Patent ID: 8025751

Claim:
A process of forming a wearable and functional fabric comprising the steps of: a. fabricating a precursor fabric by a process comprising the steps of: (i) providing a composite comprising at least one web of staple fibers, and at least one thermoplastic binder layer, wherein the melting point of each thermoplastic binder layer is lower than the melting point of the staple fibers, and wherein the composite comprises an upper and lower surface; (ii) needlepunching the staple fibers from at least one web of staple fibers into and through at least one thermoplastic binder layer, wherein ends of fibers originating from the needle-entrance side substantially cover the opposite needle exit-side, and wherein the density of needlepunching penetrations is greater than about 40 penetrations per cm 2 ; (iii) restraining the composite between two smooth surfaces of an apparatus, which are positioned to apply uniform pressure under about 50 psi throughout the upper and lower surfaces; and (iv) heating the composite, while continuing to restrain the composite, for a finite time period to remove the thermal stresses in the composite, wherein each thermoplastic binder layer is fully melted and the staple fibers are not melted, deformed or decomposed, wherein all molten thermoplastic is confined to a thickness smaller than or equal to about one-third of the thickness of the whole composite, and wherein the molten thermoplastic does not extend into either the upper surface or lower surface; and b. providing the precursor fabric with at least one finishing substance to improve the wearability and functionality of the precursor fabric.