Corrugated fiberfill structures for filling and insulation

A process for forming a corrugated fiberfill structure comprising:

• feeding clumps of fiber stock from a bale comprising fiberfill material and a binder fiber to a picker where the fiberfill and the binder fiber are opened up;
• feeding the opened up fiberfill and the binder fiber to a blender to form a uniform mixture;
• carding the blend to form a fibrous web;
• vertically folding the fibrous web to form a closely packed, corrugated fiberfill structure having a configuration of essentially lengthwise rectangular cross-section having continuous alternating peaks and valleys of approximately equal spacing, and a plurality of vertically aligned pleats which extend between each peak and valley;
• and
• heating the corrugated fiberfill structure to bond the binder fibers and the fiberfill material so that the structure is consolidated and maintains its corrugations, wherein the structure has a bulk density of about 5 to about 18 kg/m3, a height of about 10 mm to about 50 mm and a peak frequency which occurs at about 4 to about 15 times per inch (1.58-5.91 times per cm).