Planar composite material

Abstract

A planar composite material comprises an UD fiber layer A made of discrete reinforcing fiber rovings and a fiber nonwoven layer B made of a thermoplastic nonwoven which may contain reinforcing fibers, wherein the layers A and B are needled to each other.

1 .- 15 . (canceled) 
     
     
         16 . A planar composite material comprising:
 a) at least one UD fiber layer A of discrete, unidirectional reinforcing fiber rovings ( 6 ) which are not connected to each other, having an areal weight of more than 300 and up to 2,000 g/m 2  and   b) at least one fiber mat with randomly oriented fibers B having an areal weight of 100 to 2,000 g/m 2  comprising a thermoplastic fiber nonwoven or a thermoplastic oriented fiber layer, each of which optionally contains up to 70 wt.-% reinforcing fibers wherein the layers A and B are needled to each other.   
     
     
         17 . The composite material of  claim 16 , having a layer sequence A-B. 
     
     
         18 . The composite material of  claim 16 , the fiber mat with randomly oriented fibers B comprises a thermoplastic fiber nonwoven which is a needled nonwoven or a non-needled carding or airlay nonwoven which is formed of thermoplastic fibers and optionally contains 30 to 70 wt.-% reinforcing fibers. 
     
     
         19 . The composite material of  claim 18 , further comprising, on the side of the layer B which is facing away from the layer A, a fiber layer C comprising nondirectional reinforcing fibers having an areal weight of 50 to 500 g/m 2 . 
     
     
         20 . The composite material of  claim 16 , wherein the fiber mat with randomly oriented fibers B comprises a thermoplastic oriented fiber layer of continuous thermoplastic fibers, which optionally continuous reinforcing fibers. 
     
     
         21 . The composite material of  claim 16 , comprising 30 to 80 wt.-% UD fibers based on the total weight of the composite material. 
     
     
         22 . The composite material of  claim 16 , wherein the reinforcing fiber rovings of layer A are glass, carbon, aramide or basalt fibers with a titer of 200 to 4,800 tex. 
     
     
         23 . The composite material of  claim 16 , wherein the thermoplastic of layer B is unmodified polypropylene, polyamide-6, or polyamide-6,6. 
     
     
         24 . The composite material of  claim 18 , wherein the UD fibers of layer A are carbon fibers and the fiber nonwoven layer B contains 30 to 70 wt.-% recycled carbon fibers and 70 to 30 wt.-% of a polyamide. 
     
     
         25 . A continuous method for producing a composite material of  claim 18 , comprising initially arranging UD fibers of layer A adjoining each other on a circulating endless band a fiber nonwoven layer B is laid thereon, and subsequently, layers A and B are needled to each other. 
     
     
         26 . The continuous method of  claim 25 , wherein prior to needling, a nondirectional fiber layer C is laid onto layer B, and subsequently the layers A, B and C are needled to each other. 
     
     
         27 . The continuous method of  claim 25 , wherein UD fibers of layer A are initially arranged on a circulating endless band, endless fibers of layer B are laid thereon from traversing feeders, and subsequently the layers A and B are needled to each other. 
     
     
         28 . A process for producing fiber reinforced composite components, comprising pressing a pre-cut part made of a composite material of  claim 16  in a mold at temperatures above the softening point of the thermoplastic of randomly oriented fiber layer B. 
     
     
         29 . A process for producing a thermoplastically moldable planar semifinished product, comprising pressing a composite material of  claim 16  in a double band press at a temperature above the softening point of the thermoplastic of randomly oriented fiber layer B. 
     
     
         30 . A process for producing components, comprising pressing a pre-cut part made of a composite material of  claim 16  together with a GMT or NMT semifinished product in a mold at a temperature above the softening point of the thermoplastic of randomly oriented fiber layer B.