Complex matting with a layer of volumized fibers

Abstract

Method for manufacturing a multi-layered mat formed by means of fibers, strands, yarns or twists, a multi-layered mat manufactured according to the method and/or a molded article manufactured therefrom, as well as an apparatus for carrying out the method.

1 - 12 . (canceled)  
     
     
         13 . A method for manufacturing a mat, comprising the steps of: 
 providing a layer that comprises volumized strands, yarns or twists;    providing at least one further layer formed of fibers; and    connecting the layers by stitching.    
     
     
         14 . The method according to  claim 13 , wherein non-volumized as well as volumized strands, yarns or twists are placed on top of each other in layers, on a conveyor belt, the layers then being stitched together.  
     
     
         15 . The method according to  claim 14 , wherein the fibers or the strands, yarns or twists formed therefrom are placed by cutting continuous fibers, continuous strands, continuous yarns or continuous twists.  
     
     
         16 . The method according to  claim 13 ,  14  or  15 , wherein the layers are formed by fibers, strands, yarns or twists that are arranged parallel to the surface of the mat.  
     
     
         17 . The method according to  claim 13 ,  14  or  15 , wherein the fibers, strands, yarns or twists provided for the layer structure have a length of between 5 to 200 mm and/or the hollow microbodies used for volumization have an average diameter of 20 to 300 μm.  
     
     
         18 . The method according to  claim 13 ,  14  or  15 , wherein the central ply as well as the surface plies are formed of glass fibers.  
     
     
         19 . The method according to  claim 13 ,  14  or  15 , wherein the mat is introduced into a mold, and hardenable resins are introduced into the mold for manufacturing a fiber-reinforced molded article.  
     
     
         20 . A product made according to the method of  claim 13  comprising a central ply of volumized strands, yarns, twists, as well as surface plies of non-volumized fibers that are stitched together.  
     
     
         21 . A product according to  claim 20 , wherein the fibers, strands, yarns or twists are arranged parallel to the surface.  
     
     
         22 . A product according to  claim 20 , wherein the fibers, strands, yarns or twists are formed exclusively from glass fibers.  
     
     
         23 . An apparatus for manufacturing a mat according to  claim 13 , consisting of three cutters arranged behind one another that are disposed above a conveyor belt, as well as of means for stitching cut fibers, strands, yarns or twists placed on the conveyor belt that come from the cutters.  
     
     
         24 . The apparatus according to  claim 23 , wherein volumized strands, yarns or twists are fed to the cutter arranged in the middle, and non-volumized strands, yarns or twists are fed to the other two cutters.