LAYERED COMPOSITE ARTICLES AND METHODS OF MAKING SAME

Described is a method of making a densified fiber batt that includes the steps of: a) providing a fiber batt comprising a first plurality of fibers having a first melting point and a second plurality of fibers having a second melting point different from the first melting point; b) subjecting the fiber batt to heat, thereby producing a heated fiber batt; and c) after step b) subjecting the heated fiber batt to pressure in a static press, thereby forming a densified fiber batt having a first surface and an opposed second surface, wherein the densified fiber batt comprises at least 30% by weight of the first plurality of fibers being a plurality of multi-component fibers. Also disclosed is a layered composite article comprising such a fiber batt.