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 needle-punched densified fiber batt and a second needle-punched densified fiber batt, wherein the first needle-punched densified fiber batt and the second needle-punched densified fiber batt have different densities,
• wherein the first needle-punched densified fiber batt comprises a respective second plurality of fibers and at least 30% by weight of a respective first plurality of fibers,
• wherein the first plurality of fibers of the first needle-punched densified fiber batt being multi-component fibers and having a melting point different from a melting point of the second plurality of fibers of the first needle-punched densified fiber batt,
• wherein the second needle-punched densified fiber batt comprises a respective second plurality of fibers and a respective first plurality of fibers,
• wherein the first plurality of fibers of the second needle-punched densified fiber batt being multi-component fibers and having a melting point different from a melting point of the second plurality of fibers of the second needle-punched densified fiber batt,
• wherein the rigid core comprises at least 30% by weight of multi-component fibers, and;
• b) a decorative portion having:
• a first surface and an opposed second surface, and
• an aesthetic layer and a wear layer, wherein the aesthetic layer defines the opposed second surface of the decorative portion and is directly affixed to a first surface of the first needle-punched densified fiber batt, and
• wherein the wear layer is affixed to a first surface of the aesthetic layer, and
• wherein the first surface of the rigid core is the first surface of the first needle-punched densified fiber batt.