Layered composite articles and methods of making same

A layered composite article, comprising:

• a) a rigid backing portion comprising a rigid core having a first surface and an opposed second surface,
• wherein the rigid core comprises a first densified fiber batt and a second densified fiber batt,
• wherein at least one of the first densified fiber batt or the second densified fiber batt comprises respective first plurality of fibers and respective second plurality of fibers,
• wherein the first plurality of fibers of the first densified fiber batt has a melting point different from a melting point of the second plurality of fibers of the first densified fiber batt,
• wherein the first plurality of fibers of the second densified fiber batt has a melting point different from a melting point of the second plurality of fibers of the second densified fiber batt,
• i) wherein the first plurality of fibers of the first densified fiber batt comprises single component polyester fibers having a first melting point, and the second plurality of fibers of the first densified fiber batt comprises sheath-core multi-component fibers comprising a polyester having the first melting point as a core component and a polyester having a second melting point as a sheath component, wherein the second melting point is different from the first melting point, and wherein the first densified fiber batt comprises at least 30% by weight of the sheath-core multi-component fibers, or
• wherein the first plurality of fibers of the second densified fiber batt comprises single component polyester fibers having a first melting point, and the second plurality of fibers of the second densified fiber batt comprises sheath-core multi-component fibers comprising a polyester having the first melting point as a core component and a polyester having a second melting point as a sheath component, wherein the second melting point is different from the first melting point, and wherein the second densified fiber batt comprises at least 30% by weight of the sheath-core multi-component fibers,
• wherein the rigid core is needlepunched,
• wherein the first densified fiber batt and the second densified fiber batt have different densities, and
• wherein at least one of the first densified fiber batt or the second densified fiber batt has a density from 30 lb/ft3 to about 100 lb/ft3;
• and
• b) a decorative portion having a first surface and an opposed second surface, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core,
• wherein the decorative portion comprises:
• 1) an aesthetic layer comprising a film, a woven material, a veneer of slate, a veneer of ceramic, a veneer of stone, a veneer of wood, or a veneer of cork, or 2) a printed image layer, wherein the aesthetic layer or the printed image layer is directly affixed to a first surface of the first densified fiber batt or the second densified fiber batt,
• wherein the first surface of the rigid core is the first surface of the first densified fiber batt or the second densified fiber batt.