Abstract: A method of forming a laminated fabric which includes an inner air-laid, batt-like material comprising randomly arrayed fibers of carbon and a thermoplastic copolyvinyl sich as Vinyon is manufactured by feeding the outer shell layers on opposite sides of the batt through an ultrasonic treatment station where ultrasonic energy is applied to the material. The sonic horn engages one side of the laminate, while a patterned anvil roller from which pins extend radially in a predetermined pattern engages the other side of the material being treated. Accordingly, ultrasonic energy applied by the ultrasonic horn is concentrated at the pins, which fuses the thermoplastic fibers in the batt at the places where the pins engage. Since the shell fabrics are also thermoplastic, the columns formed through the batt due to their engagement by the pins and the ultrasonic energy are also fused to the outer shell fabrics.