Patent ID: 7824762

Claim:
A laminate comprising at least two layers of fibrous nonwoven mats bonded together with a thermoplastic resinous film, the fibrous nonwoven mats comprising about 60 to about 90 wt. percent of fibers and about 16 to about 32 wt. percent of a cured resin binder locking the fibers in each of the fibrous nonwoven mats together at the fiber crossover locations in the fibrous nonwoven mats, the binder selected from a group consisting of polyacrylic acid solution polymer and melamine solution polymer, the majority of the fibers in each of the at least two fibrous nonwoven mats being glass fibers having a fiber diameter of at least about 12 microns and having lengths in the range of about 0.25 to about 1.25 inches, the at least two layers of fibrous nonwoven mats bonded together with the thermoplastic resinous film between each of the two layers of fibrous nonwoven mats, the thermoplastic resinous film being thermoplastic and of a different polymer than the polymer or polymers in the cured resin binder bonding the fibers together in said fibrous nonwoven mats, each of the fibrous nonwoven mats having a basis weight in the range of about 0.5 to about 6 lbs. per 100 sq. feet, one of the fibrous nonwoven mats having a basis weight of at least about 4.1 lbs. per 100 sq. ft. and in the range of about 1.5 times to about 3 times the basis weight of another fibrous nonwoven mat in the laminate, the thickness of the laminate being at least about 150 mils, a bottom or top layer of the laminate being a fibrous nonwoven mat comprised of at least about 70 wt. percent glass fibers and about 6 to about 10 wt. percent polymer fibers.