Underbody shield compositions and articles that provide enhanced peel strength and methods of using them

A method of forming a composite article comprising:

• combining a thermoplastic polymer, reinforcing fibers and a lofting agent in an aqueous solution;
• mixing the aqueous solution comprising the thermoplastic polymer, reinforcing fibers and lofting agent to disperse the reinforcing fibers and the lofting agent in the thermoplastic polymer to provide an aqueous foam dispersion;
• disposing the aqueous foam dispersion onto a forming element;
• removing liquid from the disposed aqueous foam to provide a core layer comprising a web formed from the thermoplastic polymer, the reinforcing fibers and the lofting agent;
• heating the core layer above a softening temperature of the thermoplastic polymer of the core layer;
• disposing an adhesive layer comprising a thermoplastic polymer and a thermosetting material on the core layer;
• disposing a skin material on the disposed adhesive layer to provide a composite article;
• and
• lofting the core layer of the composite article using heat to increase a thickness of the core layer and provide a peel strength between the disposed skin material and the lofted core layer of at least 0.5 N/cm as tested by DIN 53357 A dated Oct. 1, 1982.

A method of forming a composite article comprising:

• combining a thermoplastic polymer, reinforcing fibers and a lofting agent in an aqueous solution;
• mixing the aqueous solution comprising the thermoplastic polymer, reinforcing fibers and lofting agent to disperse the reinforcing fibers and the lofting agent in the thermoplastic polymer to provide an aqueous foam dispersion;
• disposing the aqueous foam dispersion onto a forming element;
• removing liquid from the disposed aqueous foam to provide a web comprising the thermoplastic polymer, the reinforcing fibers and the lofting agent;
• heating the web above a softening temperature of the thermoplastic polymer of the web;
• disposing an adhesive layer comprising a thermoplastic polymer and a thermosetting material on a first surface of the heated web;
• and
• disposing a scrim on the disposed adhesive layer to provide a composite article.