CN110253979A - 一种由不同密度层构成的针刺预制体及其制备方法 - Google Patents

一种由不同密度层构成的针刺预制体及其制备方法 Download PDF

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CN110253979A
CN110253979A CN201910542487.9A CN201910542487A CN110253979A CN 110253979 A CN110253979 A CN 110253979A CN 201910542487 A CN201910542487 A CN 201910542487A CN 110253979 A CN110253979 A CN 110253979A
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尹锋
吴桑
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YIXING HUAHENG HIGH PERFORMANCE FIBER TEXTILE CO Ltd
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Abstract

本发明公开一种由不同密度层构成的针刺预制体及其制备方法，该预制体由多层密度不同的密度层组成，每个密度层由一个或多个预制体结构单元组成，所述的预制体结构单元通过网毡与编织布针刺而成；该预制体的多层密度层的密度变化为由外向内密度逐层变小或者由内向外密度逐层变小。该针刺预制体的典型的密度变化为由外向内，密度逐层变小，具体应用为航空航天领域的高速飞行器外壳部分；或者由内向外密度逐层变小，如发动机的喷管部分。其高密度区，保证了材料的力学性能，保证了材料的结构强度，耐冲刷；中密度区，实现了平缓的过度作用；低密度区，确保了材料的隔热保温性。

Description

一种由不同密度层构成的针刺预制体及其制备方法
技术领域
本发明涉及一种高强度隔热材料，具体涉及一种体密度逐层缓变化的针刺预制体及其制备方法。
背景技术
高性能石英纤维针刺预制体，与树脂、陶瓷等材料制成复合材料后，具有耐冲刷、耐高温、密度低等性能，是现代发展新兴的高科技新型材料，是航空航天领域应用广泛的新型材料。
当前的石英纤维针刺预制体如果密度高，强度高，隔热性能较差，如果密度低，保温隔热性能较好，但强度达不到要求。因此，需要研发一种兼顾隔热性能和强度的石英纤维针刺预制体。
发明内容
鉴于背景技术提出的技术问题，本发明的目的在于提供一种体密度逐层缓变化的针刺预制体及其制备方法，其高密度区，保证了材料的力学性能，保证了材料的结构强度，耐冲刷；中密度区，实现了平缓的过度作用；低密度区，确保了材料的隔热保温性。
本发明的目的可以通过以下技术方案实现：
一种由不同密度层构成的针刺预制体，该预制体由多层密度不同的密度层组成，每个密度层由一个或多个预制体结构单元组成，所述的预制体结构单元通过网毡与编织布针刺而成；该预制体的多层密度层的密度变化为由外向内密度逐层变小或者由内向外密度逐层变小。上述的针刺预制体，通过控制针刺的密度来控制每个预制体结构单元的体密度，进而控制每层密度层的密度。
上述的针刺预制体，采用以下方法制备：
(1)将制作好的模具固定在针刺设备上；
(2)将编织布铺设在模具上进行针刺；
(3)将网毡铺设在编织布上进行针刺，完成一个预制体结构单元的制作；
(4)以一个预制体结构单元作为第一个密度层，或者重复步骤(2)、(3)完成第一个密度层的制作；
(5)重复步骤(2)、(3)、(4)完成其余密度层的制作；
(6)将预制体从模具上取下，并修整，完成预制体的制作。
作为一种优选技术方案，所述编织布的面密度：50-300g/㎡；所述网毡的面密度：20-150g/㎡；所述针刺的针刺密度为：30-50针/cm2；预制体结构单元的体密度：0.1-0.6g/cm2；预制体结构单元的厚度：1-20mm。
作为一种优选技术方案，所述的密度层为2～10层，每个密度层由1～5个预制体结构单元组成。
进一步优选的，所述的密度层为4层，每个密度层由2个预制体结构单元组成，但不限于此。更进一步优选的，各层的具体工艺参数为：
第一密度层：密度为0.1～0.2g/cm3，但不包括0.2g/cm3，由50～100g/㎡的编织布与20～50g/㎡的网毡配比针刺，针刺密度30-40针/cm2；
第二密度层：密度为0.2～0.3g/cm3，但不包括0.3g/cm3，由100～150g/㎡的编织布与20～50g/㎡的网毡配比针刺，针刺密度30-40针/cm2；
第三密度层：密度为0.3～0.5g/cm3，但不包括0.5g/cm3，由150～250g/㎡的编织布与50～100g/㎡的网毡配比针刺，针刺密度40-50针/cm2；
第四密度层：密度0.5～0.6g/cm3，由200～300g/㎡的编织布与100～150g/㎡的网毡配比针刺，针刺密度40-50针/cm2。
上述预制体的类型为平板形、圆柱形、圆锥形或类似圆锥形。
所述模具形状为平板，圆柱形，任意形状。
上述针刺预制体的原材料为石英纤维、玻璃纤维、芳纶纤维和碳纤维中的任意一种或几种纤维的混合。
本发明的有益效果：
本发明提供一种体密度逐层缓变化的针刺预制体，为由不同密度层构成的针刺预制体，其高密度区，保证了材料的力学性能，保证了材料的结构强度，耐冲刷；中密度区，实现了平缓的过度作用；低密度区，确保了材料的隔热保温性。
附图说明
图1为一个预制体结构单元结构图。
图2为4层密度层构成的石英纤维针刺预制体。
具体实施方式
下面结合附图和实施例，对本发明进行具体描述。
实施例1
一种由不同密度层构成的石英纤维针刺预制体，该预制体由四层密度不同的密度层组成(圆柱形针刺预制体但不限于此，由内而外依次为第一密度层1、第二密度层2、第三密度层3、第四密度层4)，每个密度层由两个预制体结构单元组成，所述的预制体结构单元通过网毡5与编织布6针刺而成；该预制体的多层密度层的典型密度变化为由外向内密度逐层变小。通过控制针刺的密度来控制每个预制体结构单元的体密度，进而控制每层密度层的密度。采用以下方法制备：
(1)将制作好的模具固定在针刺设备上；
(2)将编织布铺设在模具上进行针刺；
(3)将网毡铺设在编织布上进行针刺，完成一个预制体结构单元的制作；
(4)重复步骤(2)、(3)完成第一个密度层的制作；
(5)重复步骤(2)、(3)(4)完成其余密度层的制作；
(6)将预制体从模具上取下，并修整，完成预制体的制作。
各层针刺的工艺参数为：
第一密度层：密度0.1～0.2g/cm3，但不包括0.2g/cm3，由50～100g/㎡的编织布与20～50g/㎡的网毡配比针刺，针刺密度30-40针/cm2；
第二密度层：密度0.2～0.3g/cm3，但不包括0.3g/cm3，由100～150g/㎡的编织布与20～50g/㎡的网毡配比针刺，针刺密度30-40针/cm2；
第三密度层：密度0.3～0.5g/cm3，但不包括0.5g/cm3，由150～250g/㎡的编织布与50～100g/㎡的网毡配比针刺，针刺密度40-50针/cm2；
第四密度层：密度0.5～0.6g/cm3，由200～300g/㎡的编织布与100～150g/㎡的网毡配比针刺，针刺密度40-50针/cm2。
更具体的各工艺参数为：
第一密度层：密度0.15g/cm3，由80g/㎡的编织布与35g/㎡的网毡配比针刺，针刺密度35针/cm2；
第二密度层：密度0.25g/cm3，由125g/㎡的编织布与35g/㎡的网毡配比针刺，针刺密度35针/cm2；
第三密度层：密度0.4g/cm3，由200g/㎡的编织布与80g/㎡的网毡配比针刺，针刺密度45针/cm2；
第四密度层：密度0.55g/cm3，由250g/㎡的编织布与130g/㎡的网毡配比针刺，针刺密度45针/cm2。
上述的具体工艺参数并不限于此，可根据具体要求在指定范围内进行调整。
每个预制体结构单元层通过控制针刺的密度控制预制体的厚度，从而实现最终每层体密度的不同。
功能：低密度层保温隔热；高密度区实现较高的结构强度，耐冲刷；中密度实现过度作用，过度平缓，多设几个单元层。
本发明公开一种由不同密度层构成的石英纤维针刺预制体，该预制体由多层密度不同预制体结构单元通过网毡与编织布针刺而成。典型的密度变化为由外向内，密度逐层变小，具体应用为航空航天领域的高速飞行器外壳部分；或者由内向外密度逐层变小，如发动机的喷管部分。

Claims (10)

1.一种由不同密度层构成的针刺预制体，其特征在于，该预制体由多层密度不同的密度层组成，每个密度层由一个或多个预制体结构单元组成，所述的预制体结构单元通过网毡与编织布针刺而成；该预制体的多层密度层的密度变化为由外向内密度逐层变小或者由内向外密度逐层变小。
2.根据权利要求1所述的针刺预制体，其特征在于，通过控制针刺的密度来控制每个预制体结构单元的体密度，进而控制每层密度层的密度。
3.根据权利要求1所述的针刺预制体，其特征在于，采用以下方法制备：
(1)将制作好的模具固定在针刺设备上；
(2)将编织布铺设在模具上进行针刺；
(3)将网毡铺设在编织布上进行针刺，完成一个预制体结构单元的制作；
(4)以一个预制体结构单元作为第一个密度层，或者重复步骤(2)、(3)完成第一个密度层的制作；
(5)重复步骤(2)、(3)、(4)完成其余密度层的制作；
(6)将预制体从模具上取下，并修整，完成预制体的制作。
4.根据权利要求1或3所述的针刺预制体，其特征在于，
所述编织布的面密度：50-300g/㎡；
所述网毡的面密度：20-150g/㎡；
所述针刺的针刺密度为：30-50针/cm2。
5.根据权利要求1或3所述的针刺预制体，其特征在于，所述的密度层为2～10层，每个密度层由1～5个预制体结构单元组成。
6.根据权利要求5所述的针刺预制体，其特征在于，所述的密度层为4层，每个密度层由2个预制体结构单元组成。
7.根据权利要求6所述的针刺预制体，其特征在于，
第一密度层：密度为0.1～0.2g/cm3，但不包括0.2g/cm3，由50～100g/㎡的编织布与20～50g/㎡的网毡配比针刺，针刺密度30-40针/cm2；
第二密度层：密度为0.2～0.3g/cm3，但不包括0.3g/cm3，由100～150g/㎡的编织布与20～50g/㎡的网毡配比针刺，针刺密度30-40针/cm2；
第三密度层：密度为0.3～0.5g/cm3，但不包括0.5g/cm3，由150～250g/㎡的编织布与50～100g/㎡的网毡配比针刺，针刺密度40-50针/cm2；
第四密度层：密度0.5～0.6g/cm3，由200～300g/㎡的编织布与100～150g/㎡的网毡配比针刺，针刺密度40-50针/cm2。
8.根据权利要求1所述的针刺预制体，其特征在于，所述预制体的类型为平板形、圆柱形、圆锥形或类似圆锥形。
9.根据权利要求1所述的针刺预制体，其特征在于，该针刺预制体的原材料为石英纤维、玻璃纤维、芳纶纤维和碳纤维中的任意一种或几种纤维的混合。
10.权利要求1所述的针刺预制体的制备方法，其特征在于，包括如下步骤：
(1)将制作好的模具固定在针刺设备上；
(2)将编织布铺设在模具上进行针刺；
(3)将网毡铺设在编织布上进行针刺，完成一个预制体结构单元的制作；
(4)以一个预制体结构单元作为第一个密度层，或者重复步骤(2)、(3)完成第一个密度层的制作；
(5)重复步骤(2)、(3)(4)完成其余密度层的制作；
(6)将预制体从模具上取下，并修整，完成预制体的制作。
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