Thermally bonded composite materials

Abstract

The present disclosure provides composite materials comprising nettings, mattings or meshes thermally bonded to outer layers of nonwoven fibers that may be configured for use in a variety of applications and products. A composite material comprises a first layer of netting comprising intersecting strands and a second layer in contact with the first layer. The second layer comprises first and second fiber components. The first fiber components have a melting point at least 20 degrees higher than the melting point of the netting. The second fiber components have a melting point within 20 degrees Celsius of the fibers in the netting layer. This allows the second fiber components to thermally bond with the netting at contact points upon the application of heat and pressure. The first fiber components do not substantially thermally bond to the netting and thus form an outer layer, such as a sock, that protects the netting layer.

Dependencies are inferred from the claim text.