Composite laminates and automotive components

Abstract

Provided is a composite laminate comprising a first base material, a first high elastic modulus layer, a low elastic modulus layer, and a second high elastic modulus layer. The low elastic modulus layer has a lower elastic modulus than the first high elastic modulus layer and the second high elastic modulus layer. The composite laminate satisfies Formula 1. In Formula 1: hRs represents the distance from a surface on a subject first base material side of the first base material to an interface between a subject low elastic modulus layer and a subject high elastic modulus layer in a subject laminate; tRs represents the thickness of the subject low elastic modulus layer in the subject laminate; λs represents the position of a neutral axis in the subject laminate; hR represents the distance from the surface on the first base material side to an interface between the low elastic modulus layer and the second high elastic modulus layer; tR represents the thickness of the low elastic modulus layer; and λ represents the position of the neutral axis.

Description

Technical Field

[0001] The present disclosure relates to a composite laminate and a member for an automobile.

Background Art

[0002] In the field of automobiles, it is required to achieve both weight reduction of members and safety collision performance. For example, high-strength steel sheets, high-strength aluminum alloys, composite materials of steel sheets and fiber-reinforced plastics, etc. have been developed. In steel sheet fiber-reinforced plastic composite materials, technologies for bonding lightweight materials such as carbon fiber-reinforced plastics (CFRP) and glass fiber-reinforced plastics (GFRP) with steel sheets have been developed.

[0003] For example, Patent Document 1 discloses a vibration damping structure having a metal member and a vibration damping material for suppressing vibration of the metal member, wherein the vibration damping material is attached to the surface of the metal member, and the vibration damping material has a laminated structure of two or more layers including a fiber-reinforced resin layer containing resin and fibers and a foam layer made of a resin foam, and the foam layer is interposed between the fiber-reinforced resin layer and the metal member and is attached to the metal member.

[0004] Further, Patent Document 2 discloses a composite material component composed of at least three different material layers, having the following layer structure: a) a support layer or support structure made of metal or fiber-reinforced plastic, b) an adhesive intermediate layer made of an elastomer, c) a coating layer made of carbon fiber or carbon mixed fiber-reinforced plastic, and the arrangement of the plastic and carbon fiber or carbon mixed fiber in the coating layer is selected such that the carbon fiber or carbon mixed fiber can be visually seen on the surface of the coating layer.

[0005] In addition, Patent Document 3 discloses a steel plate member composed of a steel plate or a formed body of the steel plate, a first resin layer located on at least a part of the surface of the steel plate member and mainly composed of two different resin compositions, and a second resin layer located on at least a part of the surface of the first resin layer and composed of a fiber-reinforced resin containing reinforcing fibers in a matrix resin. The resin composition of the first resin layer contains a phenoxy resin and a polyester elastomer in a mass ratio (phenoxy resin: polyester elastomer) within the range of 20:80 to 80:20. By observing the resin composition with an atomic force microscope (AFM) equipped with a probe having a tip radius of 10 nm in an atmosphere at 25°C, in the elastic modulus phase image obtained in a plurality of arbitrary 10-μm square regions, the area ratio of the portions forming the phase separation structure due to the phenoxy resin and the polyester elastomer is 1 area% or less of the total observation area. A steel plate-fiber reinforced resin composite is disclosed.

[0006] [Patent Document 1] Japanese Unexamined Patent Application Publication No. 2016-70389 [Patent Document 2] Japanese Translation of PCT International Publication No. 2012-515667 [Patent Document 3] International Publication No. 2022 / 014587 [Summary of the Invention] [Problems to be Solved by the Invention]

[0007] Conventionally, a laminate having a base material such as a metal layer, a non-fiber reinforced resin layer, and a fiber reinforced resin layer in this order from the base material side has been used. However, there is a demand for further improvement in bending rigidity of the laminate. However, it has not been easy to improve the mechanical properties while using the same material.

[0008] In contrast, an object of the present disclosure is to provide a composite laminate having high mechanical properties and an automotive member including the composite laminate. [Means for Solving the Problems]

[0009] The means for solving the problems includes the following aspects. <1> A composite laminate comprising a first substrate, a first high modulus layer, one or more low modulus layers, and a second high modulus layer in this order, All of the layers of the low modulus layer, one or more layers, have a lower modulus than the first high modulus layer and the second high modulus layer. The thickness of the first high modulus layer and the second high modulus layer are different. A composite laminate that satisfies Equation 1 below in relation to the target laminate defined below.

[0010] The aforementioned target laminate refers to a laminate having a target first base material, a target low modulus layer, and a target high modulus layer in that order, wherein the target first base material is a base material of the same material and thickness as the first base material in the composite laminate, the target low modulus layer is a layer of the same number, material and thickness as the low modulus layer in the composite laminate, and the target high modulus layer is a layer of the same material as the second high modulus layer in the composite laminate and has the same thickness as the total thickness of the first high modulus layer and the second high modulus layer.

[0011]

number

[0012] In Equation 1, h Rs The distance from the surface of the target first substrate on the target first substrate side of the target laminate to the interface between the target low modulus layer and the target high modulus layer is t Rs The total thickness of the target low modulus layer in the target laminate is λ s The position of the neutral axis in the target laminate calculated by formula 2 is h R The distance from the surface of the first substrate side in the composite laminate to the interface between the low modulus layer and the second high modulus layer is t. R λ represents the total thickness of the low modulus layer in the composite laminate, and λ represents the position of the neutral axis in the composite laminate calculated by equation 2. In Equation 2, when calculating the position λ of the neutral axis in the composite laminate, E i The elastic modulus of the i-th layer from the surface of the first substrate is given by hi represents the distance from the surface on the first substrate side to the surface on the opposite side of the surface on the first substrate side in the i-th layer as h i-1 represents the distance from the surface on the first substrate side to the surface on the opposite side of the surface on the first substrate side in the (i - 1)-th layer (when i = 1, h i-1 becomes 0), while in Formula 2, the position λ of the neutral axis in the target laminate s when calculating, E i represents the elastic modulus in the i-th layer from the surface on the target first substrate side, h i represents the distance from the surface on the target first substrate side to the surface on the opposite side of the surface on the target first substrate side in the i-th layer, h i-1 represents the distance from the surface on the target first substrate side to the surface on the opposite side of the surface on the target first substrate side in the (i - 1)-th layer (when i = 1, h i-1 becomes 0), represents.

[0013] <2> The composite laminate according to <1>, having a second substrate on the side opposite to the first substrate of the second high elastic modulus layer. <3> The first substrate and the first high elastic modulus layer are joined by a joining member, and when having the second substrate, further, the second substrate and the second high elastic modulus layer are joined by a joining member, The composite laminate according to <1> or <2>. <4> For the composite laminate according to any one of <1> to <3>, the elastic modulus of each layer in the low elastic modulus layer is 0.8 times or less of the elastic modulus of either the first high elastic modulus layer or the second high elastic modulus layer. <5> For the composite laminate according to any one of <1> to <4>, the elastic modulus E1 of the first high elastic modulus layer is less than or equal to the elastic modulus E2 of the second high elastic modulus layer. <6> For the composite laminate according to any one of <1> to <5>, the ratio of the difference between the elastic modulus E1 of the first high elastic modulus layer and the elastic modulus E2 of the second high elastic modulus layer (|E1 - E2| / E2×100) is 1% or less. <7> The position λ of the neutral axis in the composite laminate is located within the low modulus layer. <1> ~ <6> A composite laminate as described in any one of the items. <8> At least one of the first high modulus layer and the second high modulus layer is a fiber-reinforced resin layer. <1> ~ <7> A composite laminate as described in any one of the items. <9> All layers in the aforementioned low modulus layer are resin layers that do not contain fibers. <1> ~ <8> A composite laminate as described in any one of the items. <10> The first substrate is a metal layer, Furthermore, if the second substrate is present, the second substrate is a metal layer. <1> ~ <19> A composite laminate as described in any one of the items.

[0014] <11> Used in automotive components, <1> ~ <10> A composite laminate as described in any one of the items. <12> <11> Automotive component comprising the composite laminate described above. [Effects of the Invention]

[0015] According to this disclosure, a composite laminate having high mechanical properties and an automotive component comprising the composite laminate can be provided. [Brief explanation of the drawing]

[0016] [Figure 1] This is a schematic perspective view showing a composite laminate having a first configuration according to an embodiment of the present disclosure. [Figure 2] This is a schematic perspective view showing a target laminate with a conventional configuration. [Figure 3] This is a schematic perspective view showing another example of a composite laminate having the first configuration according to an embodiment of the present disclosure. [Figure 4] This is a schematic perspective view showing a target laminate with a conventional configuration. [Figure 5]This is a schematic perspective view showing a composite laminate having a second configuration according to an embodiment of the present disclosure. [Figure 6] This is a schematic perspective view showing a target laminate with a conventional configuration. [Figure 7] This is a schematic cross-sectional view showing a composite laminate having a second configuration according to an embodiment of the present disclosure. [Figure 8] This is a schematic cross-sectional view showing another example of a composite laminate having a second configuration according to an embodiment of the present disclosure. [Modes for carrying out the invention]

[0017] An example of an embodiment of this disclosure will be described. In this specification, a numerical range represented by "~" means a range that includes the numbers before and after "~" as lower and upper limits, unless those numbers are preceded by "greater than" or "less than". If the numbers before and after "~" are preceded by "greater than" or "less than", the numerical range means a range that does not include those numbers as lower or upper limits. In the numerical ranges described stepwise in this specification, the upper limit of one stepwise numerical range may be replaced with the upper limit of another stepwise numerical range, or with the values ​​shown in the examples. Similarly, the lower limit of one stepwise numerical range may be replaced with the lower limit of another stepwise numerical range, or with the values ​​shown in the examples. Furthermore, unless otherwise specified, the percentage (%) used for content refers to "mass%". A percentage of "0" indicates that the component is optional and does not need to be included.

[0018] <Composite Laminate> The composite laminate according to the embodiment of this disclosure is a composite laminate having a first substrate, a first high modulus layer, one or more low modulus layers, and a second high modulus layer in this order. In this specification, the laminate of the first high modulus layer, one or more low modulus layers, and the second high modulus layer may be referred to as a "rigid member layer".

[0019] The composite laminate according to the embodiment of this disclosure may have a second substrate on the side of the second high modulus layer opposite to the first substrate (i.e., on the side of the second high modulus layer where the first substrate, the first high modulus layer, and the low modulus layer are laminated). Furthermore, the first substrate and the first high modulus layer may be in direct contact, or they may be joined by a bonding member such as a first adhesive layer. If the composite laminate has a second substrate, the second substrate and the second high modulus layer may be in direct contact, or they may be joined by a bonding member such as a second adhesive layer.

[0020] Examples of the configuration of the composite laminate according to the embodiments of this disclosure include the following first configuration or second configuration. (First configuration) The first configuration comprises a first base material and, in order from the first base material side, a rigid member layer having a first high modulus layer, one or more low modulus layers, and a second high modulus layer. (Second configuration) The configuration includes a first base material, a rigid member layer having a first high modulus layer, one or more low modulus layers, and a second high modulus layer, in that order from the first base material side, and a second base material on the side of the rigid member layer opposite the first base material. In the first configuration, the first substrate and the first high modulus layer are either in direct contact or laminated via the first adhesive layer. In the second configuration, the first substrate and the first high modulus layer are in direct contact or laminated via the first adhesive layer, and the second substrate and the second high modulus layer are in direct contact or laminated via the second adhesive layer. All layers of the low-modulus layer, one or more layers in total, have a lower modulus of elasticity than the first high-modulus layer and the second high-modulus layer.

[0021] In the composite laminate according to the embodiment of this disclosure, the thicknesses of the first high modulus layer and the second high modulus layer are different. Furthermore, the following equation 1, which is the relationship with the target laminate, is satisfied (the definition of the target laminate will be described later).

[0022]

number

[0023] In Equation 1, h Rs The distance from the surface of the target first substrate on the target first substrate side of the target laminate to the interface between the target low modulus layer and the target high modulus layer is t. Rs λ is the total thickness of the target low modulus layer in the target laminate. s This represents the position of the neutral axis in the target laminate calculated by Equation 2. Also, in Equation 1, h R In a composite laminate, the distance from the surface of the first substrate to the interface between the low modulus layer and the second high modulus layer is t. R λ represents the total thickness of the low modulus layer in the composite laminate, and λ represents the position of the neutral axis in the composite laminate, calculated by Equation 2.

[0024] In other words, the left side of Equation 1 is a formula derived from the terms relating to the target laminate, specifically the distance from the surface of the target first substrate to the edge of the target low modulus layer (the interface with the target high modulus layer), the total thickness of the target low modulus layer, and the position of the neutral axis of the target laminate. The right side of Equation 1 is a formula derived from the terms relating to the composite laminate, specifically the distance from the surface of the first substrate to the edge of the low modulus layer (the interface with the second high modulus layer), the total thickness of the low modulus layer, and the position of the neutral axis of the composite laminate.

[0025] In Equation 2, when calculating the position λ of the neutral axis in the composite laminate, E i The elastic modulus of the i-th layer from the surface of the first substrate is h i h is the distance from the surface on the first substrate side to the surface on the opposite side of the i-th layer on the first substrate side. i-1 This is the distance from the surface on the first substrate side to the surface on the opposite side of the i-1th layer (where i=1 is h). i-1 This represents (where is 0). On the other hand, in equation 2, the position of the neutral axis in the target laminate is λ. s When calculating E i The elastic modulus of the i-th layer from the surface of the first substrate is given by h. i h is the distance from the surface on the first substrate side to the surface on the opposite side of the i-th layer on the first substrate side. i-1This is the distance from the surface on the first substrate side to the surface on the opposite side of the i-1th layer (where i=1 is h). i-1 This represents (where is 0).

[0026] Here, we will explain the "i-th layer". In a composite laminate, the first layer is the outermost layer of the first substrate. Further along the thickness direction of the composite laminate and in the direction opposite to the surface of the first substrate, there are the second and third layers, and the outermost layer opposite to the surface of the first substrate is the nth layer. Note that if the low modulus layer consists of two or more layers, each layer is counted as one layer. Similarly, if the first or second substrate consists of multiple layers, each layer is counted as one layer. If there is an adhesive layer, the adhesive layer is counted as one layer. For example, in a composite laminate consisting of a two-layer first substrate, a first adhesive layer, a first high modulus layer, a two-layer low modulus layer, and a second high modulus layer, the i-th layer is as follows: First layer = outer layer of the first substrate The second layer = the inner layer of the first substrate. Third layer = First adhesive layer Fourth layer = First high modulus layer Fifth layer = Low modulus layer of the first layer The sixth layer = the second low-modulus layer The 7th layer = the 2nd high modulus layer Furthermore, in a composite laminate consisting of a single-layer first substrate, a first adhesive layer, a first high-modulus layer, a three-layer low-modulus layer, a second high-modulus layer, a second adhesive layer, and a single-layer second substrate, the i-th layer is as follows. First layer = First substrate Second layer = First adhesive layer Third layer = First high modulus layer The fourth layer = the first layer with low elasticity Fifth layer = second layer with low elasticity The sixth layer = the third low-modulus layer The 7th layer = the 2nd high modulus layer The 8th layer = the second adhesive layer The ninth layer = second substrate

[0027] The composite laminate according to the embodiment of this disclosure, having the above configuration, can improve the mechanical properties (specifically, bending stiffness) of the composite laminate compared to the target laminate, which is an example of a conventional composite laminate, while using the same material at the same thickness (i.e., the material used and its thickness (amount) are the same). From another perspective, compared to the target laminate, which is an example of a conventional composite laminate, the amount of material used to achieve equivalent mechanical properties can be reduced, thereby achieving a cost reduction for the composite laminate.

[0028] This effect is based on the following findings.

[0029] It is known that when a bending load is applied to a material, a greater thickness of the material is advantageous in terms of bending stiffness. Furthermore, if the material is composed of a single material, the center of the material in the thickness direction is considered the neutral axis, and compressive stress occurs on the side of the neutral axis facing the external force, while tensile stress occurs on the opposite side. On the other hand, in a material made up of multiple types of materials stacked together (a laminate), the neutral axis is not necessarily the center in the thickness direction, but changes in the stacking direction according to the thickness and mechanical properties of each material stacked.

[0030] Here, as an example, let's consider a laminate consisting of metal and fiber-reinforced resin (particularly carbon fiber reinforced resin containing carbon fibers). For example, in the automotive sector, the demand for weight reduction has been rapidly increasing in recent years, and the development of materials that can balance weight reduction and automotive safety is progressing. Bending stiffness is a representative material property related to automotive safety. Therefore, by reducing the proportion of metal, which has a large mass, and combining it with lightweight carbon fiber reinforced resin, it is being considered that both weight reduction and high bending stiffness can be achieved. The bending stiffness of a material is greatly affected by the thickness of the material, and the thicker the material, the greater the improvement in the second moment of area, which can lead to an improvement in bending stiffness. Therefore, in a laminate of metal and carbon fiber reinforced resin, increasing the thickness of the lightweight carbon fiber reinforced resin is effective in further improving bending stiffness. However, carbon fiber reinforced resin has a high material cost (i.e., it is very expensive), and when applied to automotive components, for example, further cost reduction is required. Therefore, a laminate in which a non-fiber-reinforced resin is added in addition to metal and carbon fiber reinforced resin to increase the overall thickness is being considered. Conventionally, the laminated structure has been attempted in which a material with high bending rigidity is placed in the outermost layer; in other words, a sandwich structure in which a non-fiber-reinforced resin is sandwiched between a metal layer and a carbon fiber-reinforced resin layer has been considered.

[0031] Here, the conventional laminate structure of a laminate is shown in Figure 2. The conventional laminate shown in Figure 2 has a base material 12 (e.g., a metal layer), and, in order from the base material 12 side, a low modulus layer 16 (e.g., a non-fiber-reinforced resin layer) and a high modulus layer 14 (e.g., a fiber-reinforced resin layer). In other words, the conventional laminate shown in Figure 2 has a laminate structure similar to that of the target laminate, which has the target first base material, target low modulus layer, and target high modulus layer in this order. However, laminates are required to have further improvements in bending rigidity and further cost reductions. However, achieving a reduction in material usage while maintaining mechanical properties is not easy with conventional laminate constructions.

[0032] In contrast, this disclosure has found that bending rigidity can be improved by dividing the fiber-reinforced resin layer in the lamination direction into two parts: the part between the metal layer and the non-fiber-reinforced resin layer, and the part of the non-fiber-reinforced resin layer opposite the metal layer, and by appropriately adjusting the thickness of each of the two divided fiber-reinforced resin layers. Here, the lamination configuration of the composite laminate in this disclosure is shown in Figure 1. The composite laminate in this disclosure shown in Figure 1 has a first base material 2 (e.g., a metal layer), and, in order from the first base material 2 side, a first high modulus layer 41 (e.g., a fiber-reinforced resin layer), a low modulus layer 6 (e.g., a non-fiber-reinforced resin layer), and a second high modulus layer 42 (e.g., a fiber-reinforced resin layer). The first high modulus layer 41, the low modulus layer 6, and the second high modulus layer 42 form a composite member layer 80. As shown in Figure 1, in the composite laminate, the high modulus layer is divided into upper and lower halves, with a first high modulus layer 41 provided between the first base material 2 and the low modulus layer 6, and a second high modulus layer 42 provided on the side of the low modulus layer 6 opposite the first base material 2. The thickness of each of the two divided high modulus layers is then appropriately adjusted. Specifically, the thickness adjustment is performed by adjusting the distance (h) from the surface on the first base material 2 side to the edge of the low modulus layer 6 (the interface with the second high modulus layer 42). R ) and the thickness of the low modulus layer 6 (t R It is necessary to adjust the position of the neutral axis of the composite laminate so that it satisfies Equation 1, which is the relationship between the two. This makes it possible to improve the bending rigidity of the composite laminate compared to the target laminate, which is an example of a conventional composite laminate, while using the same material and thickness. From another perspective, it is possible to reduce the amount of material used to achieve equivalent mechanical properties compared to the target laminate, thereby reducing the cost of the composite laminate.

[0033] Furthermore, in a composite laminate, the neutral axis position λ calculated by Equation 2 is preferably located within the low modulus layer, from the viewpoint of further improving the bending rigidity of the composite laminate. Moreover, it is even more preferable that it be located in a region close to the center in the thickness direction of the low modulus layer, specifically in a region near the center in the thickness direction of the low modulus layer, within 50% (more preferably within 30%) of the thickness of the low modulus layer.

[0034] In the above, a laminate comprising a metal layer, a fiber-reinforced resin layer, and a non-fiber-reinforced resin layer was used as an example. However, this disclosure has found that bending rigidity can be improved in a high-modulus layer (e.g., a fiber-reinforced resin layer) and a low-modulus layer (e.g., a non-fiber-reinforced resin layer) by dividing the high-modulus layer into two and adjusting its thickness to satisfy the aforementioned formula 1. Therefore, with respect to the first base material, the first high-modulus layer, the low-modulus layer, and the second high-modulus layer, the type of material is not limited as long as all layers of the low-modulus layer satisfy the requirement that their modulus is lower than that of the first high-modulus layer and the second high-modulus layer. Furthermore, if the composite laminate has the second configuration, the type of material for the second base material is also not limited.

[0035] The composite laminate relating to this disclosure is not limited to a plate-like shape, but the above effects are also effectively exhibited in components processed into various shapes. This is because, in any material, the mechanical properties can be improved by processing the shape, and if the composite laminate itself has higher mechanical properties than conventional laminates, it is clear that the mechanical properties of the processed product will also be improved compared to using conventional laminates.

[0036] Furthermore, one effective means of satisfying Equation 1 is to vary the thicknesses of the first and second high modulus layers. Although this is not directly related to the improvement of the bending stiffness of the composite laminate intended by this disclosure, varying the thicknesses of the first and second high modulus layers is effective in improving both the bending stiffness and the bending strength of the composite laminate. More preferably, the thickness of the high modulus layer located on the side to which the external force is applied is thinner than the thickness of the other high modulus layer.

[0037] -Definition of the target laminate- Here, we will explain the target laminate. The term "target laminate" refers to a laminate having a target first base material, a target low modulus layer, and a target high modulus layer in that order, wherein the target first base material is the same material and thickness as the first base material in a composite laminate, the target low modulus layer is the same number, same material and thickness as the low modulus layer in a composite laminate, and the target high modulus layer is the same material as the second high modulus layer in a composite laminate and has the same thickness as the total thickness of the first and second high modulus layers.

[0038] Since the target first substrate and the first substrate in the composite laminate are made of the same material, their elastic moduli are also equal. Similarly, if the other layers are made of the same material, their elastic moduli will also be equal. The statement that the target first substrate and the first substrate in the composite laminate have the same thickness means that the thickness of the target first substrate and the thickness of the composite laminate are equal in terms of the thickness determined by the method described later. Similarly, the statement that the other layers have the same thickness means that the thicknesses determined by the method described later are equal. When the number of target low modulus layers is the same as the number of low modulus layers in the composite laminate, it means that the number of target low modulus layers laminated in the target laminate is equal to the number of low modulus layers laminated in the composite laminate. Furthermore, when two or more target low modulus layers and low modulus layers are laminated, when the target low modulus layers and low modulus layers are made of the same material, it means that in each layer of the target low modulus layers and each layer of the low modulus layers, layers of the same material are laminated sequentially from either the target first substrate side or the first substrate side. Also, when the target low modulus layers and low modulus layers are made of the same thickness, it means that in each layer of the target low modulus layers and each layer of the low modulus layers, layers of equal thickness are laminated sequentially from either the target first substrate side or the first substrate side.

[0039] Let's explain the target laminate in more detail with an example. When the composite laminate is the first configuration, the target laminate comprises a target first base material and, starting from the target first base material side, a target rigid member layer having the same number of target low modulus layers and target high modulus layers as the low modulus layers in the composite laminate. When the composite laminate is the second configuration, the target laminate comprises a target first base material and, starting from the target first base material side, a target rigid member layer having the same number of target low modulus layers and target high modulus layers as the low modulus layers in the composite laminate, and a target second base material on the side of the target rigid member layer opposite the target first base material. In both the first and second configurations of the composite laminate, the target first substrate is made of the same material and has the same thickness as the first substrate in the composite laminate. In other words, the target first substrate uses the same substrate as the first substrate in the composite laminate. If the composite laminate is the second component, the target second substrate is made of the same material and has the same thickness as the second substrate in the composite laminate. In other words, the target second substrate uses the same substrate as the second substrate in the composite laminate.

[0040] Each of the target low-modulus layers is made of the same material and has the same thickness as one or more low-modulus layers in the composite laminate. In other words, the target low-modulus layers are the same layers as the low-modulus layers in the composite laminate. If the composite laminate has only one low-modulus layer, the target low-modulus layers are the same layers as this one low-modulus layer. If the composite laminate has two or more low-modulus layers, the target low-modulus layers are the same number of layers as in the composite laminate, and each layer is made of the same material and has the same thickness.

[0041] The target high modulus layer is made of the same material as the second high modulus layer in the composite laminate, and has the same thickness as the total thickness of the first and second high modulus layers. In other words, the thickness of the target high modulus layer is the same as the total thickness of the high modulus layers in the composite laminate (thickness of the first high modulus layer + thickness of the second high modulus layer). The material of the target high modulus layer is the same as the second high modulus layer in the composite laminate.

[0042] In both the first and second configurations of the composite laminate, if the first substrate and the first high modulus layer in the composite laminate are in direct contact, then the target first substrate and the target low modulus layer are also in direct contact. Furthermore, if the first substrate and the first high modulus layer in the composite laminate are laminated via a first adhesive layer, then the target first substrate and the target low modulus layer are laminated via the target first adhesive layer. The target first adhesive layer is made of the same material and has the same thickness as the first adhesive layer in the composite laminate; in other words, the target first adhesive layer is the same layer as the first adhesive layer in the composite laminate. When the composite laminate is the second component, if the second substrate and the second high modulus layer in the composite laminate are in direct contact, then the target second substrate and the target high modulus layer are in direct contact. Furthermore, if the second substrate and the second high modulus layer in the composite laminate are laminated via a second adhesive layer, then the target second substrate and the target high modulus layer are laminated via the target second adhesive layer. Note that the target second adhesive layer is made of the same material and has the same thickness as the second adhesive layer in the composite laminate; in other words, the target second adhesive layer is the same layer as the second adhesive layer in the composite laminate.

[0043] - How to determine the modulus of elasticity - In Equation 2, E i This represents the elastic modulus of the i-th layer from the surface of the first substrate (the position of the neutral axis λ in the target laminate). s When calculating this, the elastic modulus E of the i-th layer from the surface of the target first substrate is used. i (This represents...). The modulus of elasticity in each of these layers can be determined by the following method. In this disclosure, "modulus of elasticity" means "storage modulus of elasticity".

[0044] First, the layer to be measured is cut from the composite laminate using a cutting machine. The collected layer is cut into 10mm x 50mm x any thickness to prepare the DMA measurement sample. If the thickness of the DMA measurement sample is less than 2mm, measurement is performed in tensile mode; if it is 2mm or more, measurement is performed in three-point bending mode under the conditions shown below. Note that the longitudinal direction of the composite laminate and the longitudinal direction of the DMA measurement sample should be aligned.

[0045] The modulus of elasticity in this disclosure can be measured by DMA (dynamic viscoelasticity measurement). Specifically, a Hitachi High-Tech Science Corporation DMA7100 viscoelasticity measuring device is used as the DMA device, and the measurement conditions are set as follows: measurement temperature program: (1) -100℃ → (2) 200℃ → (3) -100℃ → (4) 200℃, heating rate: 3℃ / min, sampling: 20 sec, frequency: 1 Hz, measurement atmosphere: nitrogen atmosphere, measurement mode: tensile mode if the sample thickness is less than 2 mm, and 3-point bending mode if the sample thickness is 2 mm or more. The storage modulus of elasticity at 25℃ during the heating from (3) to (4) in the above measurement temperature program is defined as the modulus of elasticity in this disclosure.

[0046] - How to determine the thickness - The thickness of each layer is measured by cross-sectional observation using a microscope. First, the composite laminate is cut so that a cross-section parallel to both the thickness direction and the longitudinal direction of the laminate is formed, and the resulting first cross-section is observed with an optical microscope. When measuring the thickness of each layer, two points A and B are taken in the longitudinal direction of the first cross-section such that the straight-line distance AB is longest, and this straight line AB is divided into six equal parts. At five of these points, excluding the ends A and B, the vertical distance from the interface between the adhesive layer and the first substrate (if there is an adhesive layer) to the other end of the first substrate is measured. Similarly, the vertical distance for the thickness of the other layers is measured in the same way as for the first substrate. Furthermore, the composite laminate is cut at a point shifted perpendicular to the first cross-section by an arbitrary distance from the first cross-section to form a second cross-section, and the thickness of each layer is measured at five locations in the same way as for the first cross-section. The average value of the thickness of each layer at a total of 10 points obtained from the two cross-sections is calculated and used as the thickness of each layer. The measured value should be rounded to two or three decimal places (mm).

[0047] -Regarding the outermost layer on the opposite side of the first substrate- Here, we will explain whether the outermost layer on the opposite side of the first substrate in a composite laminate (hereinafter referred to as the "outermost layer") is considered the second high modulus layer or the second substrate. Assume a configuration in which a first base material and layers 1, 2, ..., n layers (n≧4, where n is an integer) are stacked in order from the first base material side. In this case, the nth layer corresponds to the outermost layer. If the elastic modulus of all layers from the 2nd layer to the (n-2)th layer is lower than the elastic modulus of the 1st layer (the layer closest to the first base material), the criteria for determining whether the nth layer (outermost layer) is the second high-modulus layer or the second base material are as follows. If the (n-1)th layer corresponds to the second high modulus layer (i.e., the (n-1)th layer has a higher modulus than any of the layers from the second to the (n-2)th layer), then the (n-1)th layer is designated as the second high modulus layer, and the (n)th layer is designated as the second base material. On the other hand, if the (n-1)th layer does not correspond to the second high modulus layer (i.e., the (n-1)th layer has a lower modulus than at least one of the layers from the second to the (n-2)th layer) and the (n)th layer corresponds to the second high modulus layer (i.e., the (n)th layer has a higher modulus than any of the layers from the second to the (n-1)th layer), then the (n-1)th layer is designated as the low modulus layer, and the (n)th layer is designated as the second high modulus layer.

[0048] -First configuration- A composite laminate according to the embodiment of this disclosure has, for example, the following first configuration. (First configuration) The first configuration comprises a first base material and, in order from the first base material side, a rigid member layer having a first high modulus layer, one or more low modulus layers, and a second high modulus layer.

[0049] • When there is a single layer of low modulus elasticity An example of a composite laminate having the first configuration is shown in Figure 1. The composite laminate shown in Figure 1 has a first base material 2, and, in order from the side of the first base material 2, a first high modulus layer 41, a low modulus layer 6, and a second high modulus layer 42. The composite member layer 80 is formed by the first high modulus layer 41, the low modulus layer 6, and the second high modulus layer 42. In the composite laminate, the high modulus layer is divided into upper and lower halves, with the first high modulus layer 41 provided between the first base material 2 and the low modulus layer 6, and the second high modulus layer 42 provided on the side of the low modulus layer 6 opposite to the first base material 2. In the composite laminate according to the embodiment of this disclosure, the thickness of each of the two divided high modulus layers is appropriately adjusted. Specifically, the distance (h) from the surface of the first substrate 2 to the edge of the low modulus layer 6 (interface with the second high modulus layer 42) is adjusted. R ) and the thickness of the low modulus layer 6 (t R The position of the neutral axis of the composite laminate is adjusted to satisfy Equation 1.

[0050] The target laminate for the composite laminate with the first configuration shown in Figure 1 has the configuration shown in Figure 2. The target laminate with the conventional configuration shown in Figure 2 has a target first base material 12, and, in order from the target first base material 12 side, a target low modulus layer 16 and a target high modulus layer 14. The target low modulus layer 16 and the target high modulus layer 14 form a composite member layer 81. The target first base material 12 is made of the same material and has the same thickness as the first base material 2 in the composite laminate, the target low modulus layer 16 is made of the same material and has the same thickness as the low modulus layer 6 in the composite laminate, and the target high modulus layer 14 is made of the same material as the second high modulus layer 42 in the composite laminate and has the same thickness as the total thickness of the first high modulus layer 41 and the second high modulus layer 42.

[0051] • When there are multiple layers of low elasticity layers In a composite laminate having the first configuration, the low modulus layer may be composed of multiple layers. An example of this is shown in Figure 3. The composite laminate shown in Figure 3 has a first base material 2, and, in order from the side of the first base material 2, a first high modulus layer 41, a first low modulus layer 61, a second low modulus layer 62, and a second high modulus layer 42. The composite member layer 82 is formed by the first high modulus layer 41, the first low modulus layer 61, the second low modulus layer 62, and the second high modulus layer 42. In the composite laminate, the high modulus layer is divided vertically, with the first high modulus layer 41 provided between the first base material 2 and the first low modulus layer 61, and the second high modulus layer 42 provided on the side of the second low modulus layer 62 opposite to the first base material 2. In the composite laminate according to the embodiment of this disclosure, the thickness of each of the two divided high modulus layers is appropriately adjusted. Specifically, the distance (h) from the surface of the first substrate 2 to the edge of the low modulus layer (i.e., the interface between the second low modulus layer 62 and the second high modulus layer 42) is adjusted. R ) and the total thickness (t) of the first low modulus layer 61 and the second low modulus layer 62 R The position of the neutral axis of the composite laminate is adjusted to satisfy Equation 1.

[0052] The target laminate for the composite laminate with the first configuration shown in Figure 3 has the configuration shown in Figure 4. The target laminate with the conventional configuration shown in Figure 4 has a target first base material 12, and, in order from the target first base material 12 side, a target first low modulus layer 161, a target second low modulus layer 162, and a target high modulus layer 14. The composite member layer 83 is formed by the target first low modulus layer 161, the target second low modulus layer 162, and the target high modulus layer 14. The target first base material 12 is made of the same material and has the same thickness as the first base material 2 in the composite laminate; the target first low modulus layer 161 is made of the same material and has the same thickness as the first low modulus layer 61 in the composite laminate; the target second low modulus layer 162 is made of the same material and has the same thickness as the second low modulus layer 62 in the composite laminate; and the target high modulus layer 14 is made of the same material as the second high modulus layer 42 in the composite laminate and has the same thickness as the total thickness of the first high modulus layer 41 and the second high modulus layer 42.

[0053] In both the composite laminate of the first configuration shown in Figure 1 and the composite laminate of the first configuration shown in Figure 3, the first base material 2 and the first high modulus layer 41 may be in direct contact, or the first base material 2 and the first high modulus layer 41 may be laminated via a first adhesive layer (not shown). Furthermore, when the first base material 2 and the first high modulus layer 41 in a composite laminate are in direct contact, the target laminate (for example, the target laminate shown in Figure 2 or Figure 4) is such that the target first base material 12 and the target low modulus layer 16 or target first low modulus layer 161 are in direct contact. Also, when the first base material 2 and the first high modulus layer 41 in a composite laminate are laminated via a first adhesive layer, the target laminate is such that the target first base material 12 and the target low modulus layer 16 or target first low modulus layer 161 are laminated via a target first adhesive layer of the same material and thickness as the first adhesive layer.

[0054] -Second configuration- A composite laminate according to the embodiment of this disclosure has, for example, the following second configuration. (Second configuration) The configuration includes a first base material, a rigid member layer having a first high modulus layer, one or more low modulus layers, and a second high modulus layer, in that order from the first base material side, and a second base material on the side of the rigid member layer opposite the first base material.

[0055] • When there is a single layer of low modulus elasticity An example of a composite laminate having the second configuration is shown in Figure 5. The composite laminate shown in Figure 5 has a first base material 221, and, in order from the side of the first base material 221, a first high modulus layer 241, a low modulus layer 206, a second high modulus layer 242, and a second base material 222. A composite member layer 208 is formed by the first high modulus layer 241, the low modulus layer 206, and the second high modulus layer 242. In the composite laminate, the high modulus layer is divided into upper and lower halves, with the first high modulus layer 241 provided between the first base material 221 and the low modulus layer 206, and the second high modulus layer 242 provided on the side of the low modulus layer 206 opposite to the first base material 221. In the composite laminate according to the embodiment of this disclosure, the thickness of each of the two divided high modulus layers is appropriately adjusted. Specifically, the distance (h) from the surface on the first substrate 221 side to the edge of the low modulus layer 206 (interface with the second high modulus layer 242) is adjusted. R ) and the thickness of the low modulus layer 206 (t R The position of the neutral axis of the composite laminate is adjusted to satisfy Equation 1.

[0056] The target laminate for the composite laminate with the second configuration shown in Figure 5 has the configuration shown in Figure 6. The target laminate with the conventional configuration shown in Figure 6 has a target first base material 2221, and, starting from the target first base material 2221 side, a target low modulus layer 2206 and a target high modulus layer 2204. The target low modulus layer 2206 and the target high modulus layer 2204 form a composite member layer 2208. The target first base material 2221 is made of the same material and has the same thickness as the first base material 221 in the composite laminate; the target low modulus layer 2206 is made of the same material and has the same thickness as the low modulus layer 206 in the composite laminate; the target high modulus layer 2204 is made of the same material as the second high modulus layer 242 in the composite laminate and has the same thickness as the total thickness of the first high modulus layer 241 and the second high modulus layer 242; and the target second base material 2222 is made of the same material and has the same thickness as the second base material 222 in the composite laminate.

[0057] • When there are multiple layers of low elasticity layers Furthermore, in the composite laminate having the second configuration, the low modulus layer may also be composed of multiple layers. The details are the same as those described for the composite laminate having the first configuration, and therefore the details are omitted.

[0058] In the composite laminate of the second configuration shown in Figure 5, the first substrate 221 and the first high modulus layer 241 may be in direct contact, or the first substrate 221 and the first high modulus layer 241 may be laminated via a first adhesive layer (not shown). Alternatively, the second substrate 222 and the second high modulus layer 242 may be in direct contact, or the second substrate 222 and the second high modulus layer 242 may be laminated via a second adhesive layer (not shown). Furthermore, when the first base material 221 and the first high modulus layer 241 in a composite laminate are in direct contact, the target laminate (for example, the target laminate shown in Figure 6) will have the target first base material 2221 and the target low modulus layer 2206 in direct contact. Also, when the first base material 2221 and the first high modulus layer 241 in a composite laminate are laminated via a first adhesive layer, the target first base material 2221 and the target low modulus layer 2206 will be laminated via a target first adhesive layer of the same material and thickness as the first adhesive layer. Furthermore, when the second base material 222 and the second high modulus layer 242 are in direct contact in a composite laminate, the target laminate (for example, the target laminate shown in Figure 6) will have the target second base material 2222 and the target high modulus layer 2204 in direct contact. Also, when the second base material 2222 and the second high modulus layer 242 are laminated in a composite laminate via a second adhesive layer, the target laminate will have the target second base material 2222 and the target high modulus layer 2204 laminated via a target second adhesive layer of the same material and thickness as the second adhesive layer.

[0059] -Relationships between each layer- • Elastic modulus of the low modulus layer and the high modulus layer The low modulus layer has a lower modulus than both the first high modulus layer and the second high modulus layer. Furthermore, if the composite laminate has multiple low modulus layers, all of these layers have a lower modulus than both the first high modulus layer and the second high modulus layer.

[0060] For example, the modulus of elasticity of the low-modulus layer (or the modulus of each layer if there are multiple low-modulus layers) is preferably 0.8 times or less than the modulus of elasticity of either the first high-modulus layer or the second high-modulus layer, more preferably 0.5 times or less, and even more preferably 0.1 times or less. The lower limit is not particularly limited, but is preferably 0.00001 times or more, and more preferably 0.00008 times or more.

[0061] • Elastic modulus of layers with high elastic modulus The relationship between the elastic moduli of the first high-modulus layer and the second high-modulus layer is not particularly limited. For example, the elastic moduli of the first and second high-modulus layers may be similar, or there may be a difference between them.

[0062] However, it is preferable that the elastic modulus (E1) of the first high elastic modulus layer is less than or equal to the elastic modulus of the second high elastic modulus layer (i.e., satisfying the relationship of "E1≦E2"), and it is more preferable that the elastic modulus (E1) of the first high elastic modulus layer is less than the elastic modulus of the second high elastic modulus layer (i.e., satisfying the relationship of "E1<E2"). In particular, in the composite laminate of the first configuration, it is preferable that the elastic modulus of the first high elastic modulus layer is less than or equal to the elastic modulus of the second high elastic modulus layer (more preferably, the elastic modulus of the first high elastic modulus layer is less than the elastic modulus of the second high elastic modulus layer). By satisfying the relationship of "E1≦E2" (more preferably, the relationship of "E1<E2"), the mechanical properties (specifically, bending rigidity) can be further improved.

[0063] In addition, when the elastic moduli of the first high elastic modulus layer and the second high elastic modulus layer are approximately the same, it means that the ratio of the difference between the elastic modulus E1 of the first high elastic modulus layer and the elastic modulus E2 of the second high elastic modulus layer (|E1 - E2| / E2×100) is, for example, 1% or less. Examples of the aspect where (|E1 - E2| / E2×100) is 1% or less include the case where the same material is used for the first high elastic modulus layer and the second high elastic modulus layer.

[0064] Also, when there is a difference in the elastic moduli between the first high elastic modulus layer and the second high elastic modulus layer, the ratio (|E1 - E2| / E2×100) of the elastic modulus (E1) of the first high elastic modulus layer to the second high elastic modulus layer (E2) may be, for example, more than 1% and less than 100%, or further more than or equal to 10% and less than 100%.

[0065] - Material of each layer - · Material of the rigid member layer The technology in the present disclosure is derived from adjusting the thickness of each layer according to the position of the neutral axis in the composite laminate. Therefore, the materials of the first and second high elastic modulus layers and the low elastic modulus layer constituting the rigid member layer are not particularly limited as long as the elastic modulus of all the layers of the low elastic modulus layer is lower than the elastic moduli of the first and second high elastic modulus layers.

[0066] Here, we will give examples of materials used in the first and second high modulus layers and the low modulus layer. Examples of materials used in the high modulus layer and the low modulus layer include fiber-reinforced resins, fiber-free resins (non-fiber-reinforced resins), metals, ceramics, wood, etc.

[0067] Examples of non-fiber-reinforced resins include resins used in automotive materials. Specifically, these include epoxy, polyolefins and their acid-modified products, polypropylene, polystyrene, polymethyl methacrylate, AS resin, ABS resin, thermoplastic aromatic polyesters such as polyethylene terephthalate and polybutylene terephthalate, polycarbonate, polyimide, polyamide, polyamide-imide, polyetherimide, polyethersulfone, polyphenylene ether and its modified products, polyphenylene sulfide (PPS), polyoxymethylene, polyarylate, polyether ketone, polyetherether ketone (PEEK), polyether ketone ketone, thermoplastic epoxy resin, unsaturated polyester resin, phenolic resin, urethane resin, nylon, and foamed resins. Non-fiber-reinforced resins may be curable resins such as thermosetting resins or plastic resins such as thermoplastic resins, and the foaming ratio is not particularly limited in the case of foamed resins. Furthermore, mixed resins or blended resins of the above resins may also be used.

[0068] Fiber-reinforced resin is a resin material containing a matrix resin and reinforcing fiber material, in which the reinforcing fiber material is held within the matrix resin. "Held within" refers to a state in which the reinforcing fiber material is composited with the matrix resin. Specifically, this includes states in which the reinforcing fiber material is dispersed within the matrix resin, states in which resin is impregnated into fibers arranged with a specific direction, and states in which continuous fibers are bundled together by the resin. However, the configuration is not particularly limited and can be appropriately determined by factors such as fiber length, fiber directionality, and the ratio of fibers in the resin. The matrix resin contains at least one of a curable resin and a thermoplastic resin. Examples of matrix resins in fiber-reinforced resins include the resins listed in the section on non-fiber-reinforced resins above. Examples of fibers used in fiber-reinforced resins include carbon fibers, glass fibers, aramid fibers, boron fibers, silicon carbide fibers, steel fibers, PBO fibers, alumina fibers, and high-strength polyethylene fibers. For carbon fibers, both PAN-based and pitch-based types can be used, and the choice depends on the purpose and application. Furthermore, the fiber form is not particularly limited; for example, nonwoven fabrics using chopped fibers, cloth materials using continuous fibers, and unidirectional reinforced fiber materials (UD materials) can be used as the base material for the reinforcing fibers.

[0069] The fiber-reinforced resin is not particularly limited, but from the viewpoint of easily increasing rigidity, it is preferable that the lower limit of the tensile modulus is 100 GPa or higher, and more preferably 125 GPa or higher. The upper limit of the tensile modulus may be, for example, 500 GPa, and is preferably 160 GPa or lower.

[0070] Examples of metals include iron, titanium, aluminum, magnesium, and their alloys. Examples of alloys include iron-based alloys (including steel and stainless steel), Ti-based alloys, Al-based alloys, and Mg alloys.

[0071] Furthermore, ceramic materials and wood can also be used.

[0072] The thickness of the first and second high modulus layers, and the low modulus layer (or each low modulus layer if there are multiple low modulus layers) is not particularly limited, but from the viewpoint of enhancing the effect of improving bending rigidity, it is preferable that the thickness of each layer be 0.01 mm or more.

[0073] • Preferred material for high modulus layer The second high modulus layer is preferably a fiber-reinforced resin layer, more preferably a carbon fiber-reinforced resin layer or a glass fiber-reinforced resin layer, and more preferably a carbon fiber-reinforced resin layer. This fiber-reinforced resin layer is preferably a fiber-reinforced resin layer containing continuous fibers and resin (a state in which continuous fibers are bundled by resin). Specifically, the second high modulus layer is preferably a carbon fiber-reinforced resin layer containing continuous fibers and resin or a glass fiber-reinforced resin layer containing continuous fibers and resin, and more preferably a carbon fiber-reinforced resin layer containing continuous fibers and resin.

[0074] The first high modulus layer is preferably a fiber-reinforced resin layer, more preferably a carbon fiber-reinforced resin layer or a glass fiber-reinforced resin layer, and more preferably a glass fiber-reinforced resin layer. This fiber-reinforced resin layer is preferably a fiber-reinforced resin layer containing continuous fibers and resin (a state in which continuous fibers are bundled by resin). Specifically, the first high modulus layer is preferably a carbon fiber-reinforced resin layer containing continuous fibers and resin or a glass fiber-reinforced resin layer containing continuous fibers and resin, and more preferably a glass fiber-reinforced resin layer containing continuous fibers and resin.

[0075] It is preferable that both the first high modulus layer and the second high modulus layer are fiber-reinforced resin layers.

[0076] • Preferred material for the low modulus layer The low modulus layer is preferably a resin layer (i.e., a fiber-reinforced resin layer or a non-fiber-reinforced resin layer), and preferably a non-fiber-reinforced resin layer (a resin layer that does not contain fibers).

[0077] Furthermore, when there are multiple low-modulus layers, it is preferable to have multiple layers with different moduli as the low-modulus layers. An example of having multiple layers with different moduli is an example of having resin layers made of different resins.

[0078] • Material of the base material The composite laminate of the first configuration has a first substrate, and the composite laminate of the second configuration has a first substrate and a second substrate. The material of the first substrate and the second substrate (hereinafter, when referring to both, simply referred to as "substrate") is not particularly limited.

[0079] Examples of materials used as base materials include metals, resins (including fiber-reinforced and non-fiber-reinforced resins), rubber, natural materials such as wood, and ceramics.

[0080] Examples of metals used as the base material include iron, titanium, aluminum, magnesium, and alloys thereof. Examples of alloys include iron-based alloys (including steel and stainless steel), Ti-based alloys, Al-based alloys, and Mg alloys. When the base material is made of metal, it can be applied to high-rigidity materials for the bodies of transportation equipment such as automobiles and aircraft, including pillars, bumper reinforcements, doors, and roofs. The metal material may also be surface-treated.

[0081] For steel materials, those with a tensile strength in the range of 270 MPa to 2000 MPa are preferred, and more preferably 590 MPa or higher from the viewpoint of easily increasing rigidity.

[0082] Examples of resins used for the base material include those listed as examples of non-fiber-reinforced resins and fiber-reinforced resins in the section on the material of the rigid member layer mentioned above. When the base material is made of resin, design properties can be added using the resin, making it applicable, for example, to interior parts of automobiles, or to materials where design is required, such as pillars in houses or exterior materials for home appliances.

[0083] Furthermore, when the base material is made of wood, it can be applied as an environmentally friendly material with excellent mechanical properties, such as ceiling beams in buildings, by reinforcing the wood with a rigid member layer.

[0084] Furthermore, rubber, ceramics, and other materials can also be used as the base material.

[0085] The base material is preferably a metal layer, and more preferably a layer of steel (i.e., a steel plate).

[0086] The base material is not limited to being composed of a single material, but may also be a multilayered structure in which multiple materials are laminated together.

[0087] The first and second substrates do not need to be exposed on the surface in applications where the composite laminate is used.

[0088] • Combination of materials in each layer Here, we will describe the preferred combination of materials for each layer. In the following, "substrate" refers to the first substrate if it is the first configuration, and to both the first and second substrates if it is the second configuration.

[0089] It is preferable that the base material is a metal layer, and the first and second high modulus layers are fiber-reinforced resin layers. Preferably, the base material is a metal layer, the first high modulus layer and the second high modulus layer are fiber-reinforced resin layers, and all layers in the low modulus layer are fiber-free resin layers. Preferably, the base material is a metal layer, the first high modulus layer is a fiber-reinforced resin layer, the second high modulus layer is a carbon fiber-reinforced resin layer, and all layers in the low modulus layer are fiber-free resin layers. Preferably, the base material is a metal layer, the first high modulus layer and the second high modulus layer are fiber-reinforced resin layers containing continuous fibers and resin, and all layers in the low modulus layer are resin layers that do not contain fibers. Preferably, the base material is a steel plate, the first high modulus layer and the second high modulus layer are carbon fiber reinforced resin layers containing continuous fibers and resin, and all layers in the low modulus layer are resin layers that do not contain fibers.

[0090] -Joining- The first substrate and the first high modulus layer and the second substrate and the second high modulus layer (hereinafter, when referring to both, they will simply be called "substrate and high modulus layer") may be in direct contact, or they may be laminated via adhesive layers (first adhesive layer and second adhesive layer).

[0091] In all cases, it is preferable that the base material and the high modulus layer are joined by a bonding member. Specifically, if the first configuration is present, it is preferable that the first base material and the first high modulus layer are joined by a bonding member, and if the second configuration is present, it is preferable that the first base material and the first high modulus layer and the second base material and the second high modulus layer are joined by a bonding member.

[0092] Examples of joining components include mechanical components such as bolts and adhesives. A method for joining a base material and a high-modulus layer without using joining components is to apply strong pressure to join the two.

[0093] It is preferable that the substrate and the high modulus layer are joined by an adhesive layer. In other words, in the first configuration, it is preferable that the first substrate and the first high modulus layer are joined by a first adhesive layer, and in the second configuration, it is preferable that the first substrate and the first high modulus layer are joined by a first adhesive layer, and the second substrate and the second high modulus layer are joined by a second adhesive layer.

[0094] Examples of materials used in the adhesive layer include commonly used adhesives such as adhesive resins. For example, organic adhesives such as thermoplastic resins and thermosetting resins, and inorganic adhesives such as water glass, silicate, cement, and gypsum can be used. The adhesive layer may also be formed between the substrate and the resin constituting the high modulus layer, which seeps out from the high modulus layer.

[0095] Here, an example will be given illustrating an embodiment in which mechanical fastening, such as bolt fastening, is applied to a composite laminate having a second structure.

[0096] The composite laminate 100 shown in Figure 7 is plate-shaped overall, while the composite laminate 100 shown in Figure 8 has a hat shape overall. A hat shape is, for example, a shape having a top plate portion 321, vertical wall portions 322, and flange portions 323, as shown in Figure 8. However, the shape of the composite laminate 100 is not limited to these. The composite laminate 100 shown in Figures 7 and 8 comprises a first base material 310 (e.g., a steel plate), a second base material 320 (e.g., a steel plate), and a rigid member layer 330 sandwiched between them. The rigid member layer 330 has a first high modulus layer, a low modulus layer, and a second high modulus layer. As shown in Figures 7 and 8, the first base material 310 and the second base material 320 have overlapping portions when viewed from a direction perpendicular to the surface of one of the base materials, and the rigid member layer 330 is sandwiched in at least a part of the overlapping portion. The rigid member layer 330 is only sandwiched between the first base material 310 and the second base material 320 and is not joined to the first base material 310 and the second base material 320 by an adhesive or the like. In other words, with no adhesive layer present at the interface 315 between the first substrate 310 and the second substrate 320 and the rigid member layer 330, the rigid member layer 330 is sandwiched between the first substrate 310 and the second substrate 320, causing the first substrate 310 and the second substrate 320 and the rigid member layer 330 to press against each other. As a result, the rigid member layer 330 is not substantially constrained in the planar direction relative to the first substrate 310 and the second substrate 320, but is in a pseudo-composite state due to the pressing.

[0097] As shown in Figures 7 and 8, the first base material 310 and the second base material 320 are joined by a fixing member 340. By joining the first base material 310 and the second base material 320, it becomes easier to maintain the structure of the composite laminate. The method of joining the first base material 310 and the second base material 320 is not particularly limited, and the fixing member 340 may be fastened mechanically with bolts, rivets, etc., or it may be bonded or welded. The number of fixing members 340 is also not particularly limited, and there may be one or more.

[0098] Although not shown in the figures, as a method for joining the first base material 310 and the second base material 320, an external force may be applied to the first base material 310 in the direction of the rigid member layer 330 by another member, thereby pressing the rigid member layer 330 against the second base material 320. That is, with the rigid member layer 330 positioned between the first base material 310 and the second base material 320, pressure is applied to the first base material 310 toward the second base material 320 by a member not shown, and this pressure is applied to the second base material 320 via the first base material 310 and the rigid member layer 330. As a result, the rigid member layer 330 is pressed against the second base material 320 and sandwiched between the first base material 310 and the second base material 320. For example, a composite laminate that is as a whole plate-shaped as shown in Figure 7 may be press-formed to press the rigid member layer 330 against the second base material 320.

[0099] In the composite laminate 100 shown in Figures 7 and 8, as described above, although the second base material 320 and the rigid member layer 330 are in contact under a predetermined pressing load, there is no adhesive layer interposed between the second base material 320 and the rigid member layer 330, and they are not constrained to each other in the planar direction.

[0100] -Morphology of composite laminate- The shape of the composite laminate is not particularly limited and may be, for example, flat or cylindrical. One example of a method for manufacturing a composite laminate of any shape is to process a composite laminate that has been formed into a flat shape into a predetermined shape using a hot press or the like.

[0101] -Applications- The composite laminate according to the embodiments of this disclosure can be particularly suitable for use in automotive components. [Examples]

[0102] The effects of this disclosure will be specifically explained below with reference to examples. Note that the examples shown below represent experimental results obtained through simulation.

[0103] <Example 1> As composite laminates for Target Laminate 1, Examples 1-1 to 1-3, and Comparative Examples 1-1 to 1-2, laminates were prepared by laminating a first base material (steel plate), a first high modulus layer (carbon fiber reinforced polymer using UD material), a low modulus layer (resin), and a second high modulus layer (carbon fiber reinforced polymer using UD material), having the modulus and thickness described in Table 1. Note that the target laminate does not have a first high modulus layer. In all laminates, the total thickness of the first high modulus layer and the second high modulus layer was set to be the same, and all rigid member layers were melt-bonded by hot pressing to obtain a flat plate-shaped laminate.

[0104] Regarding the prepared target laminates and composite laminates, h Rs t Rs , λ s h R t R Table 1 shows whether λ and Equation 1 are satisfied. Furthermore, in this embodiment, the bending stiffness EI of the composite laminate and the target laminate is calculated using the following formula 3. This bending stiffness EI is shown in Table 1.

[0105]

number

[0106] In Equation 3, when calculating the bending stiffness EI in a composite laminate, E i The elastic modulus of the i-th layer from the surface of the first substrate is h i h is the distance from the surface on the first substrate side to the surface on the opposite side of the i-th layer on the first substrate side. i-1 This is the distance from the surface on the first substrate side to the surface on the opposite side of the i-1th layer (where i=1 is h). i-1 (where is 0), and λ represents the position of the neutral axis in the composite laminate calculated by Equation 2. On the other hand, in Equation 3, when calculating the bending stiffness EI in the target laminate, E i The elastic modulus of the i-th layer from the surface of the first substrate is given by h. ih is the distance from the surface on the first substrate side to the surface on the opposite side of the i-th layer on the first substrate side. i-1 This is the distance from the surface on the first substrate side to the surface on the opposite side of the i-1th layer (where i=1 is h). i-1 (where is 0), and λ represents the position of the neutral axis in the target laminate calculated by equation 2 above.

[0107] [Table 1]

[0108] <Example 2> As the target laminate 2 and the composite laminates of Examples 2-1 to 2-2 and Comparative Example 2-1, laminates were prepared by laminating a first base material (steel plate), a first high modulus layer (carbon fiber reinforced polymer using UD material), a low modulus layer (glass fiber reinforced polymer using GFRP), and a second high modulus layer (carbon fiber reinforced polymer using UD material), having the elastic modulus and thickness described in Table 2. Note that the target laminate does not have a first high modulus layer. In all laminates, the total thickness of the first high modulus layer and the second high modulus layer was set to be the same, and all rigid member layers were melt-bonded by hot pressing to obtain a flat plate-shaped laminate.

[0109] Table 2 shows the bending stiffness EI and whether or not it satisfies Equation 1.

[0110] [Table 2]

[0111] <Example 3> As the composite laminates for Target Laminate 3, Examples 3-1 to 3-2, and Comparative Example 3-1, laminates were prepared by laminating a first base material (steel plate), a first adhesive layer (adhesive resin), a first high modulus layer (carbon fiber reinforced polymer using UD material), a low modulus layer (resin), and a second high modulus layer (carbon fiber reinforced polymer using UD material), having the modulus and thickness described in Table 3. Note that the target laminate does not have a first high modulus layer. In all laminates, the total thickness of the first high modulus layer and the second high modulus layer was set to be the same, and all rigid member layers were melt-bonded by hot pressing to obtain a flat plate-shaped laminate.

[0112] h Rs t Rs , λ s h R t R Table 3 shows the values ​​of λ, bending stiffness EI, and whether or not Equation 1 is satisfied.

[0113] [Table 3]

[0114] <Example 4> As the composite laminates for Target Laminate 4, Examples 4-1 to 4-2, and Comparative Example 4-1, laminates were prepared by laminating a first base material (steel plate), a first high modulus layer (glass fiber reinforced polymer), a low modulus layer (resin), and a second high modulus layer (carbon fiber reinforced polymer using UD material), having the modulus and thickness described in Table 4. Note that the target laminate does not have a first high modulus layer. In all laminates, the total thickness of the first high modulus layer and the second high modulus layer was set to be the same, and all rigid member layers were melt-bonded by hot pressing to obtain a flat plate-shaped laminate.

[0115] h Rs t Rs , λ s h R t R Table 4 shows the values ​​of λ, bending stiffness EI, and whether or not Equation 1 is satisfied.

[0116] [Table 4]

[0117] <Example 5> As composite laminates for Target Laminate 5, Examples 5-1 to 5-2, and Comparative Example 5-1, laminates were prepared by laminating a first base material (steel plate), a first high modulus layer (carbon fiber reinforced polymer using UD material), a low modulus layer (resin), and a second high modulus layer (glass fiber reinforced polymer) having the modulus and thickness described in Table 5. Note that the target laminate does not have a first high modulus layer. In all laminates, the total thickness of the first high modulus layer and the second high modulus layer was set to be the same, and all rigid member layers were melt-bonded by hot pressing to obtain a flat plate-shaped laminate.

[0118] h Rs t Rs , λ s h R t R Table 5 shows the values ​​of λ, bending stiffness EI, and whether or not Equation 1 is satisfied.

[0119] [Table 5]

[0120] <Example 6> As target laminate 6 and composite laminates of Examples 6-1 to 6-3, laminates were prepared by laminating a first base material (steel plate), a first high modulus layer (carbon fiber reinforced polymer using UD material), a low modulus layer (resin), a second high modulus layer (carbon fiber reinforced polymer using UD material), and a second base material (steel plate), having the elastic modulus and thickness described in Table 6. Note that the target laminate does not have a first high modulus layer. In all laminates, the total thickness of the first high modulus layer and the second high modulus layer was set to be the same, and all rigid member layers were melt-bonded by hot pressing to obtain a flat plate-shaped laminate.

[0121] h Rs t Rs , λ s h R t R Table 6 shows the values ​​of λ, bending stiffness EI, and whether or not Equation 1 is satisfied.

[0122] [Table 6]

[0123] As shown in Tables 1 to 6, by satisfying Equation 1 in relation to the target laminate, it is possible to improve the bending rigidity of the composite laminate while using the same material at the same thickness (i.e., using the same material and its thickness / quantity).

[0124] Furthermore, the disclosure of Japanese application 2023-060727 is incorporated herein by reference in its entirety. All documents, patent applications, and technical standards described herein are incorporated by reference to the same extent as if each individual document, patent application, and technical standard were specifically and individually noted to be incorporated by reference.

[0125] This disclosure includes the following aspects: < <1> > A first configuration comprising a first base material and, in order from the first base material side, a rigid member layer having a first high modulus layer, one or more low modulus layers, and a second high modulus layer, or A second configuration comprising a first base material, a rigid member layer having, in order from the first base material side, a first high modulus layer, one or more low modulus layers, and a second high modulus layer, and a second base material on the side of the rigid member layer opposite to the first base material, A composite laminate having, The first substrate and the first high modulus layer are in direct contact or laminated via a first adhesive layer. The second substrate and the second high modulus layer are either in direct contact or laminated via a second adhesive layer. All of the layers of the low modulus layer, one or more layers, have a lower modulus than the first high modulus layer and the second high modulus layer. The thickness of the first high modulus layer and the second high modulus layer are different. A composite laminate that satisfies Equation 1 below in relation to the target laminate defined below.

[0126] -Definition of the target laminate- The aforementioned target laminate is: If the composite laminate has the first configuration, it comprises a target first substrate and, starting from the target first substrate side, a target rigid member layer having the same number of target low modulus layers and target high modulus layers as the composite laminate; and if the composite laminate has the second configuration, it comprises a target first substrate and, starting from the target first substrate side, a target rigid member layer having the same number of target low modulus layers and target high modulus layers as the composite laminate, and a target second substrate on the side of the target rigid member layer opposite the target first substrate. The aforementioned target first substrate is made of the same material and has the same thickness as the first substrate in the composite laminate. The aforementioned second substrate is made of the same material and has the same thickness as the second substrate in the composite laminate. Each of the aforementioned low modulus layers is made of the same material and has the same thickness as one or more of the low modulus layers in the composite laminate. The aforementioned high modulus layer is made of the same material as the second high modulus layer in the composite laminate, and has the same thickness as the total thickness of the first and second high modulus layers. When the first substrate and the first high modulus layer in the composite laminate are in direct contact, when the target first substrate and the target low modulus layer are in direct contact, and when the first substrate and the first high modulus layer are laminated via the first adhesive layer, when the target first substrate and the target low modulus layer are laminated via the target first adhesive layer of the same material and thickness as the first adhesive layer, In the composite laminate, the second substrate and the second high modulus layer are in direct contact; in the case where the target second substrate and the target high modulus layer are in direct contact, and the second substrate and the second high modulus layer are laminated via the second adhesive layer, the target second substrate and the target high modulus layer are laminated via the target second adhesive layer, which is made of the same material and has the same thickness as the second adhesive layer. Represents a laminated structure.

[0127]

number

[0128] In Equation 1, hRs represents the distance from the surface of the target first substrate side in the target laminate to the interface between the target low modulus layer and the target high modulus layer, tRs represents the total thickness of the target low modulus layer in the target laminate, λs represents the position of the neutral axis in the target laminate calculated by Equation 2, hR represents the distance from the surface of the first substrate side in the composite laminate to the interface between the low modulus layer and the second high modulus layer, tR represents the total thickness of the low modulus layer in the composite laminate, and λ represents the position of the neutral axis in the composite laminate calculated by Equation 2. In Equation 2, when calculating the position λ of the neutral axis in the composite laminate, Ei represents the elastic modulus of the i-th layer from the surface on the first substrate side, hi represents the distance from the surface on the first substrate side to the surface on the opposite side of the i-th layer from the surface on the first substrate side, and hi-1 represents the distance from the surface on the first substrate side to the surface on the opposite side of the i-1-th layer from the surface on the first substrate side (however, if i=1, hi-1 is 0). On the other hand, in Equation 2, when calculating the position λs of the neutral axis in the target laminate, Ei represents the elastic modulus of the i-th layer from the surface on the target first substrate side, hi represents the distance from the surface on the target first substrate side to the surface on the opposite side of the i-th layer from the surface on the target first substrate side, and hi-1 represents the distance from the surface on the target first substrate side to the surface on the opposite side of the i-1-th layer from the surface on the target first substrate side (however, if i=1, hi-1 is 0).

[0129] < <2> > In the case of the first configuration, the first substrate and the first high modulus layer are joined by a bonding member, In the case of the second configuration described above, the first substrate and the first high modulus layer, and the second substrate and the second high modulus layer are joined together by a joining member. < <1> The composite laminate described above. < <3> > In the first configuration, the first substrate and the first high modulus layer are joined by the first adhesive layer. In the second configuration described above, the first substrate and the first high modulus layer are joined by the first adhesive layer, and the second substrate and the second high modulus layer are joined by the second adhesive layer. < <2> The composite laminate described above. < <4> > The modulus of elasticity of each layer in the low modulus layer is 0.8 times or less than the modulus of elasticity of either the first high modulus layer or the second high modulus layer. <1> >~< <3> A composite laminate as described in any one of the items. < <5> > The position λ of the neutral axis in the composite laminate is located within the low modulus layer, <1> >~< <4> A composite laminate as described in any one of the items. < <6> > The modulus of elasticity of the first high modulus layer is less than or equal to the modulus of elasticity of the second high modulus layer. <1> >~< <5> A composite laminate as described in any one of the items. < <7> > The second high modulus layer is a fiber-reinforced resin layer. <1> >~< <6> A composite laminate as described in any one of the items. < <8> > The first high modulus layer and the second high modulus layer are fiber-reinforced resin layers. <7> The composite laminate described above. < <9> > The second high modulus layer is a carbon fiber reinforced resin layer. <7> >or< <8> The composite laminate described above.

[0130] < <10> > The second high modulus layer is a carbon fiber reinforced resin layer containing continuous fibers and resin. <9> The composite laminate described above. < <11> > The second high modulus layer is a glass fiber reinforced resin layer. <7> >or< <8> The composite laminate described above. < <12> > The second high modulus layer is a glass fiber reinforced resin layer containing continuous fibers and resin. <11> The composite laminate described above. < <13> > The first high modulus layer is a glass fiber reinforced resin layer, <1> >~< <12> A composite laminate as described in any one of the items. < <14> > The ratio of the difference between the modulus E1 of the first high modulus layer and the modulus E2 of the second high modulus layer (|E1-E2| / E2) is 1% or less. <1> >~< <13> A composite laminate as described in any one of the items. < <15> > All layers in the aforementioned low modulus layer are fiber-free resin layers. <1> >~< <14> A composite laminate as described in any one of the items. < <16> > All layers in the aforementioned low modulus layer are fiber-reinforced resin layers. <1> >~< <14> A composite laminate as described in any one of the items. < <17> > The low modulus layer has multiple layers with different moduli, <1> >~< <16> A composite laminate as described in any one of the items. < <18> > In the case of the first configuration, the first substrate is a metal layer, and in the case of the second configuration, the first substrate and the second substrate are metal layers. <1> >~< <17> A composite laminate as described in any one of the items. < <19> > In the first configuration, the first base material is a steel plate, and in the second configuration, both the first and second base materials are steel plates. <18> The composite laminate described above.

[0131] < <20> > In the case of the first configuration, the first substrate is a metal layer, and in the case of the second configuration, both the first and second substrates are metal layers. The first high modulus layer and the second high modulus layer are fiber-reinforced resin layers. < <1> >~< <17> A composite laminate as described in any one of the items. < <21> > In the case of the first configuration, the first substrate is a metal layer, and in the case of the second configuration, both the first and second substrates are metal layers. The first high modulus layer and the second high modulus layer are fiber-reinforced resin layers. All layers in the aforementioned low modulus layer are resin layers that do not contain fibers. < <20> The composite laminate described above. < <22> > In the case of the first configuration, the first substrate is a metal layer, and in the case of the second configuration, both the first and second substrates are metal layers. The first high modulus layer is a fiber-reinforced resin layer, The second high modulus layer is a carbon fiber reinforced resin layer, All layers in the aforementioned low modulus layer are resin layers that do not contain fibers. < <21> The composite laminate described above. < <23> > In the case of the first configuration, the first substrate is a metal layer, and in the case of the second configuration, both the first and second substrates are metal layers. The first high modulus layer and the second high modulus layer are fiber-reinforced resin layers containing continuous fibers and resin. All layers in the aforementioned low modulus layer are resin layers that do not contain fibers. < <20> The composite laminate described above. < <24> > In the first configuration, the first base material is a steel plate, and in the second configuration, both the first and second base materials are steel plates. The first high modulus layer and the second high modulus layer are carbon fiber reinforced resin layers containing continuous fibers and resin. All layers in the aforementioned low modulus layer are resin layers that do not contain fibers. < <23> The composite laminate described above. < <25> > Used in automotive components, < <1> >~< <24> A composite laminate as described in any one of the items. < <26> > < <25> Automotive component comprising the composite laminate described above. [Explanation of Symbols]

[0132] 2, 221 1st base material 41, 241 1st high modulus layer 42, 242 2nd high modulus layer 6, 61, 62, 206 low modulus layer 80, 81, 82, 83, 208, 2208 Composite material layer 100 Composite Laminate 222 Second base material 310 1st base material 320 Second base material 330 Rigid member layer 340 Fixing member

Claims

1. A composite laminate comprising a first base material, a first high modulus layer, one or more low modulus layers, and a second high modulus layer in this order, All of the layers of the low modulus layer, one or more layers, have a lower modulus than the first high modulus layer and the second high modulus layer. The thickness of the first high modulus layer and the second high modulus layer are different. A composite laminate that satisfies Equation 1 below in relation to the target laminate defined below. The aforementioned target laminate refers to a laminate having a target first base material, a target low modulus layer, and a target high modulus layer in that order, wherein the target first base material is a base material of the same material and thickness as the first base material in the composite laminate, the target low modulus layer is a layer of the same number, material and thickness as the low modulus layer in the composite laminate, and the target high modulus layer is a layer of the same material as the second high modulus layer in the composite laminate and has the same thickness as the total thickness of the first high modulus layer and the second high modulus layer. [Math 1] In Equation 1, h Ｒｓ The distance from the surface of the target first substrate on the target first substrate side of the target laminate to the interface between the target low modulus layer and the target high modulus layer is t. Ｒｓ The total thickness of the target low modulus layer in the target laminate is λ ｓ The position of the neutral axis in the target laminate calculated by formula 2 is h Ｒ The distance from the surface of the first substrate side in the composite laminate to the interface between the low modulus layer and the second high modulus layer is t. Ｒ λ represents the total thickness of the low modulus layer in the composite laminate, and λ represents the position of the neutral axis in the composite laminate calculated by equation 2. In Equation 2, when calculating the position λ of the neutral axis in the composite laminate, the first layer is the outermost layer in the first base material, and E ｉ represents the modulus of elasticity in the i-th layer counted in the thickness direction in order from the surface on the first base material side including the layers constituting the first base material, and h ｉ represents the distance from the surface on the first base material side to the surface on the opposite side of the first base material side in the i-th layer counted in the thickness direction in order from the surface on the first base material side including the layers constituting the first base material, and h ｉ－１ represents the distance from the surface on the first base material side to the surface on the opposite side of the first base material side in the (i - 1)-th layer counted in the thickness direction in order from the surface on the first base material side including the layers constituting the first base material (however, when i = 1, h ｉ－１ is 0), and is represented as follows. On the other hand, in Equation 2, the position of the neutral axis in the target laminate is λ. ｓ When calculating, the first layer is the outermost layer of the target first substrate, E ｉ The elastic modulus of the i-th layer, counted sequentially in the thickness direction from the surface of the target first substrate, including the layers constituting the target first substrate, is h ｉ h is the distance from the surface on the first substrate side to the surface on the opposite side of the i-th layer, counted sequentially in the thickness direction from the surface on the first substrate side, including the layers constituting the first substrate. ｉ－１ This is the distance from the surface on the first substrate side to the opposite surface in the i-1 layer, counted sequentially in the thickness direction from the surface on the first substrate side, including the layers constituting the first substrate (where i=1, h ｉ－１ This represents (where is 0).

2. The composite laminate according to claim 1, wherein the second substrate is located on the side of the second high modulus layer opposite to the first substrate.

3. The first substrate and the first high modulus layer are joined by a bonding member. Furthermore, if the second substrate is present, the second substrate and the second high modulus layer are joined by a bonding member. A composite laminate according to claim 1 or claim 2.

4. The composite laminate according to claim 1, wherein the modulus of elasticity of each layer in the low modulus layer is 0.8 times or less than the modulus of elasticity of either the first high modulus layer or the second high modulus layer.

5. The composite laminate according to claim 1, wherein the modulus E1 of the first high modulus layer is less than or equal to the modulus E2 of the second high modulus layer.

6. The composite laminate according to claim 1, wherein the ratio of the difference between the modulus E1 of the first high modulus layer and the modulus E2 of the second high modulus layer (|E1 - E2| / E2 × 100) is 1% or less.

7. The composite laminate according to claim 1, wherein the position λ of the neutral axis in the composite laminate is located within the low modulus layer.

8. The composite laminate according to claim 1, wherein at least one of the first high modulus layer and the second high modulus layer is a fiber-reinforced resin layer.

9. The composite laminate according to claim 1, wherein all layers in the low modulus layer are resin layers that do not contain fibers.

10. The first substrate is a metal layer, The composite laminate according to claim 1 or claim 2, wherein if the second substrate is also present, the second substrate is a metal layer.

11. A composite laminate according to claim 1, for use in automotive components.

12. An automotive component comprising the composite laminate described in claim 11.

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