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A process is disclosed for manufacturing a high strength composite structure by needling individual webs of initially spunbonded material and then needle-punching a stack of the individual webs to enmesh and entangle filaments across the webs, with little or no loss of the initial filament-related s

A process is disclosed for manufacturing a high strength composite structure by needling individual webs of initially spunbonded material and then needle-punching a stack of the individual webs to enmesh and entangle filaments across the webs, with little or no loss of the initial filament-related strength.

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A process for manufacturing a composite structure of spunbonded layers comprising the steps of: (a) applying a finish of lubricating material to coat the filaments of a spunbonded web of synthetic polymer; (b) needling the web of coated filaments using smooth needles to break bonds between the filam

A process for manufacturing a composite structure of spunbonded layers comprising the steps of: (a) applying a finish of lubricating material to coat the filaments of a spunbonded web of synthetic polymer; (b) needling the web of coated filaments using smooth needles to break bonds between the filaments; (c) placing at least one needled web of coated filaments from step (b) in a stack; and (d) needle-punching the stack with barbed needles to enmesh filaments from the spunbonded webs and yield a composite structure of layers. A composite structure of spunbonded layers comprising: (a) at least two loosened webs of spunbonded polymer filaments wherein the filaments of each web have a coating of a lubricating material and have at least some of the bonds between the filaments broken in order to loosen the web; and (b) at least some filaments from each of the loosened webs are enmeshed with filaments of the other loosened web to join the webs.