Composite and methods of making same

A composite comprising:

• a) a knitted face fabric having a first surface and an opposing second surface, wherein:
• i. the knitted face fabric is needle punched such that fibers protrude from the first surface of the knitted face fabric;
• and
• ii. the knitted face fabric comprises a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point;
• b) a nonwoven backing material comprising fibers, wherein the nonwoven backing material has a first surface and an opposing second surface, wherein the nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point;
• wherein the fibers protruding from the first surface of the knitted face fabric are embedded in the nonwoven backing material between the first surface and the opposing second surface of the nonwoven backing material and are interlocked with the fibers of the nonwoven backing material;
• and
• wherein the knitted face fabric is further bonded to the nonwoven backing material by compressing and applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together.

A composite comprising:

• a) a woven fabric, a non-woven fabric, or a knitted face fabric having a first surface and an opposing second surface, wherein:
• i. the woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude from the first surface of the woven fabric, the non-woven fabric, or the knitted face fabric;
• and
• ii. the woven fabric, the non-woven fabric, or the knitted face fabric comprises a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point;
• b) a nonwoven backing material comprising fibers, wherein the nonwoven backing material has a first surface and an opposing second surface, wherein the nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point;
• wherein the fibers protruding from the first surface of the woven fabric, the non-woven fabric, or the knitted face fabric are embedded in the nonwoven backing material between the first surface and the opposing second surface of the nonwoven backing material and are interlocked with the fibers of the nonwoven backing material;
• and
• wherein the woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material by compressing and applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together,
• wherein the woven fabric, the non-woven fabric, or the knitted face fabric comprises from about 10 wt % to about 40 wt % of the first polymer, and from about 90 wt % to about 60 wt % of the second polymer.

A composite comprising:

• a) a woven fabric, a non-woven fabric, or a knitted face fabric having a first surface and an opposing second surface, wherein:
• i. the woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude from the first surface of the woven fabric, the non-woven fabric, or the knitted face fabric;
• and
• ii. the woven fabric, the non-woven fabric, or the knitted face fabric comprises a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point;
• b) a nonwoven backing material comprising fibers, wherein the nonwoven backing material has a first surface and an opposing second surface, wherein the nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point;
• wherein the fibers protruding from the first surface of the woven fabric, the non-woven fabric, or the knitted face fabric are embedded in the nonwoven backing material between the first surface and the opposing second surface of the nonwoven backing material and are interlocked with the fibers of the nonwoven backing material;
• and
• wherein the woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material by compressing and applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together,
• wherein the nonwoven backing material comprises from about 20 wt % to about 60 wt % of the third polymer, and from about 80 wt % to about 40 wt % of the fourth polymer.