Planar composite material

Abstract

A sheetlike composite material including at least one layer A of a nonwoven thermoplastic fiber web or a thermoplastic film, and at least two unidirectional oriented-fiber layers B and B′, the layers B and B′ having a bidirectional fiber orientation. The layers are not only needled but also stitched to one another.

1 - 20 . (canceled) 
     
     
         21 . A planar composite material comprising
 a) at least one layer A comprising a fiber nonwoven comprising 40 to 100 wt.-% thermoplastic fibers and 60 to 0 wt.-% reinforcing fibers, or comprising a thermoplastic foil, 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.   
     
     
         22 . The composite material of  claim 21 , wherein a layer arrangement is B-A-B′ or B-A-B′-A-B. 
     
     
         23 . The composite material of  claim 21 , wherein the fiber orientation of the layers B and B′ with respect to a reference direction of the composite material is 0°/90°, 30°/−30°, 45°/−45° or 60°/−60°. 
     
     
         24 . The composite material of  claim 21 , the areal weights of the individual layers each are 20 to 1,000 g/m 2 . 
     
     
         25 . The composite material of  claim 21 , the areal weights of the individual layers each are 30 to 1,000 g/m 2 . 
     
     
         26 . The composite material of  claim 21 , the areal weights of the individual layers each are 150 to 3,000 g/m 2 . 
     
     
         27 . The composite material of  claim 21 , wherein the total amount of reinforcing fibers in the composite material is 20 to 80 wt.-%, based on the total weight of the composite material. 
     
     
         28 . The composite material of  claim 21 , wherein the reinforcing fibers comprise glass fibers or carbon fibers. 
     
     
         29 . The composite material of  claim 21 , wherein the thermoplastic fibers or the thermoplastic foil of the layer A comprise polypropylene. 
     
     
         30 . The composite material of  claim 29 , wherein threads used for stitching comprise polypropylene. 
     
     
         31 . The composite material of  claim 21 , wherein the thermoplastic fibers or the thermoplastic foil of the layer A comprise polyamide. 
     
     
         32 . The composite material of  claim 31 , wherein the threads used for stitching comprise polyamide. 
     
     
         33 . The composite material of  claim 21 , wherein the thermoplastic fibers or the thermoplastic foil of the layer A comprise polyether ketone. 
     
     
         34 . The composite material of  claim 33 , the threads used for stitching comprise polyether ketone. 
     
     
         35 . A method for producing a composite material of  claim 21 , comprising:
 a) continuously merging together fiber nonwoven layer(s) A produced by a carding, airlay or spunbond nonwoven process, with oriented fiber layers B and B′, and subsequently stitching the layers to each other and thereafter needling the layers; or   b) continuously merging together thermoplastic foil(s) of the layer(s) A with the oriented fiber layers B and B′, stiching the layers to each other, and thereafter needling the layers.   
     
     
         36 . A process for producing three-dimensional components comprising heat pressing a composite material of  claim 21  in a mold. 
     
     
         37 . A process for producing a planar semifinished product with a thickness of 0.5 to 5 mm comprising of heat pressing a composite material of  claim 21  in a double band press. 
     
     
         38 . A planar heat-moldable semi-finished product comprising a molding having a thickness of 0.5 to 5 mm prepared by thermally consolidating a composite material of  claim 21  in a double band press. 
     
     
         39 . The composite material of  claim 21 , wherein the at least one layer A consists of a thermoplastic foil. 
     
     
         40 . The composite material of  claim 21 , wherein an acute angle between fiber directions of the fiber layers B and B′ is 60°.