Abstract: A three layer laminated sheet of nonwoven thermoplastic fibers made by laminating a layer of meltblown fibers between two layers of needle punched fibers, and ultrasonically welding the layers together at a number of discrete points uniformly across the length and width of the sheet.

Abstract: A cohesive layered sheet of thermoplastic fiber material formed by two outer layers of material, each outer layer having a standard full width, and an inner layer made from strips of scrap material. The strips of scrap material each have a width substantially less than the standard full width and are arranged side-by-side so as to have a combined width approximately equal to a standard full width. The layers are ultrasonically bonded together so as to form a cohesive layered sheet. A method and apparatus are provided for manufacturing such a sheet.