Method of producing non-woven fibrous material

In the method of making bulky non-woven fibrous material which entails forming a web from an aqueous suspension containing cellulosic fibers and potentially crimped synthetic fibers having two parts of different softening point temperatures and heating such web to bring out the potential crimp in the synthetic fibers, the improvement which comprises:

• a. controlling the proportions of cellulosic fibers and potentially crimped two part synthetic fibers in said aqueous suspension to assure at most weak bonding among the fibers prior to the heating which effects attainment of crimping;
• b. foaming said aqueous suspension and depositing it as a layer in such foamed condition;
• c. forming said web with weak bonding by draining and then drying the layer of step (b);
• and then
• d. releasing the potential crimp of said synthetic fibers by heating said web while supported substantially free from restraint against shrinkage to a temperature below the lower of said softening point temperatures whereby to produce a bulky non-woven fibrous material.