Abstract: The invention relates to a high loft nonwoven composite comprising a nonwoven layer having a first and second side and a thermoplastic layer. The nonwoven layer comprises about 60 to 90% by weight of a high crimp polyester fiber having between about 5 and 20 crimps per inch and about 10 to 40% by weight of a core/sheath polyester fiber, where the sheath has a lower melting temperature than the core. The nonwoven layer is calendared on at least the first side. A thermoplastic layer is applied to the first side of the nonwoven layer.

Abstract: The invention relates to a needled composite comprising a double needle bar knit layer, a nonwoven layer, and a second knit layer, wherein each layer consists essentially of polyester and wherein the knit layers and the nonwoven layer are needled together and the process to form the needled composite.