Planar composite material

A method for producing three-dimensional components, or planar semifinished products with a thickness of 0.5 to 5 mm, comprising:

• (I) for the three-dimensional components,
• heat pressing in a mold, a stitched and needled thermoformable composite material comprising
• a) at least one layer A comprising
• A1 a fiber nonwoven comprising 40 to 100 wt.-% thermoplastic fibers and 60 to 0 wt.-% reinforcing fibers,
• or comprising,
• A2 a thermoplastic film,
• and
• b) at least two unidirectionally oriented fiber layers B, each layer B comprising parallel reinforcing fiber bundles, wherein at least one layer B has a different fiber orientation relative to another layer B,
• wherein all layers are stitched together and subsequently needled, and after heat pressing, obtaining a three-dimensional component, the stitched and needled thermoformable composite material formed by:
• a) continuously merging together at least one fiber nonwoven layer A1 produced by a carding, airlay or spunbonded nonwoven process, with at least two unidirectionally oriented fiber layers B, at least one layer B having a different fiber orientation relative to another layer B, and subsequently stitching all the layers to each other, and thereafter needling all the layers;
• or:
• b) continuously merging together at least one thermoplastic film layer A2 with at least two unidirectionally oriented fiber layers B, at least one layer B having a different fiber orientation relative to another layer B, stitching all the layers to each other, and thereafter needling all the layers, and
• (II) for the planar semifinished products,
• heat pressing in a double band press a stitched and needled thermoformable composite material comprising
• a) at least one layer A comprising
• A1 a fiber nonwoven comprising 40 to 100 wt.-% thermoplastic fibers and 60 to 0 wt.-% reinforcing fibers,
• or comprising,
• A2 a thermoplastic film,
• and
• b) at least two unidirectionally oriented fiber layers B, each layer B comprising parallel reinforcing fiber bundles, wherein at least one layer B has a different fiber orientation relative to another layer B,
• wherein all layers are stitched together and also subsequently needled,
• the stitched and needled thermoformable composite material formed by:
• b) continuously merging together at least one fiber nonwoven layer A1 produced by a carding, airlay or spunbonded nonwoven process, with at least two unidirectionally oriented fiber layers B, at least one layer B having a different fiber orientation relative to another layer B, and subsequently stitching all the layers to each other and thereafter needling all the layers;
• or:
• b) continuously merging together at least one thermoplastic film layer A2 with at least two unidirectionally oriented fiber layers B′, at least one layer B′ having a different fiber orientation relative to another layer B, stitching all the layers to each other, and thereafter needling all the layers.