Abstract: A sandwich composite material formed of a core layer positioned between first and second skin layers is provided. Either the core layer or the first and second skin layers are formed of a composite material that includes reinforcement fibers and organic fibers. Preferably, the reinforcing fibers are wet use chopped strand glass fibers. The composite material may be formed by opening the reinforcement fibers, blending the reinforcement and organic fibers, forming the reinforcement and organic fibers into a sheet, and bonding the sheet. The core layer and first and second skin layers may be attached by adhesives or resin tie layers. The sandwich composite material may include a facing layer affixed to an exposed major surface of one or both of the first and second skin layers. The strength, stiffness, and load deflection of the sandwich composite material may be modified by changing the amount and/or type of fibers present.

Abstract: A composite material formed of reinforcement fibers, acoustical enhancing fibers such as polyethylene terephthalate (PET) fibers or modified polyethylene terephthalate fibers, and one or more organic fibers is provided. The acoustical enhancing fiber may be any fiber that provides increased or enhanced acoustical absorbance, particularly at low frequencies. The composite material may be formed by partially opening wet reinforcing fibers, acoustical enhancing fibers, and organic fibers, mixing the reinforcing, acoustical enhancement, and organic fibers, forming the fibers into a sheet, and bonding the fibers in the sheet. Preferably the reinforcing fibers are wet use chopped strand glass fibers. The composite material may be formed of a single layer of reinforcement, acoustical enhancement fibers, and organic fibers.

Abstract: A method of forming a multilayer insulation material formed of an acoustical composite layer and a first thermal layer is provided. The acoustical and insulting layer is formed of a polymer based thermoplastic material and reinforcing fibers. Preferably the reinforcing fibers are wet use chopped strand glass fibers (WUCS). The acoustical composite layer may be formed by opening the WUCS fibers, blending the reinforcement and polymer fibers, forming the reinforcement and polymer fibers into a sheet, and then bonding the sheet. A first thermal layer formed of one or more polymer based thermoplastic organic materials is then positioned on a first major surface of the acoustical composite layer. A second thermal layer of polymeric fibers may be optionally positioned on a second major surface of the acoustical composite layer. The multilayer acoustic material may be utilized in semi-structural and acoustical applications.