Insulator pads

An insulator pad for use in spring based upholstery comprises an embossed thermoplastic bound fibre based nonwoven material having regions of a first density isolated by interconnected regions of a second density. The second density may be higher or lower than the first density. The pad preferably comprises less than 18% by weight thermoplastic binding fibres which provide the thermoplastic bonding. The pad may be produced by subjecting a batt comprising thermoplastic binding fibres to a temperature sufficient to melt the thermoplastic fibres and then subjecting the batt to variable compression to form an embossed pad with the regions of relatively high and low density. The batt may be compressed using an embossing roller with projecting elements 20. The pad is preferably made from recycled fibres and the bonding fibres may be polyolefin (such as recycled polypropylene) and/or polyester. The pad material preferably has a mean weight of 300 to 2500 g/m2, a mean thickness of 3 to 20mm and/or mean density of 50 to 300 kg/m3.