DE3811778A1 - Thermoformable integral composite material and process for its production - Google Patents

Abstract

A one-part composite material is produced without the use of adhesives. In this case, fibres of a layer of unwoven fibres are needle-punched into a thermoformable foam element, to be precise preferably into a thermoformable semi-stiff or semi-rigid foam element having foam cells which are expandable under heat. A binder resin is applied to the layer of unwoven fibres and dried in an oven. When this preferred composite material is subsequently formed into a moulding by a thermoforming process, the foam cells expand with the fibres securely enclosed in the foam element.

Description

The invention relates to a thermoformable integral Ver bundle material or composite material and a process for making the same. In particular relates the invention on the thermoforming of three dimensions len moldings, such as roof cladding by Kraft vehicles.

In the past, many roof panels or Ceiling cladding for vehicles made of fiberglass strengthened polyester resin in a so-called Difference to the hot forming has been produced. It is known to make such an object glass fiber reinforced polyester resin on a rigid Laminate urethane form and through a soft ure to cover support fabric. Such roof cladding However, ceilings or ceiling linings work in Kind of a soundboard, which means the inside of the Vehicle gets louder. Furthermore, the build-form ver driving (lay up molding process) costly.

The plate-like cha has been tried character (boardiness) of the ceiling panels Glass fiber resin and the requirement of the construction form process by avoiding a laminate deformed warm, which consists of a stone structural, thermoformable polystyrene Foam layer and layers of hard paper or a polymeric film on each side of the Foam element is attached. This laminate is covered with a soft polyurethane cover fabric.  

The hot deformation is compared to the build-form drive cost-effectively. A stiff laminate Polystyrene element with hard paper or a polymer film, which is connected on both sides, can easily by mass production on one automatic system, cut into sheets ten, in a corresponding facility for warming molding heated and deformed under vacuum. However, such ceiling panels still have insufficient sound-absorbing properties ten, since the hard paper tends to increase the sound to reflect than to absorb.

It has been tried, the hard paper or the to remove and remove polymeric film from such laminates a layer of non-woven material on one or both sides of the rigid polystyrene foam to replace better sound absorbing To achieve properties. A difficulty with Such attempts, however, consisted in the fact that Ceiling panels of motor vehicles relatively ho hen ambient temperatures, about 85 degrees Celsius have to withstand. The well-known poystyrene Foam laminates, however, tend to delaminate tion and / or sagging or sagging, when exposed to such high temperatures.

Possible solutions to the sagging problem would be:

• 1) the use of a higher temperature foamed polymer and / or  
• 2) Laminating a non-woven material the polystyrene foam element, which poly mere binders with softening temperatures above 85 degrees Celsius.

One disadvantage of using one over higher Temperature-resistant polymer exists yet in that the foam element is more difficult thermoformed into three-dimensional objects can be. Furthermore, the material has the tendency stiffer or more rigid and less noise-killing than to be rigid thermoformable polystyrene. The Ver use of polymeric binders in a non-ge woven material, which on the foam element is laminated, with softening temperatures greater than 75 degrees Celsius, as in the US patent 45 29 641 described does not appear to be sufficient to eliminate the difficulty of sagging The line of tolerance between using Materials with excessive heat resistance what the vacuum deformation difficult, and the materials with sufficient heat resistance to meet the requirements in practice occurring temperatures and the corresponding tests it seems extremely difficult to withstand to be cash.

In US-PS 45 29 641 it is proposed to use a hard Phenolic resin as a binder for the non-woven To use material. The background is heat the laminate and shape it warm before that thermosetting resin cures. Once it hardens, there is one Deformation is no longer possible. Once it's hardened is, the thermosetting phenolic binder against any white more deformation resistant as a result of the action  of ambient temperature and up to 85 degrees Celsius.

However, the problems are the following:

• 1) The thermosetting phenolic polymer can be used during of the heating process so that it is no longer deformable when it is in the Is brought into shape and / or
• 2) The phenolic polymer component of the laminate can an undesirably short shelf life or Have durability, i.e. during storage, of transportation u. harden. So that the Laminate is no longer deformable.

The solution to the difficulty regarding a possible Delamination similarly leads to the search for suitable adhesives. The same difficulties arise here problems. Adhesive with a sufficiently high enamel score the temperatures under the test conditions can not withstand sticking well to the laminated Materials or can affect the thermoforming gene.

To solve these difficulties are in the professional world extensive tests have been carried out for many years without finding successful solutions. Thus, thermoformed laminate is still made Hard paper or polymer film and structural polystyrene foam as well as manufactured by the build-up molding process, glass fiber reinforced polyester resin for ceiling clothing used in motor vehicles.  

The object of the invention is to overcome these difficulties remedy. This object is achieved by the in the characterizing part of the subordinate patent say contained feature solved.

According to the invention, laminates are used where the use of adhesives or gluing ben is no longer required. This is achieved by creating a one-piece or integral Ver bundle material. Fibers in a layer from a non-woven company ser are in a thermoformable foam element needled. A binder resin is applied to the layer non-woven fibers applied and dried in an oven net. This composite material then becomes one Molded body thermoformed, the excellent sound absorber properties and resistance to Sagging at high temperatures. In a be a particularly preferred embodiment is the foam element a semi-rigid or semi-flexible foam, preferably a foam with cells that are thermal are expandable. In this embodiment ex pander the foam cells during the warming process Forming with firm inclusion in the foam element needled fibers.

The following are exemplary embodiments of the invention described using the drawing. In it show:

Fig. 1 is a perspective sectional view of the Ver composite materials according to the invention,

Fig. 2 is a perspective view of a clothing Deckenaus an automobile consisting of the material according to Fig. 1,

Fig. 3 is a schematic representation of the applied for the ver the implementing of the method, apparatus,

Fig. 4 is an elevational view of the staple gun used for performing the method according to the invention or splicing means,

Fig. 5 is a sectional view of the foam binder applicator, which is used for carrying out the procedural invention Rens,

Fig. 6 is a side view of the applicator shown in Fig. 5,

Fig. 7 is an enlarged view of a in a Schaumele ment before hot molding or thermoforming ge nadelten fiber bundle,

Fig. 8 is the same view as Fig. 7, but after thermoforming,

Figure 9 is a sectional view in perspective of a wide ren embodiment of the Ver. Inventive composite materials,

Fig. 10 is a schematic representation of the device used to manufacture the composite material according to Fig. 9 and

Which is used for deformation of the composite material of the invention in a contoured object or moldings Fig gen. 11 is a sectional view of a pair of Formwerkzeu.

According to the drawings and the embodiments depicted therein, a molded roof liner 20 ( FIG. 2) is made by thermoforming or thermoforming a unitary composite material 22 ( FIG. 1) having a foam element 24 in which the cells are preferably only about a third expanded to their possible size. Furthermore, this composite material 22 has a reinforcing mat and outer layers 28 and 30 made of non-woven fibers on the foam element or foam 24 . The above elements are not bonded together, but are held together by a plurality of fibers 32 that extend from layers 28 and 30 into foam element 24 . When a preferred shape of the integral composite material 22 is thermoformed with heat-expandable foam cells to form a ceiling lining 20 or a comparable molded body, the cells of the foam expand and firmly grasp the fibers in the cell matrix ( FIGS. 7 and 8). A thermoplastic binder is dispersed in the layers of non-woven fibers in order to keep the fibers in the shape of the layer without, however, disturbing the spring properties of the fiber structure. If required, upholstery or another decorative fabric can be applied to the integral composite material by conventional methods before or after the thermoforming process.

Figure 3 shows a device that can be used to assemble the composite material. A first separating device 33 separates a quantity of fibers into individual fibers and causes these fibers to be deposited in an arbitrary orientation in a position 28 on a conveyor (not shown). A reinforcing mat 26 is unwound from a roller 34 in synchronism with the passage or passing by of the non-woven fiber layer 28 . The foam element 24 is unwound in the same way from a roller 36 in synchronism with the other materials. A second fiber device 38 places a second layer of randomly oriented fibers 30 on the foam element to complete the construction of the components of a web or mat 40 .

The web 40 is then passed through a stapler 42 or a connecting device ( FIG. 4), where a pair of alternately reciprocating needle beds 46 with a number of needles 48 fibers 32 in bundles of about five fibers from the layers capture with randomly directed fibers and force these fibers into tunnels, which are formed by the needles 48 in the foam or in the foam element. The needles 48 are formed with inverted barbs, as described in US Pat. No. 3,046,173. The needles 48 in the beds th 46 are in sync with openings back and forth, which are distributed over the entire area of drum 44 . The drums 44 rotate at the same speed as the moving web 40 .

The needled web 50 is guided over a guide roller 51 and passes through a foam binder applicator 52 , where a thermoplastic synthetic resin binder is dispersed in both layers of non-woven fibers 28 , 30 ( FIGS. 3 and 5). The needles 55 transfer foam binder resin from a foam generator, not shown, and distribute the foam binder resin on the fiber layers. A pair of nip rollers 60 push the binder through the fibers in the nonwoven position and partially into the needle tunnels. The coated web 62 is passed through a drying oven 70 where the binder is dried. A cutting device 71 can cut the one-piece composite material into sheets, plates or mats, or the composite material can be wound on rollers for transport to a seller, where the material can then be deformed in ceiling coverings or the like under heat.

Fig. 9 shows a further embodiment, which facilitates the hot deformation of a more shaped or contoured three-dimensional shaped body. The unitary composite material 122 has a greater thickness, the more material it gives to facilitate a deeper pull for the formation of highly deformed objects. The material 122 has a pair of foam elements 124 a and 124 b . Fibers 132 b from the non-woven fiber layer 128 extend in the needle tunnel 131 b completely through the foam element 124 a and essentially entirely through the element 124 b . In contrast, fibers 132 a extend from the non-woven fiber layer 130 in tunnels 131 a entirely through element 124 b and essentially entirely through element 124 a . In this way, the drawn-in needled fibers not only hold the non-woven fiber layers 128 , 130 and the reinforcing mat 126 to the foam elements, but also hold the foam elements 124 a and 124 b together.

The device that can be used to construct the integral composite material 122 is shown in FIG. 10. The apparatus and method are substantially the same as in Fig. 3, except that a second foam member b 124 is withdrawn b from a roll 136 and deposited after the foam element a subtracted 124 from the roll 136 a and was placed on a reinforcing mat 126 . Furthermore, the needles extending from the needle beds are longer than those in the device according to FIG. 3 in order to facilitate the gripping and shifting of the fibers 132 a , 132 b by both foam elements.

The foam element 24 or 124 has essentially any suitable plastic foam material which is deformable under heat (thermoforming). Particularly preferred are semi-rigid polymeric foams including polystyrene and its copolymers, polyurethane, polyolefin and polyvinyl chloride foams, where foams that can be thermally expanded are particularly preferred. A semi-rigid or semi-rigid foam has a certain amount of flexibility, but would break if it were bent. If the foam element has 24 or 124 cells that are expandable under heat, then these foam cells expand significantly in volume when heat is applied. The most preferred material is a styrene-maleic anhydride copolymer foam, such as that sold by Arco Chemical Company under the trademark DYLARK 232. Other materials are semi-rigid polyurethane foams and rigid or rigid polyurethane foams which have been reactivated by saturation with a polyisocyanate and water mixture. A particularly preferred polyurethane foam is a polyester-polyol-urethane foam, as is sold by BASF-Wyandolfe under the trademark ELASTOFLEX. The foam member 24 or 124 in its preferred embodiment is a sheet or mat with a thickness of 2.03 mm to 3.8 mm (80 to 150 mils).

In a particularly preferred embodiment, the element 24 or 124 has a thickness of 140 mils and a density before expansion of 48.1 to 80.1 kg / m 3 (3 to 5 pounds / cf). After that, the integral composite material 22 or 122 was subjected to a thermoforming process, this foam element expands to a thickness of a quarter to a half of an inch. The density after expansion is 19.6 to 28.9 kg / m³ (1.2 to 1.8 pounds / cf). Although the material does not resist sagging under test conditions of 85 degrees Celsius, it does when it is in one Composite material of the invention is installed. Since no laminate is molded, there is no problem of delamination. This material is flexible or semi-rigid before thermoforming and can therefore be kept in roll form. The material is easily thermoformed at about 138 degrees Celsius and will experience a volume expansion of 300% in the preferred embodiment.

The reinforcement mat 26 is a matrix of synthetic material, which reaches at a temperature above 177 degrees Celsius. In a preferred embodiment, mat 26 includes a plurality of glass fibers that are bonded together by a thermosetting plastic such as polymeric urea formal dehyd. In a preferred embodiment, the mat has a thickness of about 0.254 to 0.76 mm (10 to 30 mils), preferably in particular 0.254 mm (10 mils). The glass fibers have a thickness of approximately 10 micrometers and a length of approximately 1.27 cm or more. The product weighs 47.4 g / cm² (2 ounces / square yard) at a thickness of 0.3 mm (12 mils) and has a density of about 0.224 kp / cm³, 80% glass and 20% synthetic resin. Such a matrix can be obtained from Johns Mansville Corporation under the trademark "DURA-GLASS 7010".

The layers of non-woven fibers have a multiplicity of essentially randomly directed artificial or natural fibers with a denier of 4.5 to 25. In a preferred embodiment, the denier is 6 . The layer is formed with a thickness of about 1.27 to 3.81 cm (1/2 to 1.5 inches) and has a weight of about 47.4 to 260.7 g / cm² at this thickness, which preferred weight is 71.1 g / cm² (3 oz / square yard). After needling the non-woven fiber layers, the layer thickness is reduced to about 0.254 cm to 1.9 cm (0.1 to 0.75 inches). In a preferred embodiment, the fiber is virgin polyester in a length of 1.27 to 6.35 cm (0.5 to 2.5 inches) which is selected for its resilient (loft) and sound absorbing properties. A natural fiber, such as cotton, is optionally preferred because of its natural memory (so-called memory effect). The cotton fibers can be virgin or regenerated and are used in lengths of 1.27 to 3.81 cm (0.5 to 1.5 inches).

According to FIG. 4, the upper perforated drum 44 rotates a counter-clockwise and the lower drum 44 b in the clockwise direction and that both in synchronization with the linear velocity of the web 40. The drums 44 and needle plates 46 extend the full width of the web 40 . The needles 48 are arranged in rows of 0.25 to 0.5 inches from each other and the needles in each row are the same as the rows from each other. In the preferred embodiment, 8 rows of needles are provided, each extending across the width of the web. The needles have a caliber of 18 to 48 at their tip and can penetrate up to 1.54 cm (one inch). The needle beds 46 alternately move back and forth through openings, not shown, in drums 44 and in the web 40 . Each bed 46 is synchronized with the rotation of the corresponding drum 44 so that the needles can reach through the openings in the drum. The movement of the beds 46 is a complex movement of a reciprocating movement with respect to the web and a limited rotational movement such that the tips of the needles 48 move laterally at approximately the same speed as the longitudinally moving web 40 . The reason for this complex movement is to reduce the amount of needle breakage that can occur if the movement of the beds 46 is a strictly reciprocating movement.

The binder resin is foamed in a foam generator, which the resin in the presence of air at an air pressure of about 4.57 kp / cm² (65 pounds / cf). The foam comes in one Dimension applied that the deposit has a weight of about 47.4 up to 189.6 g / cm² (2 to 8 ounces / square yard after drying has operation. In a preferred embodiment the dry weight about 71.1 g / cm². The application amount of the bin derharzes is adjusted so that a binder impregnation through the entire fiber layer and over 50 to 100% of the length of the Needle tunnel is guaranteed. A suitable foam genera tor, the foam (froth foam) with a capacity of 90.7 up to 120.2 kg / h is available from Latex Equipment Sales and Services available under the Model No. 500V.

Referring to FIG. 6, the foam from the foam generator that is not shown, conveyed to a dispensing nozzle 45 through a flexible sleeve 64. The nozzle 55 is arranged on a feed head 54 which can be moved back and forth perpendicular to the longitudinal movement of the web. Referring to FIG. 5, the foam is placed on a surface that between on the ground by the rollers 60, on one side of the needled web 50, a congestion located in tight contact with the roller 60 or wiping means on the other side and the ends of the rollers 60 and the damming members 56 he stretching insulating members 68 is limited. The reciprocating movement of the feed head 54 is accomplished by an air cylinder 66 or the like. The dispensing nozzle 55 extends into the area where the resin is deposited and places the deposited resin in the resin dispensed from the dispensing nozzle to produce a consistent binder resin-foam mixture.

The binder resin must be thermoplastic to keep the warm to ensure deformation, but it must be sensitive towards water and not sticky either Room temperature. The preferred glass transition temp temperature (Tg) for the resin is between 20 degrees Celsius and 121 degrees Celsius. The preferred festival body content is about 30-60% and a fire retardant the substance, such as aluminum trihydrate, is in one Share of about 25 vol .-% provided. A binder resin can be selected from the group: water-dispersed Urethane, acrylic, ethylene vinyl acetate acrylic, styrene butadiene rubber, polyvinyl acetate, copolymer of polyvinyl water-based epoxy and styrene. The most before Binder resin is a styrene butadiene rubber with a solids content of 48.5% and a Tg of 40 degrees. Such a resin is made by the Reichhold Corporation under the trademark "Tylac 68-500" sold.

The drying oven 70 operates at a temperature above the glass transition temperature of the binder to drive the solvent out of the binder. In a preferred embodiment, the binder is water-based and the drying oven operates at temperatures of about 121 to 132 degrees Celsius.

The ceiling liner 20 is formed from the integral composite material 22 or 122 by first heating the material to a temperature of about 138 degrees Celsius using heating elements and then placing it in a cool die assembly with the desired configuration. Such a mold 72 ( FIG. 11) has an upper mold half 74 and a lower mold half 76 .

According to the invention is an integral network Provided material that ver no adhesive turns so that the difficulties of the state of the Technology related to thermosetting and thermoplastic Adhesives are eliminated. In particular, a Pile or layer of nonwoven fibers on one Mat or plate of a thermoformable foam or Foam applied and staplers are used det to the fiber from the non-woven fiber layers in To pull needle tunnels into the foam. In a preferred embodiment, it has foam cell conditions that are expandable under heat and that are of the heat molding completed the expansion of the foam cells so that the Foam cells that surround the needle tunnels, in contact with the fibers in the tunnels be expanded. A binder resin is through the layer of non-woven fibers distributed so that the Hold fibers together without losing springiness or airiness (loft) of the fiber or the sound sorbent properties of the fibers disrupted or would be affected.  

The composite material can be made with a reinforcing mat be provided, which consists of a matrix of synthetic Material can be formed and through which the Fibers are guided during the needling process. To in addition, the foam element can consist of two contiguities beard elements can be formed, the fibers from the layers of the non-woven fibers essentially extend through both foam elements. To this Way, the foam elements are part of the ver bundled together.

The absence of adhesive in this composite material makes this composite less aging sensitive and less sensitive to heat. Additional Lich it can in roll form or table form to the Ver supplied to buyers for such ceiling linings be, which then the composite material in the ge wanted to thermoform three-dimensional moldings can. Furthermore, the composite material can be divided into others good usable objects are thermoformed, such as packing baskets, panels, trunk and window pillar linings.

Deviating from the described embodiment can have two individual layers of non-woven fibers individual thermoformable foam elements ge needles and then the foam elements are glued to each other. Although the use of Adhesives should preferably be avoided this application form only an adhesive layer require and this only between the foam fabric elements.

Claims (95)

1. A method for producing an integral composite material, characterized by producing a first heat-deformable foam element, attachment of the first layer of non-woven fibers to the foam element, needles of the fibers from the first layer in the foam element, application of a first order of the binder resin in the first Fiber layer as well as drying the first order. 2. The method according to claim 1, characterized, that the thermoformable foam element is a semi-rigid fes thermoformable foam element. 3. The method according to claim 2, characterized, that the semi-rigid thermoformable foam element Has cells that are expandable under heat, so that the foam cells during thermoforming of the material including that in the foam element needled fibers expand. 4. The method according to claim 1, characterized, that the fibers are essentially arbitrary in the he Most fiber layer are distributed. 5. The method according to claim 4, characterized, that the first fiber layer has a thickness of about 1.27 to 3.8 cm and a weight of about 47.4 to 260.7 g / cm² (2 to 11 oz / yard²). 6. The method according to claim 5, characterized, that the fibers in the first fiber layer have a denier of have about 4.5 to 25. 7. The method according to claim 1, characterized, that the fibers in the first fiber layer made of polyester are.   8. The method according to claim 1, characterized, that the fibers in the first layer of fibers are "green" natural Liche fibers are. 9. The method according to claim 1, characterized, that the foam element is a foam from a copoly mer polystyrene maleic anhydride with a density from about 48.1 to 80.1 kg / m³ (3-5 pounds / cf). 10. The method according to claim 1, characterized, that the foam element has a thickness of about 2.03 mm to 3.8 mm (80 to 150 mils). 11. The method according to claim 1, characterized, that the application process the following procedure stages comprises, namely foaming of the binder resin, Binder resin foam deposited on the first fiber location and distribution of foam throughout first layer. 12. The method according to claim 11, characterized, that the foam formation by stirring the binder resin in the presence of air at a pressure of about 4.57 kp / cm³ (65 pounds / square inch). 13. The method according to claim 11, characterized, that the distribution process by pressing the foam into the first layer with a squeeze roller.   14. The method according to claim 1, characterized, that the binder resin has a glass transition temperature from about 20 degrees Celsius to about 121 degrees Celsius having. 15. The method according to claim 14, characterized, that the binder resin is selected from the Group comprising water-based urethane, Acrylic, ethylene vinyl acetate acrylic, styrene butadiene Rubber, polyvinyl acetate, copolymer from Polyvinal acrylic epoxy and water-based styrene. 16. The method according to claim 15, characterized, that the drying process takes place in that the first layer of air with a temperature of about 121 Degrees Celsius exposed to about 132 degrees Celsius becomes. 17. The method according to claim 1, characterized, that the resin in an amount of about 47.4 g dry weight per cm² to 189.6 g dry weight per cm² (2 to 8 ounces Dry weight per square yard) of the coating applied becomes. 18. The method according to claim 1, characterized, that the needle operation is carried out by using a an inverted hook on at a distance to each other through the first layer and is pressed into the foam element.   19. The method according to claim 18, characterized, that the places about 0.63 cm to about 1.27 cm (a four to half an inch) apart. 20. The method according to claim 18, characterized, that the needling process further includes that the needle in the foam element essentially over the entire thickness of this element is pressed. 21. The method according to claim 1, characterized, that a reinforcing mat between the foam element and the layer of non-woven fibers is, the fibers through during the needling process the mat and needled into the foam element will. 22. The method according to claim 21, characterized, that the mat together by a thermosetting resin has connected glass fibers. 23. The method according to claim 21, characterized, that the mat has a thickness of about 0.254 mm (10 mil) to about 0.76 mm (30 mil). 24. The method according to claim 23, characterized, that the mat weighs approximately 47.4 g / cm² (2 ounces / square yard).   25. The method according to claim 1, characterized, that a second layer of non-woven fibers is adjacent opposite one side of the foam element the first layer of non-woven fibers is placed, the fibers from this second layer into the foam element needled, a second order or coating processing of a binder resin in the second layer brought and the second order is dried. 26. The method according to claim 25, characterized by arrangement of a ver Reinforcement mat between the foam element and one of the layers of non-woven fibers, the company from one position through the mat and into the Foam element to be needled. 27. The method according to claim 25, characterized by arrangement of a two semi-rigid thermoformable foam element between the first foam element and the two layer of non-woven fibers, the process the needling of the fibers from the second layer the needling of the fibers by the second foam element and includes in the first foam element. 28. The method according to claim 27, characterized, that the second foam element has cells, which are expandable under heat. 29. The method according to claim 27, characterized, that the needling of the fibers from the first layer  Needles the fibers through the first element and in comprises the second foam element. 30. The method according to claim 29, marked by Arrangement of a reinforcement mat between one the foam elements and the corresponding position from non-woven fibers, the process of the needle development also the needling of the fibers from the corre layer of non-woven fibers through the mat and one foam element and the other Foam element includes. 31. The method according to claim 1, characterized, that the composite material after the drying process is wound on a roller. 32. The method according to claim 1, characterized, that the composite material into sheets or mats of certain size divided after the drying process becomes. 33. integral composite material, marked by a first thermoformable foam element with Tunnel trainings covering a variety of tunnels form in the foam element, which becomes a open the first surface, a first layer non-woven fibers which are adjacent to the first surface arranged a variety of fibers that extend from the first layer into the tunnels as well as a binder resin in the first layer and in the tunnel training.   34. composite material according to claim 33, characterized, that the thermoformable foam element is a semi-rigid fes thermoformable foam element comprises. 35. composite material according to claim 33, characterized, that the foam has cells that expan under heat dable so that the cells due to the heat expand a hot forming device and the Close tunnels in contact with the fibers. 36. Composite material according to claim 33, characterized, that the fibers in the first layer of polyester fibers are. 37. Composite material according to claim 33, characterized, that the fibers in the first layer are "green" (virgin) are natural fibers. 38. Composite material according to claim 33, characterized, that the first layer has a thickness of about 0.1 to about 0.75 inches and a weight of about 47.4 g / cm² to 260.7 g / cm² (2 to 11 ounces / square yard). 39. Composite material according to claim 33, characterized, that the fibers in the first layer have a denier of about 4.5 to about 25.   40. composite material according to claim 33, characterized, that the foam is a copolymer of polystyrene Maleic anhydride with a density of about 48.1 to 80.1 kg / cm³ (3 to 5 pounds / cf). 41. Composite material according to claim 33, characterized, that the foam element has a thickness of about 2.03 mm to about 3.8 mm (80 to 150 mils). 42. Composite material according to claim 33, characterized, that the tunnels are spaced about 0.63 up to about 1.27 cm (a quarter to a half inch) are arranged. 43. Composite material according to claim 33, characterized, that the binder resin has a glass transition temperature from about 20 degrees Celsius to about 121 degrees Celsius having. 44. Composite material according to claim 43, characterized, that the binder resin is selected from the group comprising water-based urethane, acrylic, Ethylene vinyl acetate acrylic, styrene butadiene rubber, Polyvinyl acetate, copolymer of polyvinyl acrylic epoxy and water-based styrene. 45. Composite material according to claim 33, characterized, that the binder resin has a dry weight of about 47.4 g / cm²  up to about 189.6 g / cm² (2 to 8 ounces / square yard) of the order or the coating. 46. Composite material according to claim 33, marked by a reinforcement mat between the foam element and layer of non-woven fibers, being the fibers across the mat into the tunnels extend. 47. Composite material according to claim 46, characterized, that the mat together by a thermosetting resin which has connected glass fibers. 48. composite material according to claim 46, characterized, that the mat has a thickness of about 0.254 mm (10 mil) to about 0.76 mm (30 mil). 49. Composite material according to claim 33, marked by a second layer of non-woven fibers next to against a second surface of the foam element is arranged above the first surface, wherein the second surface has second tunnel formations, which is a variety of second tunnels in the foam that open to the second surface a second layer of non-woven fibers, which next to the second surface are arranged, with a Variety of fibers from the second layer to the two ten tunnels and in the second layer Binder resin is present.   50. composite material according to claim 49, marked by a reinforcement mat between the foam element ment and one of the layers of non-woven fibers, each bundle of fibers coming from one of the layers across the mat and into the corresponding tunnels extends. 51. Composite material according to claim 33, marked by a second semi-rigid foam element with a second tunnel formation, which is a number of tunnels in the foam that forms a first surface open the surface of the foam element, the second Foam element opposite a second surface has the first surface facing a second Area of the first foam element opposite the abuts the first surface of the first foam element, through a second layer of non-woven fibers that next to the first surface of the second foam element elements is arranged, a number of fibers that are extend from the second layer into the second tunnel and by a binder resin in the second layer. 52. Composite material according to claim 51, characterized, that the second semi-rigid foam element cells has that are expandable under heat. 53. Composite material according to claim 51, marked by a reinforcement mat between a foam element and the corresponding layer of non-woven fibers, where the fibers from the corresponding position are transverse to  Mat and extend into the appropriate tunnels. 54. Composite material according to claim 51, characterized, that the tunnels are essentially through both foam stretch fabric elements. 55. molded article made of composite material, characterized by a stiff foam fabric element, a first layer of woven fibers, the next to a first surface of the foam element is arranged, a plurality of first fibers itself from the first layer into the foam element stretch, the foam element the fibers tightly enclosed and by a binder resin in the first layer. 56. Shaped body according to claim 55, characterized, that the foam element is a foam from a copoly mer polystyrene maleic anhydride with a density from about 19.56 kg / m³ to about 28.85 kg / m³ (1.2 to 1.8 Pounds / cf). 57. Shaped body according to claim 55, characterized, that the foam element has a thickness of about 0.63 to about 1.27 cm (a quarter to a half inch). 58. Shaped body according to claim 55, characterized, that the binder resin is selected from the group around based on water-based urethane, acrylic, ethylene vinyl acetate acrylic, styrene butadiene rubber, polyvinyl acetate, copolymer of polyvinyl acrylic epoxy and on water based styrene.   59. Shaped body according to claim 55, characterized, that the binder resin has a dry weight of about 47.4 to about 189.6 g / cm² (2 to 8 ounces / square yard) of the order or the coating. 60. Shaped body according to claim 55, marked by a reinforcement mat between the foam element and the layer of non-woven fibers, the company transverse to the mat and into the foam element extend. 61. Shaped body according to claim 60, characterized, that the mat together by a thermosetting resin has connected glass fibers. 62. Shaped body according to claim 60, characterized, that the mat has a thickness of about 0.254 mm (10 mil) to about 0.76 mm (30 mil). 63. Shaped body according to claim 55, marked by a second layer of non-woven fibers next to one second surface of the foam element opposite the first surface is arranged by a variety of second fibers that extend from the second layer into the Extend foam element and through a binder resin in the second layer.   64. Shaped body according to claim 63, marked by a stiffening mat between the foam element and one of the layers of non-woven fibers, each Bundles of fibers from one layer lie across the mat and extends into the corresponding foam element. 65. Shaped body according to claim 55, marked by a second rigid foam element, which with a Surface on a second surface of the first foam elements opposite the first surface of the foam elements, a second layer of non-woven Fibers next to a second surface of the second Foam element opposite the first surface thereof is arranged, a variety of second fibers itself from the second layer into the second foam element, and through a binder resin in the second layer. 66. Shaped body according to claim 65, marked by a reinforcing mat between the one foam element and the corresponding location from non-woven Fibers, with the fibers coming from the corresponding Position across the mat and in the foam element stretch. 67. Shaped body according to claim 66, characterized, that the fibers are essentially through both foam stretch fabric elements.   68. Process for the production of a shaped body, marked by Manufacture of a first semi-rigid thermoformable Foam element, arrangement of a first layer non-woven fibers on the foam element, needling the fibers from the first layer into the foam ment, application of a first order or Be layering a binder resin in the first layer, Drying of the application or the coating and heat deformation of the foam and fiber composite material into the desired contour. 69. The method according to claim 68, characterized, that the thermoformable foam element is semi-rigid fen has thermoformable foam. 70. The method according to claim 68, characterized, that the semi-rigid thermoformable foam element Has cells that are expandable under heat, and that the foam cells during the Warmver molding including in the foam element needled fibers expand. 71. The method according to claim 68, characterized, that the fibers are essentially arbitrary in the first layer are distributed. 72. The method according to claim 71, characterized, that the first layer has a denier of about 4.5 to about 25 owns.   73. The method according to claim, characterized, that the fibers of the first layer are polyester. 74. The method according to claim 60, characterized, that the fibers in the first layer are virgin natural Liche fibers are. 75. The method according to claim 68, characterized, that the foam element is a foam from a Copolymer of polystyrene-maleic anhydride acid. 76. The method according to claim 68, characterized, that the application process foams the binder resin, the application of the binder resin foam through to the first layer and the distribution of the foam covers the entire first layer. 77. The method according to claim 76, characterized, that the foaming process is stirring the binder resin in the presence of air at a pressure of about 4.57 kp / cm² (65 pounds / square inch). 78. The method according to claim 76, characterized, that the distribution process is the pressing of the foam in includes the first layer with a nip roller.   79. The method according to claim 78, characterized, that the binder resin has a glass transition temperature from about 20 degrees Celsius to about 121 degrees Celsius includes. 80. The method according to claim 79, characterized, that the binder resin is selected from the group comprising water-based urethane, acrylic, ethylene vinyl acetate acrylic, styrene butadiene rubber, polyvinyl acetate, Polyvinyl acrylic copolymer epoxy and water-based styrene. 81. The method according to claim 80, characterized, that the drying process takes place in that the first Lay air at a temperature of about 121 degrees Celsius is exposed to about 132 degrees Celsius. 82. The method according to claim 68, characterized, that the resin in an amount of about 47.4 g to about (2 to 189.6 g dry weight per cm² (2 to 8 ounces dry weight weight / square yard) of the order or coating is built. 83. The method according to claim 68, characterized, that the needling process takes place in that a with a reversed hook through the first layer and in the foam element in at a distance ordered places is pressed.   84. The method according to claim 83, characterized, that the digits are about a quarter apart are arranged up to half an inch. 85. The method according to claim 83, characterized, that the needling process further includes the needle in the foam element essentially over the ge Entire thickness of the foam element is pressed. 86. The method according to claim 68, marked by Placement of a stiffening mat between the foam fabric element and the layer of non-woven fibers where in the needling process by needling the fibers the mat and in the foam element. 87. The method according to claim 86, characterized, that the mat together by a thermosetting resin which comprises connected glass fibers. 88. The method according to claim 86, characterized, that the mat has a thickness of about 0.254 mm (10 mil) to about 0.76 mm (30 mil). 89. The method according to claim 88, characterized, that the mat weighs approximately 47.4 g / cm² (2 ounces / square yard).   90. The method according to claim 68, marked by Arrangement of a second layer of non-woven fibers next to one side of the foam element opposite the first layer of non-woven fibers, needling of the fibers from the second layer into the foam element and on bring a second coating of a binder resin in the second layer and drying the second Coating. 91. The method according to claim 90, marked by Placement of a stiffening mat between the foam fabric element and one of the layers of non-woven fibers, the needling further comprising the needling of the fibers one layer through the mat and into the foam element includes. 92. The method according to claim 90, marked by Arrangement of a second semi-rigid foam element between the first foam element and the second Layer of non-woven fibers, the process of Needling the fibers from the second layer also the Needles the fibers through the second foam element and in the first foam element. 93. The method according to claim 92, characterized, that the semi-rigid foam element has cells, which are expandable under heat.   94. The method according to claim 92, characterized, that the process of needling the fibers from the first Also lay the needles of the fibers through the first Element and includes in the second foam element. 95. The method according to claim 94, marked by Arrangement of a reinforcement mat between one of the Foam elements and the corresponding position non-woven fibers, the process of needling further the needling of the fibers from the corresponding Layer of non-woven fibers through the mat and that one foam element and in the other foam element includes.