Polymer/wucs mat for use in automotive applications

An acoustical and thermally insulative non woven chopped strand mat suitable for use in automotive applications comprising:

• bundles of dehydrated wet reinforcement fibers;
• and
• a thermoplastic bonding material having a melting point less than the melting point of said bundles of dehydrated wet reinforcement fibers, said thermoplastic bonding material bonding at least a portion of said bundles of dehydrated wet reinforcement fibers and said thermoplastic bonding material;
• and
• wherein said bundles of dehydrated wet reinforcement fibers and said thermoplastic bonding material are substantially uniformly distributed throughout said chopped strand mat.

A method of forming a laminate composite comprising the steps of:

• placing a first adhesive layer formed of a first adhesive on a scrim;
• depositing a first chopped strand mat layer on said first adhesive layer, said chopped strand mat including bundles of dehydrated wet reinforcement fibers and a thermoplastic bonding material having a melting point less than the melting point of said dehydrated wet reinforcement fibers, said thermoplastic bonding material having been heat treated to at least partially melt and bond at least a portion of said bundles of dehydrated wet reinforcement fibers and said thermoplastic bonding material;
• placing a second adhesive layer formed of a second adhesive on said first chopped strand mat layer;
• and
• positioning a foam material on said second adhesive layer to form a laminate composite.

A method of forming a laminate composite product comprising the steps of:

• forming a first layered material including:
• depositing a first adhesive layer formed of a first adhesive onto a first scrim;
• positioning a first chopped strand mat layer on said first adhesive layer, said chopped strand mat including bundles of dehydrated wet reinforcement fibers and a thermoplastic bonding material having a melting point less than the melting point of said dehydrated wet reinforcement fibers, said thermoplastic bonding material bonding said bundles of dehydrated wet reinforcement fibers and said thermoplastic bonding material;
• and
• placing a second adhesive layer formed of a second adhesive on said first chopped strand mat layer;
• forming a second layered material including:
• depositing a third adhesive layer formed of a third adhesive onto a foam material layer;
• placing a second chopped strand mat layer on said third adhesive layer;
• depositing a fourth adhesive layer formed of a fourth adhesive onto said second chopped strand mat layer;
• and
• placing a second scrim on said fourth adhesive layer;
• and
• positioning said second layered material and said first layered material such that said foam material layer is adjacent to said second adhesive layer to form said laminate composite product.