Method for producing a planar composite component and composite component produced thereby

A method for producing a planar composite component having a core layer (B) arranged between and integrally bonded to two cover layers (A, A′), wherein the cover layers contain a cover-layer thermoplastic and wherein the core layer contains a core-layer thermoplastic, comprising the following steps:

• a) providing corresponding pre-cut parts of the two cover layers and of the core layer and forming therefrom a stack with layer sequence A-B-A′ is heated to a temperature above the melting temperature of both the cover-layer thermoplastic and the core-layer thermoplastic;
• b) pressing the heated stack A-B-A;
• c) cooling the pressed stack, whereby the planar composite component with consolidated layers integrally bonded to each other is formed;
• and
• wherein
• in step a) the initially provided pre-cut parts of the two cover layers (A, A′) are provided in unconsolidated flexible form, at least one cover layer (A) comprising an unconsolidated flexible fibrous nonwoven layer (C) of 10 to 100 wt.-% thermoplastic fibers of the cover-layer thermoplastic and 0 to 90 wt.-% of reinforcing fibers having an areal weight of 300 to 3000 g/m2, and
• in step a) the initially provided pre-cut parts of the core layer (B) comprise at least one randomly-oriented-fiber nonwoven layer (D) formed from reinforcing fibers and thermoplastic fibers of the core-layer thermoplastic, and having an areal weight of 500 to 10,000 g/m2, and
• after step c) the consolidated cover layer(s) has/have an air pore content of <5 vol.-% and the consolidated core layer has an air pore content of 20 to 80 vol-%.