fiber is kosa type 254 celbond u00ae which is a bicomponent fiber with a polyester core and a copolyester sheath the sheath component melting temperature is approximately 230 u00b0 f 110 u00b0 c the binder fiber alternatively can be a polyester copolymer rather than a bicomponent fiber 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.