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 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 and B′ comprising parallel reinforcing fiber bundles, wherein at least two layers B and B′ have different fiber orientations relative to at least one other B or B′ layer prior to stitching and needling,
• wherein all layers are stitched together and subsequently needled, the thermoformable composite material being formed by:
• a) continuously merging together at least one fiber nonwoven layer A1 produced by a carding, airlay or spunbound nonwoven process, with at least two unidirectionally oriented fiber layers B and B′, at least one layer B and one layer B′ having different fiber orientations relative to each other and subsequently stitching the layers to each other and thereafter needling the layers;
• or:
• b) continuously merging together at least one thermoplastic film layer A2 with the at least two unidirectionally oriented fiber layers B and B′, at least one layer B and one layer B′ having different fiber orientations relative to each other, stitching the layers to each other and thereafter needling the layers, and
• (II) for the planar semifinished product,
• heat pressing in a double band press a 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 and B′ comprising parallel reinforcing fiber bundles, wherein at least two layers B and B′ have different fiber orientations relative to at least one other B or B′ layer prior to stitching and needling,
• wherein all layers are both stitched together and also subsequently needled, the thermoformable composite material being formed by:
• a) continuously merging together at least one fiber nonwoven layer A1 produced by a carding, airlay or spunbound nonwoven process, with at least two unidirectionally oriented fiber layers B and B′, at least one layer B and one layer B′ having different fiber orientations relative to each other and subsequently stitching the layers to each other and thereafter needling the layers;
• or:
• b) continuously merging together at least one thermoplastic film layer A2 with at least two unidirectionally oriented fiber layers B and B′, at least one layer B and one layer B′ having different fiber orientations relative to each other, stitching the layers to each other and thereafter needling the layers.