The present invention provides multiple processes of making fabric composites using fabric and/or fiber waste, or virgin fabric or fiber as starting material and via a needle punching process. The fabric and/or fiber waste, or virgin fabric or fiber, are regenerated to form fabric composites for reuse.

Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer.

A composite fabric includes a film having a first side and a second sides, a first fibrous layer having a first side facing the second side of the film and a second side, a fabric layer having a first side facing the second side of the first fibrous layer and a second side, a second fibrous layer having a first side facing the second side of the fabric layer and a second side, and a plurality of retaining members connected to and extending away from the second side of the second fibrous layer, the plurality of retaining members configured to contact a surface on which the composite fabric is placed to resist movement of the composite fabric relative to the surface and such that the second side of the fibrous layer is entirely spaced from the surface.

A composite fabric includes a film, a first fibrous layer, a fabric layer, and a second fibrous layer and one or more retaining members. The film has a first side and a second side. The first fibrous layer has a first side connected to the second side of the film and a second side. The fabric layer has a first side connected to the second side of the first fibrous layer and a second side. The second fibrous layer has a first side connected to the second side of the fabric layer and a second side. The film can be a non-heat shrinking film. The retaining members may be configured to contact a surface on which the composite fabric is placed and resist movement of the composite fabric relative to the surface where the retaining members include a corrosion inhibitor.

Described is a composite made from a woven fabric, a non-woven fabric, or a knitted face fabric and a non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude into the non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric has a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point. 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. The woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together.

A fiber sheet structure includes a knit weave and has a cell-mounting front surface and a back surface, the average pore size of the back surface is smaller than the average pore size of the cell-mounting surface, the knit weave includes doubled yarn bundles made of gelatin fiber bundle and thermoplastic resin fiber bundle, the thickness of the fiber sheet structure is 30 to 5000 m, the number of gelatin fibers constituting the gelatin fiber bundle is 5 to 60, the fineness of the gelatin fiber is 0.5 to 10 dtex, the total number of gelatin fiber bundles and thermoplastic resin fiber bundles in the doubled yarn bundle is 2 to 20, and the ratio of the number of gelatin fiber bundles to thermoplastic resin fiber bundles in the doubled yarn bundle is 5:1 to 1:5.

Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer.