastic fibers such as polyester that they become sticky and tacky when melted, as that term is used herein. For purposes of illustrating the process and fire combustion modified batt and not by way of limitation, the binder fiber is KoSa Type 254 Celbond® which is a bicomponent fiber with a polyester core and a copolyester sheath. The sheath component melting temperature is approximately 230° F. (110° C.). The binder fiber, alternatively, can be a polyester copolymer rather than a bicomponent fiber. 
         [0051]    While the homogeneous mixture of nonwoven fibers and charred thermoplastic fibers such as oxidized PAN fibers can be any of a number of suitable fiber blends, for purposes of illustrating the process and first blend, the mixture is comprised of binder finders in an amount sufficient for binding the fibers of the blend together upon application of heat at the appropriate temperature to melt the binder fibers. In one example, the binder fibers are in the range of approximately 5 percent to 50 percent by total volume of the blend. Preferably, the binder finders are present in the range of approximately 10 percent to 15 percent for a high loft batt, and in the range of approximately 15 percent to 40 percent for a densified batt, as those characteristics are discussed below. The relative percent volume of charred thermoplastic fibers to carrier fibers in the remaining blend volume ranges anywhere from 15 percent to 85 percent. In the preferred embodiment, the relative volume of charred thermoplastic fibers to carrier fibers is about 50 percent to 50 percent. Thus, for example, a blend having 10 percent by volume of binder fibers and a 50 to 50 percent relative volume of charred thermoplastic fibers to carrier fibers, the volume of charring PAN fibers and carrier fibers in the blend is 45 percent each. In another example, the volume of charred thermoplastic fibers and carrier fibers in the blend is 45 percent each. In a further example, the volume of charred thermoplastic fibers and carrier fibers having a 50 to 50 percent relative volume is 40 percent each in a blend having 20 percent by volume of binder fibers. In a further example, a blend having 20 percent binder fibers and a 75 percent to 25 percent relative volume mix of charred thermoplastic fibers to carrier fibers, the volume of charred thermoplastic fibers and carrier fibers is 60 percent and 20 percent, respectively. Blends having other percentages of binder, carrier and charred thermoplastic fibers are also within the scope of the invention. 
         [0052]    Referring back to  FIG. 1 , the method further comprises an optional step of blending a homogenous second blend of carrier and binder fibers to form a second web. The fibers can be the same as or similar to those of the first web discussed herein, such as, for example, polyester fibers. Other synthetic or natural fibers can be used depending upon the precise processing limitations imposed and the characteristics of the second web which are desired at the end of the process. While the homogeneous mixture of carrier and binder fibers can be any of a number of suitable fiber blends, for purposes of illustrating the process and second blend, the mixture is comprised of binder finders in the range of approximately 10 percent to 20 percent by volume and carrier fibers in the range of approximately 90 to 80 percent by volume. Preferably, the binder finders and carrier fibers are present in the range of approximately 10 percent to 15 percent and approximately 90 to 85 percent by volume, respectively. 
         [0053]    Referring to  FIG. 2 , a schematic top plan view of the general processing line  10  for forming a batt of the present invention is illustrated. The following example is directed to the formation of a web in general and thus is applicable to forming both the first web comprising charred thermoplastic fibers such as oxidized PAN fibers and nonwoven fibers and the second web of nonwoven fibers. As discussed above, fibers are blended in a fiber blender  12  and conveyed by conveyor pipes  14  to a web forming machine or, in this example, three machines  16 ,  17 ,  18 . A suitable web forming apparatus is a garnett machine. An air laying machine, known in the trade as a Rando webber, or any other suitable apparatus can also be used to form a web structure. Garnett machines  16 ,  17 ,  18  card the blended fibers into a nonwoven web having a desired width and deliver the web to cross-lappers  16 ′,  17 ′,  18 ′ to cross-lap the web onto a slat conveyor  20  which is moving in the machine direction. Cross-lappers  16 ′,  17 ′  18 ′ reciprocate back and forth in the cross direction from one side of conveyor  20  to the other side to form the web having multiple thicknesses in a progressive overlapping relationship. The number of layers which make up the web is determined by the speed of the conveyor  20  in relation to the speed at which successive layers of the web are layered on top of each other and the number of cross-lappers  16 ′,  17 ′,  18 ′. Thus, the number of single layers which make up the web can be increased by slowing the relative speed of the conveyor  20  in relation to the speed at which cross layers are layered, by increasing the number of cross-lappers  16 ′,  17 ′  18 ′ or both. Conversely, a fewer number of single layers can be achieved by increasing the relative speed of conveyor  20  to the speed of laying the cross layers, by decreasing the number of cross-lappers  16 ′,  17 ′,  18 ′ or both. In the present invention, the number of single layers which make up the first web of charring and nonwoven fibers and the second web of nonwoven fibers can be approximately the same or can vary depending on the desired characteristics of the fire combustion modified batt of the present invention. Accordingly, the relative speed of the conveyor  20  to the speed at which cross layers are layered and the number of cross-lappers  16 ′,  17 ′,  18 ′ for forming the first web and the second web may be different. 
         [0054]    Referring back to  FIG. 1 , the process of the present invention further comprises disposing a surface of the first web in a conforming relationship to a surface of the second web to form the fire combustion modified batt. 
         [0055]    While there are a variety of thermal bonding methods which are suitable for the present invention, one such method comprises holding the batt by vacuum pressure applied through perforations of first and second counter-rotating drums and heating the batt so that the relatively low melting temperature binder fibers in the first web and the second web soften or melt to the extent necessary to fuse the low melt binder fibers together and to the charring and carrier fibers in the first and second webs. Alternatively, the batt moves through an oven by substantially parallel perforated or mesh wire aprons to melt the low temperature binder fibers. 
         [0056]    Referring to  FIGS. 2 and 3A , a vacuum pressure method generally comprises using counter-rotating drums  40 ,  42  having perforations  41 ,  43 , respectively, which are positioned in a central portion of a housing  30 . Housing  30  also comprises an air circulation chamber  32  and a furnace  34  in an upper portion and a lower portion, respectively, thereof. Drum  40  is positioned adjacent an inlet  44  though which the batt is fed. The batt is delivered from the blending and web forming processes described herein by means of an infeed apron  46 . A suction fan  50  is positioned in communication with the interior of drum  40 . The lower portion of the circumference of drum  40  is shielded by a baffle  51  positioned inside drum  40  so that the suction-creating air flow is forced to enter drum  40  through perforations  41  which are proximate the upper portion of drum  40  as it rotates. 
         [0057]    Drum  42  is downstream from drum  40  in housing  30 . Drums  40 ,  42  can be mounted for lateral sliding movement relative to one another to facilitate adjustment for a wide range of batt thicknesses (not shown). Drum  42  includes a suction fan  52  which is positioned in communication with the interior of drum  42 . The upper portion of the circumference of drum  42  is shielded by a baffle  53  positioned inside drum  42  so that the suction-creating air flow is forced to enter drum  42  through perforations  43  which are proximate the lower portion of drum  42  as it rotates. 
         [0058]    The batt is held in vacuum pressure as it moves from the upper portion of rotating drum  40  to the lower portion of counter rotating drum  42 . Furnace  34  heats the air in housing  30  as it flows from perforations  41 ,  43  to the interior of drums  40 ,  42 , respectively, to soften or melt the relatively low melting temperature binder fibers in the first and second webs to the extent necessary to fuse the low melt binder fibers together and to the charring and carrier fibers in the first and second webs. 
         [0059]    REFERRING TO  FIG. 3B , in an alternative thermal bonding process, the batt enters housing  30 ′ by a pair of substantially parallel perforated or mesh wire aprons  60 ,  62 . Housing  30 ′ comprises an oven  34 ′ which heats the batt to soften or melt the relatively low melting temperature binder fibers in the first and second webs to the extent necessary to fuse the low melt binder fibers together and to the charring and carrier fibers in the first and second webs. 
         [0060]    Referring back to  FIGS. 2 ,  3 A and  3 B, the batt is compressed and cooled as it exits from housing  30 ,  30 ′ by a pair of substantially parallel first and second perforated or wire mesh aprons  70 ,  72 . Aprons  70 ,  72  are mounted for parallel movement relative to each other to facilitate adjustment for a wide range of batt thicknesses (not shown). The batt can be cooled slowly through exposure to ambient temperature air or, alternatively, ambient temperature air can forced through the perforations of one apron, through the batt and through the perforations of the other apron to cool the batt and set it in its compressed state. The batt is maintained in its compressed form upon cooling since the solidification of the low melt temperature binder fibers in their compressed state bonds the fibers together in that state. 
         [0061]    Referring to  FIGS. 1 and 2 , the cooled batt moves into cutting zone  80  where its lateral edges are trimmed to a finished width and it is cut transversely to the desired length of batt. 
         [0062]    Referring TO  FIGS. 4 and 5 , an example of batt  100  and batt  200  formed by the thermal bonding method of the present invention is illustrated. Batt  100  is comprised of first web  110  having nonwoven fibers  112  and charred thermoplastic fibers such as oxidized PAN fibers  114 , and second web  120  having nonwoven fibers  122  as discussed previously. Batt  200  is comprised of first web  210  having nonwoven fibers  212  and charred thermoplastic fibers such as oxidized PAN fibers  214 . The weight, density and thickness  102 ,  202  of batt  100 ,  200 , respectively, are determined by, among other factors, the process of compressing the batt as it is cooled. The ratio of batt density to batt thickness  102  generally dictates whether batt  100  is a high loft batt or a densified bat. For purposes herein, a densified batt has approximately a 2 to 1 or greater ratio of weight in ounces per square foot to thickness in inches. Accordingly, a densified batt has a density of approximately 1.5 pounds per cubic foot or more. Batts have less than a 2 to 1 ratio of weight to thickness and less than 1.5 pounds per cubic foot density are defined herein as high loft bats. For illustration purposes, batt  100  is a high loft batt while batt  200  is densified. Tables I, II and III provide examples of various weights and corresponding thicknesses of batts processed by the thermal bonding method of the present invention. 
         [0000]    
       
         
               
               
               
             
           
               
                   
                 TABLE I* 
               
               
                   
                   
               
               
                   
                 Weight 
                 Thickness 
               
               
                   
                 (oz/sq. ft.) 
                 (inches) 
               
               
                   
                   
               
             
             
               
                   
                  ¼-½ 
                  ½ 
               
               
                   
                  ½-¾ 
                  ¾ 
               
               
                   
                  ¾-1 
                  ⅞ 
               
               
                   
                   1-1¼ 
                 1¼ 
               
               
                   
                 1¼-1½ 
                 1½ 
               
               
                   
                 1½-1¾ 
                 1¾ 
               
               
                   
                 1¾-2 
                 2 
               
               
                   
                   2-2¼ 
                 2¼ 
               
               
                   
                 2¼-2¾ 
                 2¾ 
               
               
                   
                 2¾-3 
                 3 
               
               
                   
                   3-3½ 
                 3½ 
               
               
                   
                 3½-4 
                 4 
               
               
                   
                   
               
               
                   
                 *Suitable blends for the weights and thicknesses in Table I are thermally bonded batts having bicomponent low melt binder fibers in the amount of approximately 10 percent to 20 percent by total volume of the blend. The remaining blend volume comprises a relative percent volume of charred thermoplastic fibers to carrier fibers in the range of approximately 15 percent to 85 percent by relative volume. 
               
             
          
         
       
     
         [0000]    
       
         
               
               
               
             
           
               
                   
                 TABLE II* 
               
               
                   
                   
               
               
                   
                 Weight 
                 Thickness 
               
               
                   
                 (oz/sq. ft.) 
                 (inches) 
               
               
                   
                   
               
             
             
               
                   
                  ⅜-¾ 
                  ¼ 
               
               
                   
                  ¾-1½ 
                  ½ 
               
               
                   
                 1⅛-2¼ 
                  ¾ 
               
               
                   
                 1⅜-2⅜ 
                  ⅞ 
               
               
                   
                 1½-3 
                 1 
               
               
                   
                 1⅝-3⅜ 
                 1⅛ 
               
               
                   
                 1⅞-3¾ 
                 1¼ 
               
               
                   
                 2¼-4½ 
                 1½ 
               
               
                   
                 2⅝-5¼ 
                 1¾ 
               
               
                   
                   3-6 
                 2 
               
               
                   
                 3¼-6⅜ 
                 2⅛ 
               
               
                   
                 3⅜-6¾ 
                 2¼ 
               
               
                   
                 3¾-7½ 
                 2½ 
               
               
                   
                 4⅛-8¼ 
                 2¾ 
               
               
                   
                 4½-9 
                 3 
               
               
                   
                   
               
               
                   
                 *Suitable blends for the weights and thicknesses in Table II are thermally bonded batts having bicomponent low melt binder fibers in the amount of approximately 10 percent to 20 percent by total volume of the blend. The remaining blend volume comprises a relative percent volume of charred thermoplastic fibers to carrier fibers in the range of approximately 15 percent to 85 percent by relative volume. The batts are compressed to a ratio of weight (ounces per square foot) to thickness (inches) in the range of about 1.5 to 1 ratio up to about 3 to 1 ratio. 
               
             
          
         
       
     
         [0000]    
       
         
               
               
               
             
           
               
                   
                 TABLE III* 
               
               
                   
                   
               
               
                   
                 Weight 
                 Thickness 
               
               
                   
                 (oz/sq. ft.) 
                 (inches) 
               
               
                   
                   
               
             
             
               
                   
                   4-6¼ 
                 3⅛ 
               
               
                   
                 4⅛-6½ 
                 3¼ 
               
               
                   
                 4⅜-7 
                 3½ 
               
               
                   
                 4⅝-7½ 
                 3¾ 
               
               
                   
                   5-8 
                 4 
               
               
                   
                 5⅛-8¼ 
                 4⅛ 
               
               
                   
                 5¼-8½ 
                 4¼ 
               
               
                   
                 5⅝-9 
                 4½ 
               
               
                   
                 5⅞-9½ 
                 4¾ 
               
               
                   
                 6¼-10 
                 5 
               
               
                   
                 6⅜-10¼ 
                 5⅛ 
               
               
                   
                 6½-10½ 
                 5¼ 
               
               
                   
                 6⅞-11 
                 5½ 
               
               
                   
                 7¼-11½ 
                 5¾ 
               
               
                   
                 7½-10½ 
                 6 
               
               
                   
                 7⅝-10⅝ 
                 6⅛ 
               
               
                   
                 7⅞-11 
                 6¼ 
               
               
                   
                 8⅛-11⅜ 
                 6½ 
               
               
                   
                 8½-10⅛ 
                 6¾ 
               
               
                   
                 8¾-10½ 
                 7 
               
               
                   
                 8⅞-10⅔ 
                 7⅛ 
               
               
                   
                   9-10⅞ 
                 7¼ 
               
               
                   
                 9⅜-11¼ 
                 7½ 
               
               
                   
                 9⅝-11 1/16 
                 7¾ 
               
               
                   
                  10-12 
                 8 
               
               
                   
                   
               
               
                   
                 *Suitable blends for the weights and thicknesses in Table III are thermally bonded batts having bicomponent low melt binder fibers in the amount of approximately 10 percent to 20 percent by total volume of the blend. The remaining blend volume comprises a relative percent volume of charred thermoplastic fibers to carrier fibers in the range of approximately 15 percent to 85 percent by relative volume. The batts are compressed to a ratio of weight (ounces per square foot) to thickness (inches) in the range of about 1.25 to 1 ratio up to about 2 to 1 ratio. 
               
             
          
         
       
     
         [0063]    Referring to  FIG. 6 , the method for forming the fire combustion modified batt comprising resin bonding process is representatively and schematically illustrated. Charred thermoplastic fibers, such as oxidized PAN fibers or FR rayon fibers, and carrier fibers are blended to form a first web. Low melt temperature binder fibers are not required as a heat curable binder material is used. The charred thermoplastic fibers and carrier fibers of the blend for the thermal bonding process are suitable for this application as well. For example, Pyron® is a suitable charring fiber, specifically an oxidized PAN fiber, and thermoplastic fibers such as polyester, and more specifically, KoSa Type 209 or KoSa Type 295 are suitable carrier fibers. However, other synthetic and natural fibers can be used depending upon the precise processing limitations imposed and the characteristics of the batt which are desired at the end of the process. While the mixture of charred thermoplastic fibers and carrier fibers in the first web for the resin bonding method can be any of a number of suitable fiber blends, for purposes of illustrating the process, the first blend is comprised of charred thermoplastic fibers, such as oxidized PAN fibers or FR rayon fibers, in the range of approximately 15 percent to 100 percent by volume and corresponding carrier fibers in the range of approximately 85 percent to a negligible amount. 
         [0064]    Referring back to  FIG. 5 , the resin bonding method can also optionally comprise a second blend of carrier nonwoven fibers to form a second web. The nonwoven fibers can be the same as or similar to those blended with the charred thermoplastic fibers discussed above, such as, for example, polyester thermoplastic polymer fibers. Other synthetic or natural fibers can be used depending upon the precise processing limitations imposed and the characteristics of the second web which are desired at the end of the process. 
         [0065]    The resin bonding method further comprises forming a first web and a second web, from first and second blends, respectively, using web forming machines such as garnetts, cross-lappers or air laying apparatus. The method also comprises the step of disposing a surface of the first web in a conforming relationship to a surface of the second web to form the batt. While the second nonwoven web provides a lighter color to a surface of the batt and may impart additional loft and comfort, alternatively, a relatively thin layer of a nonwoven facing material may be suitable for reinforcement to the first web of charring and carrier fibers. The web and batt forming steps for the resin bonding method are generally similar to those for the thermal bonding process which details are discussed above. An air laying machine can also be used. Generally, the fibers are introduced into an air stream which carries the fibers to an air permeable support such as a perforated drum which is rotating. Accumulation of the fibers onto the drum surface results in a web formation. A vacuum is applied through the web from one side of the web to the other and through said air permeable support sufficient to reduce the thickness and increase the density of the web throughout the thickness of the web to form a batt. 
         [0066]    Referring back to the schematic of  FIG. 6 , heat curable resin is applied to the batt for bonding the web fibers. While there are a variety of applications, generally resin in the form of liquid is sprayed while froth resin is extruded onto the batt. Alternatively, the batt is fed or dipped into a bath of resin. Resins suitable for the present invention are curable by heat and can be any of a variety of compositions. Generally, the resin is comprised of latex or acrylic binders. Additionally, the resin can comprise fire resistant chemicals which further enhance the fire resistance of the finished batt. 
         [0067]    In the application of liquid resin, as the batt moves along a conveyor in the machine direction, the resin is sprayed onto the batt from one or more spray heads which move in a transverse or cross direction to substantially coat the batt. Froth resin is extruded onto the batt using a knife or other means. The batt could also be fed through or dipped into a resin bath. The applied resin is crushed into the batt for saturation therethrough by nip rollers which are disposed along the transverse direction of the conveyor to apply pressure to the surface of the batt. Alternatively, the resin is crushed into the batt by vacuum pressure applied through the batt. The batt moves into an oven heated to a temperature which cures the resin. The batt exits the oven and is cooled. The batt is maintained substantially in its oven state upon cooling since the heat cures the resin which bonds the fibers of the batt together in this state. The batt moves into a cutting zone where its lateral edges are trimmed to a finished width and it is cut transversely to the desired length. 
         [0068]    Referring to  FIG. 7 , an example of batt  300  formed by the resin saturated bonding method of the present invention is illustrated. Batt  300  is comprised of first web  310  having carrier fibers  312  and charred thermoplastic fibers  314  and a relatively thin nonwoven layer  320 . The weight, density and thickness  302  of batt  300  are determined by, among other factors, the heating process which cures the resin and fixes the web in this state. Batt  300  can be high loft or densified depending on the processing conditions and the desired batt characteristics. As discussed herein, a densified batt has approximately a 2 to 1 or greater ratio of weight in ounces per square foot to thickness in inches which, in terms of density is approximately 1.5 pounds per cubic foot or more. For illustration purposes, batt  300  is densified. Table IV provides examples of various weights and corresponding thicknesses of batts processed by the resin bonding method of the present invention. 
         [0000]    
       
         
               
               
               
             
           
               
                   
                 TABLE IV* 
               
               
                   
                   
               
               
                   
                 Weight 
                 Thickness 
               
               
                   
                 (oz/sq. ft.) 
                 (inches) 
               
               
                   
                   
               
             
             
               
                   
                  ¼-¾ 
                 ⅛-¼ 
               
               
                   
                  ¾-1½ 
                 ¼-½ 
               
               
                   
                 1½-3 
                 ½-1 
               
               
                   
                   
               
               
                   
                 *Suitable blends for the weights and thicknesses in Table IV are resin bonded batts having from 15 percent oxidized PAN fibers up to 100 percent and the remaining volume of polymer carrier fibers. 
               
             
          
         
       
     
         [0069]    Referring to  FIGS. 8A and 8B , side views of a traditional mattress and one which incorporates the thermal and resin bonded batts of the present invention are provided. In the construction of a traditional mattress  400 , upper structure  420  positioned over the coil structure  440  includes a quilt panel  422  comprising a cover or ticking  424 , a layer of fiber  426  and a quilt backing  428 . Ticking  424 , fiber layer  426  and quilt backing  428  are stitched together and form quilt pattern  423 . The quilt panel  422  provides loft, comfort and resilience to the mattress  400 . Upper structure  420  of the mattress  400  further comprises a layer of foam filling  430  which imparts durability to the mattress  400  as the foam is relatively stiff as compared to a fiber layer. An insulator  432  separates the foam filling  430  from the coils  440  to minimize the wear of the foam filling  430  which coils  440  may impart. The lower structure positioned under the coil structure  440  is a mirror image of the upper structure  440  and thus is not shown. 
         [0070]    Referring to  FIGS. 4 ,  5 ,  7  and  8 B, mattress  400 ′ which incorporates the fire combustion modified batts of the present invention is shown. Quilt panel  422 ′ of upper structure  420 ′ is comprised of ticking  424 , a resin bonded densified batt  300  having the light colored nonwoven layer  320  proximate the ticking  424 , a thermally bonded high loft batt of charring and nonwoven fibers  110  and a resin bonded densified batt  310  which replaces quilt backing  428 . The resin bonded batt  300  provides fire resistant properties to the mattress near its surface where a flame is likely to contact while providing a light color for aesthetic purposes. The thermal bonded high loft fire combustion modified batt  110  provides sufficient loft, comfort and resilience to effectively replace the fiber layer  426  of the traditional mattress quilt panel  422  while imparting additional fire resistance to the mattress. Upper structure  420 ′ of mattress  400 ′ further comprises a thermally bonded densified batt  200  which replaces foam filling  430  to impart durability to mattress  400 ′. Insulator  432  is replaced with resin bonded batt  310  to enhance the fire resistant properties of mattress  400 . A second thermally bonded densified batt  200  replaces the coil structure  440 . 
         [0071]    Referring to  FIG. 9 , a mattress border  500  constructed of a thermally bonded high loft batt  100  of the present invention is provided. Border  500  further comprises ticking  502 , a foam layer  504  and a quilt backing  506 . Batt  100  has a layer  120  of carrier and binder fibers  122  which is proximate ticking  502  and layer  110  of charred thermoplastic fibers  114  and carrier and binder fibers  112  which is proximate the foam layer  504 . Ticking  502 , batt  100 , foam layer  504  and quilt backing  506  are stitched together and form quilt pattern  508 . The thermal bonded high loft fire combustion modified batt  100  provides loft, comfort and resilience to the border while providing fire resistant properties to the border and a light color layer  120  of carrier and binder fibers  122  proximate ticking  502  for aesthetic purposes. 
         [0072]    The thermal and resin bonded batts formed from the methods of the present invention offer substantial advantages as fire barrier layers in a wide variety of products, particularly as mattress components described above. Fire tests conducted on three mattresses which incorporate various batts of the present invention were conducted under the State of California Technical Bulletin  129  Flammability Test Procedure for Mattresses for Use in Public Building, October 1992. A brief description of the test is as follows. A mattress is placed on a support system. Flames from a multi hole burner (fueled by propane at the rate of 12 1/min) impinge on the side of the mattress for a period of 180 seconds. Test observations are made. The tests were performed on mattresses comprising the fire combustion modified batts to determine, among other things, the burning behavior of the mattresses by measuring the response time which the fire barrier layers would provide to a fire victim to safely escape and a fire department to successfully extinguish the fire. 
         [0073]    In a first test, a traditional mattress comprising a quilt panel of ticking, a polyester fiber layer, a urethane foam layer and a quilt backing, two layers of foam and an insulator proximate the coil structure was tested under the California Technical Bulletin  129 . The test ended after 1 minute 27 seconds when unsafe escalating combustion was noted. In a second test, a thermally bonded high loft batt replaced the polyester fiber layer beneath the ticking of a mattress described under the first test. The thermally bonded high loft batt was comprised of a first layer of approximately 10 to 15 percent by volume of binder polyester fibers and the remaining volume was a 50 to 50 percent by volume blend of Pyron® oxidized PAN fibers and polyester carrier fibers. The batt further comprised a second layer of approximately 10 to 15 percent by volume of binder polyester fibers and the remaining volume was carrier polyester fibers. The weight of each layer was approximately 0.5 ounce per square inch for a total batt weight of about 1 ounce per square inch. The second test ended after 18 minutes 40 seconds before unsafe escalating combustion was noted. Thus, the use of a fire barrier layer in a mattress as described in the second test effectively increased the time by 17 minutes 13 seconds over the traditional mattress of the first test. This increase could provide valuable time for a fire victim to escape or a fire department to extinguish the fire. 
         [0074]    In a third test, a densified resin bonded batt replaced the insulator proximate the coil structure of the traditional mattress of the first test. The densified batt was comprised of 50 percent by volume of oxidized PAN fibers and 50 percent by volume of polyester fibers and weighed about ¾ ounces per square foot. The third test ended after 30 minutes 43 seconds before unsafe escalating combustion was noted. Thus, the use of a densified batt formed from the method of the present invention substantially increases the time over the traditional mattress of the first test by 29 minutes 16 seconds. 
         [0075]    The thermal and resin bonded batts formed from the methods of the present invention offer substantial advantages as fire barrier layers in other products as well. For example, a thermally bonded fire combustion modified batt having a density of less than 1.5 pounds per cubic foot, a high loft batt, can be used as a wrap for or an additional layer to cushion seats, backs and arms in furniture, vehicle and aircraft seats. In seats having a light colored decorative covering, the batt comprising a layer of nonwoven fibers would be positioned with the light colored layer proximate the decorative covering to essentially hide the dark color oxidized PAN fiber. The thermally bonded high loft batt is also suitable as an insulation lining in apparel and fire safety gear such as, for example, in fire fighter jackets and oven mitts for welding or industrial furnace purposes. Further, the high loft batt is suitable as a fire barrier air filter and as an insulator for appliances such as hot water tanks and furnaces. Insulation for aircraft walls, automobile walls, building walls and recreational vehicle wall cavities are also suitable applications of the high loft batt. 
         [0076]    Thermal bonded batts formed from the method of the present invention having a density of about 1.5 pounds per cubic foot or greater, densified batts, are suitable as a replacement to cushion backs, seats and arms in furniture, vehicle and aircraft seats. The densified batts are also suitable as replacements for mattress cores, such as, for example, the foam or inner springs in mattresses, particularly for use in public occupancies and correctional institutions. Additionally, densified thermally bonded batts are suitable for insulation lining in apparel and safety gear such as race driver suits, and as insulation for walls, furnaces and ducting applications. Densified thermally bonded batts are particularly suitable for sound deadening and thermal transfer applications. 
         [0077]    Resin bonded batts, preferably densified batts which are relatively thin, having a thickness in the range of approximately ⅛ inch to approximately ½ inch, have applications as dust covers in mattresses and furniture. Densified resin bonded batts are also suitable as wraps for cushion seats, backs and arms and for deck padding for furniture and curtain backing material. Further applications include wraps for hot water tanks and furnaces and fire and heat shields in building and vehicle walls. 
         [0078]    While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Those skilled in the art will readily see other embodiments within the scope of the invention. Accordingly it is to be understood that the method for forming fire combustion modified batts of the present invention has been described by way of illustration only and not limitation.