Composite material and method for manufacturing composite material

Abstract

To provide a composite material of fiber-reinforced plastic and rubber material, preventing separation between the fiber-reinforced plastic and the rubber material.SOLUTION: A composite material comprises a first member including fiber-reinforced plastic, and a second member comprising rubber material in direct contact with the first member in at least a partial region of the first member. The first member and the second member are made in an integral unit.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a composite material having a fiber reinforced plastic and a rubber material, and a method for manufacturing the composite material.

Background Art

[0002] Currently, since fiber reinforced plastic (FRP) has both light weight and high strength, it is widely used as a material for industrial products such as transportation-related equipment such as aircraft, automobiles, and bicycles, sports goods such as tennis rackets and golf clubs, and building structures such as earthquake reinforcement materials. In addition, industrial products are sometimes required to have not only light weight and high strength but also a beautiful appearance. From the above, as a material having light weight, high strength, and a beautiful appearance, a composite material in which a member having a beautiful appearance is adhered to a fiber reinforced plastic may be used.

[0003] Conventionally, as the above composite material having light weight, high strength, and a beautiful appearance, it is a composite material in which two members, a first member made of a fiber reinforced plastic and a decorative material, are integrated, and a thermoplastic resin layer is formed at the joint portion between the first member and the decorative material, and a composite material in which the thermoplastic resin layer includes some of the reinforcing fibers of the reinforcing fiber group of the first member has been proposed (Patent Document 1). In Patent Document 1, as the decorative material, a plastic film, a metal plate, a woven fabric, a cloth, a non-woven fabric, artificial leather, etc. have been proposed.

[0004] In Patent Document 1, since the thermoplastic resin layer interposed between the fiber reinforced plastic and the decorative material functions as an adhesive layer and includes some of the reinforcing fibers of the fiber reinforced plastic, it is a composite material in which excellent adhesive strength is imparted between the fiber reinforced plastic and the decorative material.

[0005] On the other hand, materials using fiber-reinforced plastics are sometimes required to possess not only lightness and high strength, but also vibration damping and deformation resistance. Therefore, composite materials, in which rubber materials are bonded to fiber-reinforced plastics using adhesives, are sometimes used as materials that possess lightness, high strength, vibration damping, and deformation resistance.

[0006] However, in composite materials where rubber material is bonded to fiber-reinforced plastic using an adhesive, uneven application of the adhesive can result in insufficient adhesion between the fiber-reinforced plastic and the rubber material, leaving room for improvement in the adhesive strength between the two. Furthermore, the manufacturing method of composite materials in which adhesive is applied to fiber-reinforced plastic to bond rubber material is complicated due to the need for an adhesive application step, and the difficulty in uniformly applying the adhesive prevents the manufacturing process from being simplified. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] Japanese Patent Publication No. 2006-44264 [Overview of the project] [Problems that the invention aims to solve]

[0008] In view of the above circumstances, the present invention aims to provide a composite material of fiber-reinforced plastic and rubber material in which delamination between the fiber-reinforced plastic and rubber material is prevented, and a method for manufacturing a composite material of fiber-reinforced plastic and rubber material that can be manufactured easily without complicating the manufacturing process. [Means for solving the problem]

[0009] The gist of the present invention is as follows: [1] A first member having fiber-reinforced plastic, and a second member having rubber material formed in direct contact with the first member in at least a portion of the area of ​​the first member, A composite material in which the first member and the second member are integrated. [2] The composite material according to [1], wherein the first member and the second member are in direct contact, and no adhesive member is interposed between the first member and the second member. [3] The composite material according to [1] or [2], wherein the first member and the second member are in the form of sheets, and the composite material has a laminated structure. [4] The composite material according to any one of [1] to [3], wherein the rubber material is at least one selected from the group consisting of nitrile rubber, fluororubber, butyl rubber, ethylene propylene diene rubber, hydrogenated nitrile rubber, and silicone rubber. [5] The composite material according to any one of [1] to [4], wherein the rubber material is at least one selected from the group consisting of nitrile rubber, fluororubber and butyl rubber. [6] The composite material according to any one of [1] to [5], wherein the fiber-reinforced plastic is a carbon fiber-reinforced plastic. [7] The composite material according to any one of [1] to [6], wherein the first member is a multilayer structure having a first fiber-reinforced plastic forming a first layer having a fiber orientation angle in a first direction, and a second fiber-reinforced plastic forming a second layer having a fiber orientation angle in a second direction different from the first direction. [8] The composite material according to any one of the first members [1] to [7], wherein the outer surface of the composite material is the outer surface of the composite material. [9] The composite material according to any one of the second member [1] to [7], wherein the outer surface of the composite material is the outer surface of the composite material.

[10] A composite material according to any one of [1] to [9], which is formed in the shape of a plate or a tube.

[11] A step of preparing a first precursor which is an uncured or semi-cured material in which a resin is impregnated into fibers, A step of directly laminating a second precursor having unvulcanized rubber onto at least a portion of the prepared first precursor to obtain a laminate of the first precursor and the second precursor, The obtained laminate is heat-treated to heat-cur the resin of the first precursor to obtain a first member having fiber-reinforced plastic, and the unvulcanized rubber of the second precursor is vulcanized to obtain a second member having rubber material, and the first member and the second member are integrated in an integration step. A method for manufacturing composite materials having

[12] A method for manufacturing a composite material according to

[11] , wherein a second precursor having unvulcanized rubber containing a vulcanizing agent is directly laminated onto the first precursor prepared without an adhesive member in between. [Effects of the Invention]

[0010] According to an embodiment of the composite material of the present invention, a composite material of fiber-reinforced plastic and rubber material can be obtained, comprising a first member having fiber-reinforced plastic and a second member having rubber material formed in direct contact with the first member in at least a portion of the area on the first member, wherein the first member and the second member are integrated, thereby preventing delamination between the first member having fiber-reinforced plastic and the second member having rubber material.

[0011] According to an embodiment of the composite material of the present invention, the first member and the second member are in direct contact, and no adhesive member is interposed between the first member and the second member. This prevents uneven adhesion caused by the adhesive member, and thus prevents delamination between the first member and the second member.

[0012] According to an embodiment of the composite material of the present invention, by having the rubber material be at least one selected from the group consisting of nitrile rubber, fluororubber, butyl rubber, ethylene propylene diene rubber, hydrogenated nitrile rubber, and silicone rubber, adhesion can be obtained between the first member and the second member, and peeling can be prevented.

[0013] According to an embodiment of the composite material of the present invention, by having the rubber material be at least one selected from the group consisting of nitrile rubber, fluororubber, and butyl rubber, reliable adhesion is obtained between the first member and the second member, and peeling is reliably prevented.

[0014] In an embodiment of the method for manufacturing a composite material of the present invention, a laminate is obtained by directly laminating a second precursor having unvulcanized rubber onto at least a portion of a region of a first precursor which is an uncured or semi-cured material in which fibers are impregnated with resin. The laminate is then heat-treated to obtain a first member having fiber-reinforced plastic by thermal curing the resin of the first precursor, and a second member having rubber material by vulcanizing the unvulcanized rubber of the second precursor, and the first member and the second member are integrated. That is, by heat-treating the laminate, the prepreg, which is an uncured or semi-cured material in which fibers are impregnated with resin, is thermally cured, and the unvulcanized rubber is vulcanized to simultaneously obtain fiber-reinforced plastic and vulcanized rubber material, and the obtained fiber-reinforced plastic and vulcanized rubber material are integrated.

[0015] Therefore, according to an embodiment of the manufacturing method for the composite material of the present invention, when integrating a first member having fiber-reinforced plastic and a second member having rubber material, the adhesive application step itself is not required, nor is uniform application of adhesive required. From the above, according to an embodiment of the manufacturing method of the present invention, the complexity of the manufacturing process for the composite material of fiber-reinforced plastic and rubber material can be prevented, and the manufacturing of the composite material can be made easier. Furthermore, according to an embodiment of the manufacturing method for the composite material of the present invention, by heat-treating the laminate, the resin of the first precursor is heat-cured to obtain a first member having fiber-reinforced plastic, and the unvulcanized rubber of the second precursor is vulcanized to obtain a second member having rubber material, and the first member and the second member are integrated, so that peeling between the first member having fiber-reinforced plastic and the second member having rubber material can be prevented, and a composite material of fiber-reinforced plastic and rubber material can be obtained.

[0016] According to an aspect of the method for manufacturing the composite material of the present invention, by laminating the second precursor having unvulcanized rubber directly on the first precursor without using an adhesive member, uneven adhesion caused by the adhesive member can be prevented, so that peeling between the first member and the second member can be prevented.

Brief Description of the Drawings

[0017] [Figure 1] It is an explanatory diagram showing an outline of an embodiment of the composite material of the present invention. [Figure 2] It is an exploded explanatory diagram of the composite material showing an aspect in which the outer surface of the composite material of the present invention is the first member. [Figure 3] It is an exploded explanatory diagram of the composite material showing an aspect in which the outer surface of the composite material of the present invention is the second member.

Embodiments for Carrying Out the Invention

[0018] Hereinafter, the composite material of the present invention will be described in detail. FIG. 1 is an explanatory diagram showing an outline of an embodiment of the composite material of the present invention. The composite material 1 of the present invention includes a first member 10 having a fiber-reinforced plastic and a second member 20 having a rubber material formed in direct contact with the first member 10 in at least a part of the region on the first member 10. The composite material 1 is a composite material of a fiber-reinforced plastic and a rubber material in which the first member 10 and the second member 20 are integrated. In the composite material 1 of the present invention, the first member 10 is adhered to the second member 20, so that a joint portion 30 where the first member 10 is joined to the second member 20 is formed, and the first member 10 and the second member 20 are integrated. The composite material 1 of the present invention is integrated in a state where at least a part of the region on the first member 10 is in direct contact with the second member 20.

[0019] As shown in Figure 1, in the composite material 1 according to an embodiment of the present invention, no adhesive member such as an adhesive is interposed between the first member 10 and the second member 20 at the joint 30 where the first member 10 and the second member 20 are in direct contact. In the composite material 1 of the present invention, it is sufficient that at least a portion of the area on the first member 10 is in direct contact with the second member 20 and integrated with the second member 20, and that at least a portion of the area on the second member 20 is in direct contact with the first member 10 and integrated with the first member 10.

[0020] In the composite material 1 according to an embodiment of the present invention, substantially the entire surface of the first member 10 facing the second member 20 is integrated with the second member 20 in a state of direct contact with the second member 20. Furthermore, substantially the entire surface of the second member 20 facing the first member 10 is integrated with the first member 10 in a state of direct contact with the first member 10. Therefore, in the composite material 1, no adhesive member is interposed across the entire joint 30 where the first member 10 and the second member 20 face each other.

[0021] In composite material 1, a portion of the matrix in the surface area and vicinity of the fiber-reinforced plastic constituting the first member 10 penetrates into the surface area and vicinity of the rubber material constituting the second member 20, and a portion of the surface area and vicinity of the rubber material constituting the second member 20 penetrates into the surface area and vicinity of the fiber-reinforced plastic constituting the first member 10. As a result, the first member 10 is joined to the second member 20 to form a joint 30, and the first member 10 and the second member 20 are integrated. That is, at the joint 30 of composite material 1, the first member 10 exerts an anchoring effect on the second member 20, and the second member 20 exerts an anchoring effect on the first member 10, thereby integrating the first member 10 and the second member 20.

[0022] The shape of the composite material 1 according to the embodiment of the present invention is not particularly limited. In the composite material 1 shown in Figure 1, the first member 10 and the second member 20 are in the form of sheets, and the composite material 1 has a sheet-like laminated structure.

[0023] When both the first member 10 and the second member 20 are in sheet form, the thickness of the first member 10 is not particularly limited, and for example, it may be 0.05 mm or more and 10 mm or less, more specifically, 0.10 mm or more and 5.0 mm or less. Similarly, the thickness of the second member 20 is not particularly limited, and may be the same as or different from the thickness of the first member 10. For example, the thickness of the second member 20 may be 0.05 mm or more and 10 mm or less, more specifically, 0.10 mm or more and 5.0 mm or less.

[0024] The composite material 1 comprises a first member 10 having fiber-reinforced plastic and a second member 20 having rubber material that is in direct contact with the first member 10 in at least a portion of the surface of the first member 10. The first member 10 and the second member 20 are integrated by the anchoring effect, thereby preventing delamination between the first member 10 having fiber-reinforced plastic and the second member 20 having rubber material. Furthermore, in the composite material 1 shown in Figure 1, the first member 10 and the second member 20 are in direct contact over the entire joint 30, and no adhesive member is interposed between the first member 10 and the second member 20. This prevents uneven adhesion and unevenness in joint strength at the joint caused by the adhesive member, thus preventing delamination between the first member 10 and the second member 20.

[0025] Examples of fiber-reinforced plastics that constitute the first member 10 include carbon fiber reinforced plastic (CFRP), glass fiber reinforced plastic (GFRP), aramid fiber reinforced plastic (AFRP), and cellulose fiber reinforced plastic. Of these, carbon fiber reinforced plastic is preferred in terms of lightness, high strength, and rigidity. The resin component of the matrix resin of the fiber-reinforced plastic is not particularly limited. Specifically, examples include thermosetting resins such as epoxy resin, phenolic resin, cyanate resin, vinyl ester resin, and unsaturated polyester resin, with epoxy resin being particularly preferred. The fiber-reinforced plastic that constitutes the first member 10 is a member obtained by thermosetting an uncured (or semi-cured) thermosetting prepreg, which is an intermediate material in which a matrix resin is impregnated into fibers, by heat treatment or the like.

[0026] In the composite material 1 according to an embodiment of the present invention, the first member 10 is a multilayer structure having a first fiber-reinforced plastic layer 11 (11-1) with a fiber orientation angle in a first direction, and a second fiber-reinforced plastic layer 11 (11-2) with a fiber orientation angle in a second direction different from the first direction. By making the first member 10 a multilayer structure of multiple fiber-reinforced plastics with different fiber orientation angles, the strength of the first member 10 in the entire planar direction is improved. In Figure 1, for the sake of explanation, the first member 10 is shown as a multilayer structure consisting of two fiber-reinforced plastic layers 11, but it may also be a multilayer structure having three or more fiber-reinforced plastic layers 11. In the case of a multilayer structure having three or more fiber-reinforced plastic layers 11, a third fiber-reinforced plastic layer 11 with a fiber orientation angle in a third direction different from both the first and second directions, a fourth fiber-reinforced plastic layer 11 with a fiber orientation angle in a fourth direction different from both the first, second and third directions, and other fiber-reinforced plastic layers 11 with mutually different fiber orientation angles may be provided. Alternatively, the first member 10 may be a structure consisting of a single fiber-reinforced plastic layer 11.

[0027] Examples of rubber materials constituting the second member 20 include nitrile rubber (NBR) such as acrylonitrile butadiene rubber, fluororubber (FKM), butyl rubber (IIR), ethylene propylene diene rubber (EPDM), hydrogenated nitrile rubber (HNBR), silicone rubber, urethane rubber, acrylic rubber (ACM), isoprene rubber (IR), styrene rubber (SBR), butadiene rubber (BR), ethylene propylene rubber (EPM), chloroprene rubber (CR), chlorinated polyethylene, and natural rubber (NR). These rubber materials may be used individually or in combination of two or more. The rubber material constituting the second member 20 is a member obtained by vulcanizing unvulcanized rubber through heat treatment or the like.

[0028] Of these rubber materials, nitrile rubber, fluororubber, butyl rubber, ethylene propylene diene rubber, hydrogenated nitrile rubber, and silicone rubber are preferred because they provide good adhesion between the first member 10 and the second member 20 and prevent peeling. Nitrile rubber, fluororubber, and butyl rubber are particularly preferred because they reliably provide good adhesion between the first member 10 and the second member 20 and reliably prevent peeling.

[0029] In addition to the rubber material, the second component 20 contains a vulcanizing agent. Various additives such as antioxidants, processing aids, tackifiers, vulcanization accelerators, fillers, plasticizers, and vulcanization accelerators may also be added as needed.

[0030] Next, the laminated structure of the first member 10 and the second member 20 in the composite material 1 according to an embodiment of the present invention will be described. Figure 2 is an exploded explanatory diagram of the composite material showing an embodiment in which the outer surface of the composite material of the present invention is the first member. Figure 3 is an exploded explanatory diagram of the composite material showing an embodiment in which the outer surface of the composite material of the present invention is the second member. In Figures 2 and 3, in order to explain the laminated structure of the first member 10 and the second member 20 in the composite material 1, the laminated structure consisting of the layer of the first member 10 and the layer of the second member 20 is exploded into each layer.

[0031] As shown in Figure 2, the composite material 1 can be a laminated structure in which the outer surface of the composite material 1 is the first member 10. In Figure 2, both outer surfaces forming the main surface of the sheet-like composite material 1 are the first member 10 having fiber-reinforced plastic. Therefore, the layer of the second member 20 having rubber material is interposed between the layers of the first member 10 having fiber-reinforced plastic. In Figure 2, there are two layers of the second member 20 having rubber material, and a layer of the first member 10 consisting of six fiber-reinforced plastic layers 11 is interposed between the layers of the second member 20. In addition, a layer of the first member 10 consisting of two fiber-reinforced plastic layers 11 is provided on the surface of each layer of the second member 20. The number of layers in the first member 10, the fiber-reinforced plastic layer 11, and the second member 20 shown in Figure 2 are for illustrative purposes only. Depending on the usage conditions of the composite material 1, the number of layers in the first member 10, the fiber-reinforced plastic layer 11, and the second member 20 can be appropriately selected.

[0032] In a composite material 1 having a laminated structure in which the outer surface of the composite material 1 is a first member 10 and layers of a second member 20 having a rubber material are interposed between the layers of the first member 10, the amount of deformation before fracture due to bending etc. is increased, and the deformation resistance of the composite material 1 is improved. Furthermore, in a composite material 1 having a laminated structure in which the outer surface of the composite material 1 is a first member 10 and layers of the second member 20 are interposed between the layers of the first member 10, the vibration damping is improved.

[0033] Furthermore, as shown in Figure 3, the composite material 1 can also be a laminated structure in which the outer surface of the composite material 1 is a second member 20. In Figure 3, both outer surfaces forming the main surface of the sheet-like composite material 1 are second members 20 having rubber material. Therefore, the layers of the first member 10 having fiber-reinforced plastic are interposed between the layers of the second member 20 having rubber material. In Figure 3, there are two layers of the second member 20 having rubber material, and a layer of the first member 10 consisting of 10 fiber-reinforced plastic layers 11 is interposed between the layers of the second member 20. The number of layers of the first member 10, the fiber-reinforced plastic layers 11, and the second member 20 in Figure 3 are for illustrative purposes only, and the number of layers of the first member 10, the fiber-reinforced plastic layers 11, and the second member 20 can be appropriately selected depending on the usage conditions of the composite material 1. Furthermore, in addition to the second member 20 that forms the outer surface of the composite material 1, layers of the second member 20 may be interposed between the layers of the first member 10.

[0034] In a composite material 1 with a laminated structure in which the outer surface of the composite material 1 is a second member 20 and layers of the first member 10 having fiber-reinforced plastic are interposed between the layers of the second member 20, the scattering of fibers from the first member 10 when the composite material 1 breaks can be prevented, thus improving the safety of the composite material 1 when it breaks. Furthermore, because the outer surface of the composite material 1 is a second member 20 having rubber material, the composite material 1 can be given effects derived from rubber material, such as oil resistance, weather resistance, durability, chemical resistance, and ozone resistance. In addition, in a composite material 1 with a laminated structure in which the outer surface of the composite material 1 is a second member 20 and layers of the first member 10 are interposed between the layers of the second member 20, vibration damping is improved.

[0035] Composite material 1 can be molded into desired shapes, such as plates or cylinders, depending on its application in transportation-related equipment, sporting goods, building structures, etc.

[0036] Next, the method for manufacturing the composite material of the present invention will be described. The method for manufacturing the composite material of the present invention includes (1) a step of preparing a first precursor which is an uncured or semi-cured material in which a resin is impregnated into fibers; (2) a step of directly laminating a second precursor having unvulcanized rubber onto at least a portion of the prepared first precursor to obtain a laminate of the first precursor and the second precursor; and (3) an integration step of heat-treating the obtained laminate to heat-cur the resin of the first precursor to obtain a first member having fiber-reinforced plastic and a second member having rubber material by vulcanizing the unvulcanized rubber of the second precursor, and integrating the first member and the second member.

[0037] (1) A step of preparing a first precursor, which is an uncured or semi-cured material in which resin is impregnated into fibers. This process involves preparing a prepreg, which is an uncured or semi-cured material made by impregnating reinforcing fibers such as carbon fibers with a resin such as a thermosetting resin. As the first precursor, a single-layer prepreg may be used, or a laminated prepreg, which is made by laminating multiple prepregs, may be used. The number of laminated prepregs can be appropriately selected depending on the usage conditions of the composite material.

[0038] (2) A process to obtain a laminate by directly laminating a second precursor having unvulcanized rubber onto a first precursor. This process involves laminating a second precursor, which has unvulcanized rubber containing a vulcanizing agent, onto the surface of a first precursor, which is a (laminated) prepreg. In this process, the second precursor, which has unvulcanized rubber, is directly laminated onto the first precursor without the use of an adhesive member. When laminating the second precursor onto the first precursor, if necessary, the laminate of the first and second precursors may be subjected to, for example, pressing.

[0039] (3) Integration process In the integration process, a laminate of the first precursor and the second precursor is heat-treated to thermocur the resin of the first precursor, forming a fiber-reinforced plastic from the prepreg, thereby obtaining a first member having the fiber-reinforced plastic. Furthermore, the unvulcanized rubber of the second precursor is vulcanized to obtain a second member having the rubber material, and the first and second members are integrated. In other words, in the integration process, a laminate of the first precursor and the second precursor is heat-treated to thermocur the prepreg, which is an uncured or semi-cured material in which resin is impregnated into the fibers, and further, the unvulcanized rubber is vulcanized to simultaneously obtain a fiber-reinforced plastic and a vulcanized rubber material, and the obtained fiber-reinforced plastic and vulcanized rubber material are integrated. When forming the fiber-reinforced plastic from the prepreg, a portion of the resin constituting the first precursor enters into the unvulcanized rubber constituting the second precursor, and when forming the rubber material by vulcanizing the unvulcanized rubber, a portion of the unvulcanized rubber constituting the second precursor enters into the resin constituting the first precursor. The interaction between the first and second precursors described above causes the first and second members to join together, forming a joint and integrating them. As a result, a portion of the matrix resin in and near the surface of the fiber-reinforced plastic constituting the first member penetrates into and near the surface of the rubber material constituting the second member, and a portion of the surface of and near the rubber material constituting the second member penetrates into and near the surface of the fiber-reinforced plastic constituting the first member, forming a joint.

[0040] As a method for heat-treating the laminate of the first precursor and the second precursor, heat treatment conditions suitable for the first precursor can be appropriately selected.

[0041] According to the present invention's method for manufacturing composite materials, when integrating a first member having fiber-reinforced plastic and a second member having rubber material, the adhesive application process itself is not required, and therefore, uniform application of adhesive is also not required. As a result, the complexity of the manufacturing process for composite materials of fiber-reinforced plastic and rubber material can be prevented, and the manufacturing of composite materials can be simplified. Furthermore, in the present invention's method for manufacturing composite materials, by heat-treating a laminate of a first precursor and a second precursor, the resin of the first precursor is heat-cured to obtain a first member having fiber-reinforced plastic, and the unvulcanized rubber of the second precursor is vulcanized to obtain a second member having rubber material. At the same time, the first member and the second member can be integrated, so that a composite material of fiber-reinforced plastic and rubber material can be obtained in which delamination between the first member having fiber-reinforced plastic and the second member having rubber material is prevented.

[0042] Furthermore, in the method for manufacturing the composite material of the present invention, since unvulcanized rubber is directly laminated onto the first precursor without the use of an adhesive member, uneven adhesion caused by the adhesive member can be prevented, and delamination between the first member and the second member can be prevented. [Examples]

[0043] Next, examples of the composite material of the present invention will be described, but the composite material of the present invention is not limited to the following examples.

[0044] Examples 1-3 Unvulcanized rubber and a vulcanizing agent were mixed according to the proportions shown in Table 1 below, and then combined to prepare a second precursor, which is a precursor for the second component used in Examples 1 to 3. Nitrile rubber (Example 1), fluororubber (Example 2), and butyl rubber (Example 3) were used as the unvulcanized rubbers. Although not listed in Table 1 below, various additives (anti-aging agents, processing aids, tackifiers, vulcanization accelerators, fillers, plasticizers, vulcanization accelerators, etc.) are added as appropriate.

[0045] The first precursor (precursor of the first component) used in Examples 1 to 3 is as follows: • P2255S-15: Prepreg sheet with a sheet thickness of 0.122 mm, resin content of 24.0% by mass, and carbon fiber content of 76.0%, manufactured by Toray Industries, Inc.

[0046] The evaluation criteria are as follows: (1) Peel test The first precursor prepreg was laminated in a (0° / 90°)5 layer structure to obtain a 1.22 mm thick laminated prepreg sheet. Next, the resulting laminate was placed in a sheet press machine and subjected to a pressure of 8 kgf / cm². 2 A test sample of a composite material was prepared by heat treatment at 150°C for 60 minutes, integrating the first and second components. A peel test was performed on the obtained test sample, in which the second component was peeled off the composite material in which the first and second components were integrated. The peel test was conducted at a test speed of 50 mm / min in accordance with JIS K 6854, and the maximum load (in N) when peeling the second component from the composite material was measured. The peel test was performed five times, and the maximum load of the average value was used to evaluate the peel resistance between the fiber-reinforced plastic and the rubber material. A maximum load of 100 N or more was judged as "pass" as a composite material with excellent peel resistance between the fiber-reinforced plastic and the rubber material.

[0047] (2) Surface observation The joint-side surfaces of the first member and the second member of the test samples after the peel test described above were observed with an optical microscope (magnification 100x), and the integrity between the fiber-reinforced plastic and the rubber material was evaluated according to the following criteria. ○: Since many fragments of rubber material are attached to the joint-side surface of the first member, and many carbon fibers and matrix resin are attached to the joint-side surface of the second member, the first member and the second member are firmly integrated by an anchoring effect. △: Since small fragments of rubber material are attached to the joint-side surface of the first member, and small amounts of carbon fibers and matrix resin are attached to the joint-side surface of the second member, the first member and the second member are integrated by an anchoring effect. ×: Since no fragments of rubber material are attached to the joint-side surface of the first member, and / or no carbon fibers or matrix resin are attached to the joint-side surface of the second member, the first member and the second member are not joined by an anchoring effect.

[0048] The evaluation results are shown in Table 1 below.

[0049] [Table 1]

[0050] As shown in Table 1 above, by heat-treating a laminate of the first and second precursors, the prepreg was thermosetting, and further, the unvulcanized rubber was vulcanized to simultaneously obtain fiber-reinforced plastic and vulcanized rubber material. In Examples 1 to 3, in which the fiber-reinforced plastic and vulcanized rubber material were integrated, the maximum load when peeling the second member from the composite material was 100 N or more, and the first and second members were firmly integrated by the anchoring effect. Therefore, in Examples 1 to 3, it was possible to obtain a composite material in which delamination between the fiber-reinforced plastic and the rubber material was prevented.

[0051] (3) Bending test (deformation resistance) As examples, test samples of composite materials in which the first and second members were integrated, as described in Examples 1 to 3 above, were used. In Comparative Example 1, only the layer ((90° / 0°)5) of the first member was used as the test sample.

[0052] Bending tests were conducted in accordance with JIS K 7074, and the displacement until the test sample fractured was measured and evaluated according to the following criteria. ○: Displacement of 5.0 mm or more △: Displacement of 3.5 mm or more and less than 5.0 mm ×: Displacement less than 3.5 mm

[0053] The evaluation results are shown in Table 2 below.

[0054] [Table 2]

[0055] As shown in Table 2 above, Examples 1 to 3, in which fiber-reinforced plastic and vulcanized rubber material were integrated, exhibited large displacement and excellent deformation resistance. On the other hand, Comparative Example 1, in which a second member containing rubber material was not formed, exhibited small displacement and poor deformation resistance. [Industrial applicability]

[0056] Because the composite material of the present invention prevents delamination between the fiber-reinforced plastic and the rubber material, it has high utility as a material for a wide range of fields, such as transportation-related equipment, sporting goods, and building structures. [Explanation of symbols]

[0057] 1 Composite material 10 First member 11 Fiber-reinforced plastic layer 20 Second component

Claims

1. It comprises a first member having fiber-reinforced plastic, and a second member having rubber material formed in direct contact with the first member in at least a portion of the area of ​​the first member, The first member is a multilayer structure having a first fiber-reinforced plastic forming a first layer with a fiber orientation angle in a first direction, and a second fiber-reinforced plastic forming a second layer with a fiber orientation angle in a second direction different from the first direction, and the first member and the second member are integrated into a composite material, A portion of the matrix of the first member in the surface portion and its vicinity extends into the surface portion and its vicinity of the rubber material constituting the second member, and a portion of the surface portion and its vicinity of the rubber material constituting the second member extends into the surface portion and its vicinity of the first member, thereby the first member having a joint portion joined to the second member. A composite material in which the maximum load when peeling the second member from the composite material in a peel test conducted at a test speed of 50 mm / min in accordance with JIS K 6854 is 100 N or more.

2. The composite material according to claim 1, wherein the first member and the second member are in direct contact, and no adhesive member is interposed between the first member and the second member.

3. The composite material according to claim 1 or 2, wherein the first member and the second member are in the form of sheets, and the composite material has a laminated structure.

4. The composite material according to any one of claims 1 to 3, wherein the rubber material is at least one selected from the group consisting of nitrile rubber, fluororubber, butyl rubber, ethylene propylene diene rubber, hydrogenated nitrile rubber, and silicone rubber.

5. The composite material according to any one of claims 1 to 4, wherein the rubber material is at least one selected from the group consisting of nitrile rubber, fluororubber, and butyl rubber.

6. The composite material according to any one of claims 1 to 5, wherein the fiber-reinforced plastic is a carbon fiber-reinforced plastic.

7. The composite material according to any one of claims 1 to 6, wherein the outer surface of the composite material is the first member.

8. The composite material according to any one of claims 1 to 6, wherein the outer surface of the composite material is the second member.

9. A composite material according to any one of claims 1 to 8, which is formed into a plate or a cylindrical shape.

10. A step of preparing a first precursor, which is an uncured or semi-cured material in which resin is impregnated into fibers, A step of obtaining a laminate of the first and second precursors by directly laminating a second precursor having unvulcanized rubber onto at least a portion of the area on the prepared first precursor, wherein, when laminating the second precursor onto the first precursor, pressing is performed on the laminate of the first and second precursors, The obtained laminate is heat-treated to heat-cur the resin of the first precursor to obtain a first member having fiber-reinforced plastic, and the unvulcanized rubber of the second precursor is vulcanized to obtain a second member having rubber material, and the first member and the second member are integrated in an integration step. A method for manufacturing a composite material having the following characteristics: The first member is a multilayer structure comprising a first fiber-reinforced plastic forming a first layer in which the fiber orientation angle is in a first direction, and a second fiber-reinforced plastic forming a second layer in which the fiber orientation angle is in a second direction different from the first direction. A portion of the matrix of the first member in the surface portion and its vicinity extends into the surface portion and its vicinity of the rubber material constituting the second member, and a portion of the surface portion and its vicinity of the rubber material constituting the second member extends into the surface portion and its vicinity of the first member, thereby the first member having a joint portion joined to the second member. In a peel test conducted at a test speed of 50 mm / min in accordance with JIS K 6854, the maximum load when peeling the second member from the composite material is 100 N or more. A method for manufacturing composite materials.

11. A method for producing a composite material according to claim 10, wherein a second precursor having unvulcanized rubber containing a vulcanizing agent is directly laminated onto the first precursor that has been prepared, without the use of an adhesive member.

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