Molded composite fabrics and methods of making

B - Operations – Transporting – 32 – B

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B32B 5/24 (2006.01) A41C 3/10 (2006.01) A41C 5/00 (2006.01) A43B 23/00 (2006.01) B29C 70/34 (2006.01) B32B 5/20 (2006.01) B32B 7/12 (2006.01) D04H 1/72 (2006.01)

Patent

CA 2525611

A molded composite fabric and methods of making are provided. The molded composite fabric has a polyethylene foam layer and a first fabric layer adhered to a first side of the polyethylene foam layer to define a composite fabric. The molded composite fabric also includes a feature molded in the composite fabric. The first fabric layer has a non-woven fabric with a web of randomly disbursed fibers. The method includes selecting a non-woven fabric having a web of randomly disbursed fibers, exposing the non-woven fabric to mechanical agitation, laminating the non-woven fabric to a first side of a polyethylene foam layer to a composite fabric, compressing the composite fabric between a top mold and a bottom mold, and maintaining the composite fabric between the top and bottom molds for a predetermined dwell time.

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