CN117549611B - Gradient density preform, preparation method thereof and heat insulation material - Google Patents

Gradient density preform, preparation method thereof and heat insulation material Download PDF

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Publication number
CN117549611B
CN117549611B CN202311583844.9A CN202311583844A CN117549611B CN 117549611 B CN117549611 B CN 117549611B CN 202311583844 A CN202311583844 A CN 202311583844A CN 117549611 B CN117549611 B CN 117549611B
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density
layer
region
preform
gradient
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CN117549611A (en
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缪云良
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Jiangsu Tianniao High Technology Co ltd
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Jiangsu Tianniao High Technology Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/14—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density

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  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

The invention provides a gradient density preform, a preparation method thereof and a heat insulation material, wherein the gradient density preform comprises a first layer, a second layer and a third layer; the density of the first layer is more than or equal to the density of the second layer, and the density of the second layer is more than or equal to the density of the third layer; the second layer includes a first density region, a second density region, and a second layer transition region transitioning from the first density region to the second density region; the first density region and the second density region of the second layer have different densities. The invention solves the problems of inconsistent thermal expansion coefficients among the preformed bodies in different density areas, possible thermal expansion mismatch and layering of composite materials in a high-temperature environment, and the obtained heat insulation material has excellent performance and wide application prospect.

Description

Gradient density preform, preparation method thereof and heat insulation material
Technical Field
The invention relates to the technical field of preform design, in particular to a gradient density preform, a preparation method thereof and a heat insulation material.
Background
The heat-proof and insulating composite material is one of the most important key materials of the aerospace craft, and is a material capable of preventing heat transfer and protecting instruments or equipment from working normally.
At present, the demand on the heat-proof and heat-insulating composite material is higher and higher, and the development is gradually towards the directions of low density, low quality, long-time high temperature resistance, high performance and low cost. Wherein the fiber preform is the critical reinforcing substrate for the composite material, determining the structure and final properties of the composite material.
The gradient density preform material is a heat resistant material. The material with continuously changing functions and structures in space consists of surface layer heat-proof material, inner layer heat-insulating material and intermediate transition layer material. Wherein the surface layer is made of a compact heat-proof material with near zero ablation and shearing resistance; the inner layer is made of loose heat insulation material with low density and low heat conductivity; the intermediate transition layer is made of buffer material with thermal physical parameters and better continuous transition with the surface layer and the inner layer. However, if a scientific and reasonable method cannot be adopted to enable functions and performances of the gradient density material to be changed in a reasonable gradient manner, interface problems can be caused, and when serious, a heat-proof system manufactured by the novel material is invalid, disastrous results are brought. And the fiber is affected by the structural performance of the fiber, the mechanical property is low, the brittleness is high, the fracture force among the fibers is poor, the breaking elongation is low, the fiber is easy to break and crush in the needling process, the fiber in the plane is difficult to introduce into the Z direction, and the effective interlayer connection is difficult to form.
Therefore, there is a need to design new gradient density preforms that promote efficient interlayer bonding.
Disclosure of Invention
In view of the problems in the prior art, the invention provides a gradient density preform, a preparation method thereof and a heat insulation material, and solves the problems that the thermal expansion coefficients of the preforms are inconsistent, thermal expansion mismatch is likely to occur in a high-temperature environment, and a composite material is layered in the prior art.
To achieve the purpose, the invention adopts the following technical scheme:
In a first aspect, the present invention provides a gradient density preform comprising a first layer, a second layer, and a third layer; the density of the first layer is more than or equal to the density of the second layer, and the density of the second layer is more than or equal to the density of the third layer; the second layer includes a first density region, a second density region, and a second layer transition region transitioning from the first density region to the second density region; the first density region and the second density region of the second layer have different densities.
The gradient density preform provided by the first aspect of the invention is divided into three layers, the density is reduced layer by layer, and meanwhile, two density areas and a transition area are arranged in the middle second layer, so that the problem of thermal expansion mismatch between the layers is reduced, and material delamination is not easy to occur.
Preferably, the thickness of the first layer is 5-10% of the total thickness of the gradient density preform, for example, 5%, 6%, 7%, 8%, 9% or 10% or the like. For example, the thickness of the first layer is 1.4 to 1.6mm, etc.
The bulk density of the first layer is preferably 0.60 to 1.0g/cm 3, and may be 0.60g/cm3、0.64g/cm3、0.68g/cm3、0.72g/cm3、0.76g/cm3、0.79g/cm3、0.83g/cm3、0.87g/cm3、0.91g/cm3、0.94g/cm3 or 1.0g/cm 3, for example, but is not limited to the values recited, and other values not recited in this range are equally applicable.
Preferably, the first layer includes a third density region, a fourth density region, and a first layer transition region transitioning from the third density region to the fourth density region.
The invention further preferably also provides two density areas and a transition area in the first layer, which can better avoid the situation of layering materials while ensuring the heat-proof performance.
Preferably, the first layer transition region comprises a first sub-layer and a second sub-layer which are stacked in sequence from top to bottom.
Preferably, the density of the first sub-layer is higher than the density of the second sub-layer.
Preferably, the density of the first sub-layer is comparable to the density of the third density region.
Preferably, the density of the second sub-layer is comparable to the density of the fourth density region.
The density of the third density region is preferably 0.6 to 0.7g/cm 3, and may be, for example, 0.60g/cm 3、0.64g/cm3、0.68g/cm3 or 0.70g/cm 3, etc., but is not limited to the values recited, and other values not recited in this range are equally applicable.
The density of the fourth density region is preferably 0.8 to 0.94g/cm 3, and may be, for example, 0.80g/cm 3、0.83g/cm3、0.87g/cm3、0.91g/cm3 or 0.94g/cm 3, etc., but is not limited to the values recited, and other values not recited in this range are equally applicable.
Preferably, the thickness of the first sub-layer is 25 to 50% of the thickness of the first layer, for example, 25%, 28%, 31%, 34%, 37%, 39%, 42%, 45%, 48% or 50%, etc., but not limited to the recited values, and other non-recited values within this range are equally applicable.
Preferably, the width of the transition region of the first layer is 30 to 60mm, for example, 30mm, 34mm, 37mm, 40mm, 44mm, 47mm, 50mm, 54mm, 57mm or 60mm, etc., but not limited to the recited values, and other values not recited in the range are equally applicable.
Preferably, the thickness of the second layer is 15-30% of the total thickness of the gradient density preform, for example, 15%, 16%, 17%, 18%, 20%, 22%, 25%, 28% or 30%, etc., but not limited to the recited values, and other non-recited values within this range are equally applicable. For example, the thickness of the second layer is 2 to 5mm.
The bulk density of the second layer is preferably 0.25 to 0.58g/cm 3, which may be 0.25g/cm3、0.26g/cm3、0.32g/cm3、0.37g/cm3、0.43g/cm3、0.48g/cm3、0.54g/cm3 or 0.58g/cm 3, for example, but is not limited to the values recited, and other values not recited in this range are equally applicable.
Preferably, the width of the transition region of the second layer is 30 to 60mm, for example, 30mm, 34mm, 37mm, 40mm, 44mm, 47mm, 50mm, 54mm, 57mm or 60mm, etc., but not limited to the recited values, and other values not recited in the range are equally applicable.
The width of the transition region of the second layer is further preferably set in the above range, and the delamination prevention effect is more excellent.
Preferably, the first density region and the second density region of the second layer transition region are ply-bonded in a wedge-shaped manner.
According to the invention, the transition areas of the second layer are connected in a layering manner in a wedge-shaped manner, so that the first density area in the second layer gradually and transversely transits to the second density, and the transition areas of the second layer and the first layer are mutually matched with each other in a transition manner by adopting the first sub-layer and the second sub-layer, thereby cooperatively improving the thermal expansion resistance of the preform.
Preferably, the bulk density of the first density region in the second layer is 0.25 to 0.40g/cm 3, which may be 0.25g/cm3、0.27g/cm3、0.29g/cm3、0.32g/cm3、0.34g/cm3、0.36g/cm3、0.38g/cm3 or 0.40g/cm 3, for example, but is not limited to the recited values, and other non-recited values within this range are equally applicable.
Preferably, the second density region in the second layer has a bulk density of 0.42 to 0.58g/cm 3, for example 0.42g/cm3、0.45g/cm3、0.50g/cm3、0.53g/cm3、0.55g/cm3、0.57g/cm3 or 0.58g/cm 3, but is not limited to the values recited, and other values not recited in this range are equally applicable.
The bulk density of the third layer is preferably 0.08 to 0.20g/cm 3, and may be 0.08g/cm3、0.12g/cm3、0.125g/cm3、0.129g/cm3、0.134g/cm3、0.138g/cm3、0.143g/cm3、0.147g/cm3、0.152g/cm3、0.156g/cm3、0.16g/cm3、0.18g/cm3、0.19g/cm3 or 0.20g/cm 3, for example, but is not limited to the values recited, and other values not recited in this range are equally applicable.
Preferably, the thickness of the third layer is 40-80% of the total thickness of the gradient density preform, for example, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75% or 80%, etc., but not limited to the recited values, and other non-recited values within this range are equally applicable.
Preferably, the gradient density preform is a fiber preform, preferably, the material of the gradient density preform is any one or a combination of at least two of carbon fiber, silicon carbide fiber, quartz fiber, glass fiber, high silica fiber or basalt fiber, and more preferably, quartz fiber.
In a second aspect, the present invention provides a method for preparing a gradient density preform according to the first aspect, the method comprising: and forming a first layer, a second layer and a third layer by adopting a three-coordinate scanning technology and adopting different needling depths and needling densities to prepare the gradient density preform.
According to the preparation method provided by the second aspect of the invention, the three-dimensional digital-analog accurate profiling outer layer high-density woven cloth layer structure is used, and the profiling precision can be detected by using a three-coordinate scanning technology.
Preferably, the first layer comprises two layers of fibrous cloth and one layer of fibrous web felt, or the first layer comprises one layer of fibrous cloth and one layer of fibrous web felt.
Preferably, the needling density of the first layer is 25 to 35 needles/cm 2, for example, 25 needles/cm 2, 27 needles/cm 2, 28 needles/cm 2, 29 needles/cm 2, 30 needles/cm 2, 31 needles/cm 2, 32 needles/cm 2, 33 needles/cm 2, 34 needles/cm 2 or 35 needles/cm 2, etc., but not limited to the recited values, and other non-recited values within the range are equally applicable.
The needling depth of the first layer is preferably 15 to 20mm, and may be, for example, 15mm, 15.5mm, 15.9mm, 16.4mm, 16.8mm, 17.3mm, 17.7mm, 18.2mm, 18.6mm, 19mm, or 20mm, etc., but is not limited to the values recited, and other values not recited in this range are equally applicable.
Preferably, the first layer transition region is formed by overlapping, cross-laminating and needling the cloth layers in the third density region and the fourth density region.
Preferably, the fiber cloth in the first layer is fiber five-piece satin cloth.
The mass per unit area of the fiber cloth in the first layer is preferably 220 to 360g/m 2, and may be 220g/m2、230g/m2、250g/m2、280g/m2、283g/m2、285g/m2、287g/m2、289g/m2、292g/m2、294g/m2、296g/m2、298g/m2、300g/m2 or 360g/m 2, for example, but not limited to the recited values, and other non-recited values within this range are equally applicable.
The mass per unit area of the web mat in the first layer is preferably 60 to 200g/m 2, and may be 60g/m2、63g/m2、66g/m2、69g/m2、72g/m2、74g/m2、77g/m2、80g/m2、83g/m2、85g/m2、100g/m2、110g/m2、120g/m2、150g/m2、180g/m2 or 200g/m 2, for example, but is not limited to the values recited, and other values not recited in this range are equally applicable.
Preferably, the first density zone in the second layer comprises a layer of fibrous cloth and a layer of fibrous web felt.
The fiber web felt of the first density region in the second layer preferably has a mass per unit area of 130 to 170g/m 2, for example 130g/m2、135g/m2、139g/m2、144g/m2、148g/m2、153g/m2、157g/m2、162g/m2、166g/m2 or 170g/m 2, etc., but is not limited to the recited values, and other non-recited values within this range are equally applicable.
Preferably, the second density region in the second layer comprises two layers of fiber cloth and one layer of fiber web felt, or the second density region in the second layer comprises one layer of fiber cloth and one layer of fiber web felt.
The second density region of the second layer preferably has a web felt mass per unit area of 60 to 85g/m 2, which may be 60g/m2、63g/m2、66g/m2、69g/m2、72g/m2、74g/m2、77g/m2、80g/m2、83g/m2 or 85g/m 2, for example, but is not limited to the values recited, as other non-recited values within this range are equally applicable.
Preferably, the needling density in the second layer is 15 to 25 needles/cm 2, for example, 15 needles/cm 2, 17 needles/cm 2, 18 needles/cm 2, 19 needles/cm 2, 20 needles/cm 2, 21 needles/cm 2, 22 needles/cm 2, 23 needles/cm 2, 24 needles/cm 2, or 25 needles/cm 2, etc., but not limited to the recited values, and other non-recited values within this range are equally applicable.
The second layer preferably has a needling depth of 13 to 17mm, for example, 13mm, 13.5mm, 13.9mm, 14.4mm, 14.8mm, 15.3mm, 15.7mm, 16.2mm, 16.6mm, 17mm, etc., but not limited to the values recited, and other non-recited values within this range are equally applicable.
Preferably, the fiber cloth in the second layer is fiber five-piece satin cloth.
The mass per unit area of the fiber cloth in the second layer is preferably 280 to 300g/m 2, and may be 280g/m2、283g/m2、285g/m2、287g/m2、289g/m2、292g/m2、294g/m2、296g/m2、298g/m2 or 300g/m 2, for example, but not limited to the values recited, and other values not recited in the range are equally applicable.
Preferably, the second layer transition region is formed by layering and connecting the cloth layers of the first density region and the second density region in a wedge-shaped manner, and pressing the first density region with high density against the second density region with low density.
Preferably, the second layer transition zone is also sewn.
The second layer transition region is preferably sewn, and the first density region and the second density region can be better connected on the basis of paving connection in a wedge-shaped mode, so that the heat resistance of the preform is remarkably improved.
Preferably, the mode of the stitching process comprises single strand bi-directional stitching.
Preferably, the seam is applied at a spacing of 2-10 mm weft X2-10 mm warp, preferably 3mm weft X6 mm warp.
Preferably, the third layer is formed by needlepunching a quartz fiber net felt.
Preferably, the needling density in the third layer is 5 to 10 needles/cm 2, for example, 5 needles/cm 2, 6 needles/cm 2, 7 needles/cm 2, 8 needles/cm 2, 9 needles/cm 2 or 10 needles/cm 2, etc., but not limited to the recited values, and other non-recited values within this range are equally applicable.
The third layer preferably has a needling depth of 11 to 15mm, for example, 11mm, 12mm, 13mm, 14mm, 15mm, or the like, but the present invention is not limited to the values recited, and other values not recited in the range are equally applicable.
The invention preferably adopts different needling depths and needling densities to process different layers to form different density areas, can take the effects of needling loading and coupling of the preforms with different densities into account, and improves the bonding strength of the integrated molding of the density gradient fiber preforms.
As a preferred technical solution of the second aspect of the present invention, the preparation method includes:
and forming a first layer, a second layer and a third layer by adopting a three-coordinate scanning technology and adopting different needling depths and needling densities to prepare the gradient density preform.
The forming a first layer includes: adopting fiber cloth and a fiber net felt, wherein the needling density is 25-35 needles/cm 2, the needling depth is 15-20 mm, overlapping, cross lamination and needling are carried out on the cloth layers in the third density area and the fourth density area in the transition area of the first layer, the unit area mass of the fiber cloth in the first layer is 220-360 g/m 2, and the unit area mass of the fiber net felt is 60-200 g/m 2;
Forming the second layer includes: forming a first density area of a second layer, wherein the first density area comprises fiber cloth and fiber net felt, and the unit area mass of the fiber net felt in the first density area is 130-170 g/m 2; the second density region comprises fiber cloth and fiber net felt, and the unit area mass of the fiber net felt in the second density region is 60-85 g/m 2; the needling density in the second layer is 15-25 needles/cm 2, and the needling depth is 13-17 mm; the unit area mass of the fiber cloth in the second layer is 280-300 g/m 2; layering and connecting the cloth layers of the first density area and the second density area in a wedge-shaped mode in the second layer transition area, and pressing the first density area with high density to the second density area with low density;
Forming the third layer includes: the quartz fiber net felt is adopted for needling molding, the needling density is 5-10 needles/cm 2, and the needling depth is 11-15 mm.
In a third aspect, the present invention provides a thermal insulation material made using the gradient density preform of the first aspect.
The heat insulation material provided by the invention has a lower total heat conductivity coefficient, and the surface layer of the heat insulation material is of a high-temperature-resistant ablation-resistant heat-resistant layer structure, so that the problems of thermal expansion mismatch, composite material layering and the like can be effectively avoided in a high-temperature environment.
Compared with the prior art, the invention has at least the following beneficial effects:
(1) The density of the gradient density preform provided by the invention changes in a gradient manner, the needling loading and the coupling effect among different densities are outstanding, and the accurate control of the density and physical size of the preform is better; the gradient density preform has excellent mechanical properties, and after the preform is made into a heat-resistant material, the tensile strength is more than 332MPa, the bending strength is more than 346MPa, the compression strength is more than 431MPa, the in-plane shearing strength is more than 121MPa, and the interlayer shearing strength is more than 37.6 MPa;
(2) The inner layer of the gradient density preform provided by the invention is a light low-density heat insulation layer, the middle layer is a transition layer, the outer layer is a high-temperature-resistant ablation-resistant heat-proof layer structure, and meanwhile, a transition region is adopted in the second layer, so that the problems of thermal expansion mismatch, composite material layering and the like can be effectively avoided.
Drawings
FIG. 1 is a schematic view of a gradient density preform provided in example 1 of the present invention.
Fig. 2 is a schematic illustration of the first layer of fig. 1 in accordance with the present invention.
FIG. 3 is a schematic illustration of a first density region of the second layer of FIG. 1 in accordance with the present invention.
Fig. 4 is a schematic illustration of a second density region of the second layer of fig. 1 in accordance with the present invention.
In the figure: 1. a first layer; 11. a third density region; 12. a first layer transition region; 13. a fourth density region; 2. a second layer; 21. a first density region; 211. a first quartz fiber cloth; 212. a first quartz fiber web mat; 22. a second layer transition region; 221. a second quartz fiber cloth; 222. a third quartz fiber cloth; 223. a second quartz fiber web mat; 23. a second density region; 3. and a third layer.
Detailed Description
The technical scheme of the invention is further described below by the specific embodiments with reference to the accompanying drawings.
The present invention will be described in further detail below. The following examples are merely illustrative examples of the present invention and are not intended to represent or limit the scope of the invention as set forth in the claims.
Example 1
The present embodiment provides a gradient density preform, as shown in fig. 1, comprising a first layer 1, a second layer 2 and a third layer 3.
As shown in fig. 2, the first layer 1 comprises two layers of quartz fiber cloth and one layer of quartz fiber net felt, the thickness of the first layer 1 is 1.5mm, and the first layer 1 comprises a third density region 11, a fourth density region 13 and a first layer transition region 12 which transits from the third density region 11 to the fourth density region 13; the first layer transition region 12 comprises a first sub-layer and a second sub-layer which are stacked in sequence from top to bottom; the density of the first sub-layer is higher than the density of the second sub-layer; the thickness of the first sub-layer accounts for 33% of the thickness of the first layer 1; the width of the first layer transition zone 12 is 50mm; specifically, the first sub-layer and the third density region 11 each have a density of 0.60g/cm 3, and the second sub-layer and the fourth density region 13 each have a density of 0.94g/cm 3.
The second layer 2 comprises a first density region 21, a second density region 23, and a second layer transition region 22 transitioning from the first density region 21 to the second density region 23; the first density region 21 and the second density region 23 of the second layer 2 have different densities; the thickness of the second layer 2 is 3mm; the width of the second layer transition zone 22 is 35mm; the first density area 21 and the second density area 23 of the second layer transition area 22 are connected in a layering manner in a wedge-shaped manner; as shown in fig. 3, the first density region 21 in the second layer 2 includes a layer of quartz fiber cloth and a layer of quartz fiber net felt, which are respectively a first quartz fiber cloth 211 and a first quartz fiber net felt 212; the bulk density of the first density region 21 in the second layer 2 is 0.30g/cm 3; as shown in fig. 4, the second density area 23 in the second layer 2 includes two layers of quartz fiber cloth and one layer of quartz fiber net felt, which are respectively a second quartz fiber cloth 221, a third quartz fiber cloth 222 and a second quartz fiber net felt 223; the second density region 23 in the second layer 2 has a bulk density of 0.60g/cm 3.
The bulk density of the third layer 3 is 0.14g/cm 3; the thickness of the third layer 3 is 12mm; the third layer 3 is a quartz fiber net felt.
The quartz fiber cloth is five-piece satin cloth of quartz fibers.
The embodiment also provides a preparation method of the gradient density preform, which comprises the following steps:
Forming a first layer, a second layer and a third layer by adopting a three-coordinate scanning technology and adopting different needling depths and needling densities to prepare a gradient density preform;
The forming a first layer includes: adopting two layers of fiber cloth and one layer of fiber net felt, wherein the needling density of the third density area is 25 needles/cm 2, and the needling depth is 15mm; the needling density of the fourth density area is 35 needles/cm 2, and the needling depth is 19mm; overlapping, cross-laminating and needling are carried out on cloth layers in a third density area and a fourth density area in a first layer transition area, wherein the unit area mass of the fiber cloth in the first layer is 295g/m 2, and the unit area mass of the fiber net felt is 75g/m 2;
Forming the second layer includes: forming a first density area of a second layer, wherein the first density area comprises a layer of fiber cloth and a layer of fiber net felt, and the unit area mass of the fiber net felt in the first density area is 155g/m 2; the second density region comprises two layers of fiber cloth and one layer of fiber net felt, and the unit area mass of the fiber net felt in the second density region is 75g/m 2; the needling density in the second layer is 20 needles/cm 2, and the needling depth is 15mm; the unit area mass of the fiber cloth in the second layer is 295g/m 2; layering and connecting the cloth layers of the first density area and the second density area in a wedge-shaped mode in the second layer transition area, and pressing the first density area with high density to the second density area with low density;
forming the third layer includes: the quartz fiber net felt is adopted for needling molding, the needling density is 8 needles/cm 2, and the needling depth is 13mm.
After the gradient density preform prepared in the embodiment is prepared into a heat insulation material according to the existing method, the tensile strength is 332MPa, the bending strength is 386MPa, the compression strength is 447MPa, the in-plane shear strength is 121MPa, and the interlayer shear strength is 43.1MPa.
Example 2
The present embodiment provides a gradient density preform including a first layer, a second layer, and a third layer.
The first layer comprises two layers of quartz fiber cloth and a layer of quartz fiber net felt, the thickness of the first layer is 1.4mm, and the first layer comprises a third density region, a fourth density region and a first layer transition region which transits from the third density region to the fourth density region; the first layer transition zone comprises a first sub-layer and a second sub-layer which are stacked in sequence from top to bottom; the density of the first sub-layer is higher than the density of the second sub-layer; the thickness of the first sub-layer is 25% of the thickness of the first layer; the width of the first layer transition zone is 30mm; specifically, the first sub-layer and the third density region each have a density of 0.65g/cm 3, and the second sub-layer and the fourth density region each have a density of 0.90g/cm 3.
The second layer includes a first density region, a second density region, and a second layer transition region transitioning from the first density region to the second density region; the first density region and the second density region of the second layer are different in density; the thickness of the second layer is 4mm; the width of the second layer transition zone is 50mm; the first density area and the second density area of the second layer transition area are connected in a layering way in a wedge-shaped mode; the first density area in the second layer comprises a layer of quartz fiber cloth and a layer of quartz fiber net felt; the bulk density of the first density region in the second layer is 0.40g/cm 3; the second density area in the second layer comprises two layers of quartz fiber cloth and one layer of quartz fiber net felt, and the volume density of the second density area in the second layer is 0.70g/cm 3.
The bulk density of the third layer is 0.13g/cm 3; the thickness of the third layer is 10mm; the third layer is a quartz fiber net felt.
The quartz fiber cloth is five-piece satin cloth of quartz fibers.
The embodiment also provides a preparation method of the gradient density preform, which comprises the following steps:
Forming a first layer, a second layer and a third layer by adopting a three-coordinate scanning technology and adopting different needling depths and needling densities to prepare a gradient density preform;
The forming a first layer includes: adopting two layers of fiber cloth and one layer of fiber net felt, wherein the needling density of a third density area is 28 needles/cm 2, and the needling depth is 16mm; the needling density of the third density area is 32 needles/cm 2, and the needling depth is 18mm; overlapping, cross-laminating and needling are carried out on the cloth layers in the third density area and the third density area in the first layer transition area, wherein the unit area mass of the fiber cloth in the first layer is 280g/m 2, and the unit area mass of the fiber web felt is 85g/m 2;
Forming the second layer includes: forming a first density region of a second layer, wherein the first density region comprises a layer of fiber cloth and a layer of fiber net felt, and the unit area mass of the fiber net felt in the first density region is 170g/m 2; the second density region comprises two layers of fiber cloth and one layer of fiber net felt, and the unit area mass of the fiber net felt in the second density region is 85g/m 2; the needling density in the second layer is 25 needles/cm 2, and the needling depth is 16mm; the unit area mass of the fiber cloth in the second layer is 295g/m 2; layering and connecting the cloth layers of the first density area and the second density area in a wedge-shaped mode in the second layer transition area, and pressing the first density area with high density to the second density area with low density;
Forming the third layer includes: the quartz fiber net felt is adopted for needling molding, the needling density is 5 needles/cm 2, and the needling depth is 12mm.
After the gradient density preform prepared in the embodiment is prepared into a heat insulation material according to the existing method, the tensile strength is 392MPa, the bending strength is 346MPa, the compression strength is 431MPa, the in-plane shearing strength is 144MPa, and the interlayer shearing strength is 39.5MPa.
Example 3
The present embodiment provides a gradient density preform including a first layer, a second layer, and a third layer.
The first layer comprises two layers of quartz fiber cloth and a layer of quartz fiber net felt, the thickness of the first layer is 1.6mm, and the first layer comprises a third density region, a fourth density region and a first layer transition region which transits from the third density region to the fourth density region; the first layer transition zone comprises a first sub-layer and a second sub-layer which are stacked in sequence from top to bottom; the density of the first sub-layer is higher than the density of the second sub-layer; the thickness of the first sub-layer is 50% of the thickness of the first layer; the width of the first layer transition zone is 50mm; specifically, the first sub-layer and the third density region each have a density of 0.60g/cm 3, and the second sub-layer and the fourth density region each have a density of 0.92g/cm 3.
The second layer includes a first density region, a second density region, and a second layer transition region transitioning from the first density region to the second density region; the first density region and the second density region of the second layer are different in density; the thickness of the second layer is 5mm; the width of the second layer transition zone is 45mm; the first density area and the second density area of the second layer transition area are connected in a layering way in a wedge-shaped mode; the first density area in the second layer comprises a layer of quartz fiber cloth and a layer of quartz fiber net felt; the bulk density of the first density region in the second layer is 0.20g/cm 3; the second density area in the second layer comprises two layers of quartz fiber cloth and one layer of quartz fiber net felt, and the volume density of the second density area in the second layer is 0.60g/cm 3.
The bulk density of the third layer is 0.16g/cm 3; the thickness of the third layer is 13mm; the third layer is a quartz fiber net felt.
The quartz fiber cloth is five-piece satin cloth of quartz fibers.
The embodiment also provides a preparation method of the gradient density preform, which comprises the following steps:
Forming a first layer, a second layer and a third layer by adopting a three-coordinate scanning technology and adopting different needling depths and needling densities to prepare a gradient density preform;
The forming a first layer includes: adopting two layers of fiber cloth and one layer of fiber net felt, wherein the needling density of the third density area is 25 needles/cm 2, and the needling depth is 15mm; the needling density of the fourth density area is 33 needles/cm 2, and the needling depth is 18mm; overlapping, cross-laminating and needling are carried out on cloth layers in a third density area and a fourth density area in a first layer transition area, wherein the unit area mass of the fiber cloth in the first layer is 300g/m 2, and the unit area mass of the fiber web felt is 60g/m 2;
forming the second layer includes: forming a first density area of a second layer, wherein the first density area comprises a layer of fiber cloth and a layer of fiber net felt, and the unit area mass of the fiber net felt in the first density area is 130g/m 2; the second density region comprises two layers of fiber cloth and one layer of fiber net felt, and the unit area mass of the fiber net felt in the second density region is 85g/m 2; the needling density in the second layer is 18 needles/cm 2, and the needling depth is 14mm; the unit area mass of the fiber cloth in the second layer is 280g/m 2; layering and connecting the cloth layers of the first density area and the second density area in a wedge-shaped mode in the second layer transition area, and pressing the first density area with high density to the second density area with low density;
forming the third layer includes: the quartz fiber net felt is adopted for needling molding, the needling density is 10 needles/cm 2, and the needling depth is 15mm.
After the gradient density preform prepared in the embodiment is prepared into a heat insulation material according to the existing method, the tensile strength is 398MPa, the bending strength is 348MPa, the compressive strength is 486MPa, the in-plane shear strength is 149MPa, and the interlayer shear strength is 37.6MPa.
Example 4
The present embodiment provides a gradient density preform, where the first density region and the second density region of the second layer transition region are not connected by layering in a wedge-shaped manner, but are disposed outside a first sub-layer and a second sub-layer stacked in sequence, and the rest is the same as embodiment 1, and details thereof are not repeated herein.
Compared with the embodiment 1 and the embodiment 4, in the embodiment 1, two cloth layers with different density structures are connected in a layering manner in a wedge-shaped manner, the higher density is pressed, the lower density is pressed, the stable structure of a transition area is ensured, the material structure is not easy to generate the problem of material layering in the thermal expansion process, and the direct lamination arrangement in the embodiment 4 is equivalent to the combination of 2 prefabricated layers with different densities, so that the problems of thermal expansion mismatch, composite material layering and the like are easily caused.
Example 5
The present embodiment provides a gradient density preform, and the rest of the gradient density preform is the same as embodiment 1 except that the first layer is all the third density region, and will not be described herein.
Example 6
The present embodiment provides a gradient density preform, and the rest of the gradient density preform is the same as embodiment 1 except that the first layer is the fourth density region, and will not be described herein.
The first layer of examples 5-6 may be configured as a density zone that is comparable to the thermal insulation properties of example 1, depending on the desired environmental requirements.
Example 7
The present embodiment provides a gradient density preform, which is the same as embodiment 1 except that the width of the transition region of the second layer is 10mm, and will not be described herein.
In example 7, the transition region was too narrow, which resulted in difficult stitching, and the operation was difficult, and it was difficult to obtain a corresponding gradient density preform.
Example 8
The present embodiment provides a gradient density preform, which is the same as embodiment 1 except that the width of the transition region of the second layer is 80mm, and will not be described herein.
In embodiment 8, the transition region of the second layer is wider, so that the transition region needs to be manufactured for too long, the working efficiency is low, the overall average volume density of the second layer will be affected, and the design requirement is difficult to meet.
Comparative example 1
This comparative example provides a gradient density preform that is identical to example 1 except that the second layer is not provided with a transition region and will not be described again.
In comparative example 1, the direct connection, the unstable structure, and the easy breakage of the connection by external force, the tensile property, the bending property, the compression property, the in-plane shearing property, and the interlayer shearing property were all reduced as compared with example 1.
Comparative example 2
This comparative example provides a gradient density preform that is identical to example 1 except that the second layer is entirely the first density region and will not be described in detail herein.
The combination of 2 prefabricated layers with different densities in the comparative example is equivalent to the problem that thermal expansion mismatch, composite material layering and the like are easy to occur.
The application method comprises the following steps: the gradient density preform is prepared into a heat insulation material according to the prior method.
And tensile property, bending property, in-plane shearing property and interlayer shearing property are respectively tested according to GJB8736-2015, GB/T6569-2006, GJB8737-2015, ASTMC1292-16 and DqES-98.
In summary, it can be seen that the gradient density preform provided by the invention has excellent mechanical properties, and after the preform is made into a heat-resistant material, the tensile strength is above 332MPa, the bending strength is above 346MPa, the compressive strength is above 431MPa, the in-plane shear strength is above 121MPa, and the interlayer shear strength is above 37.6 MPa.
The detailed structural features of the present invention are described in the above embodiments, but the present invention is not limited to the above detailed structural features, that is, it does not mean that the present invention must be implemented depending on the above detailed structural features. It should be apparent to those skilled in the art that any modifications of the present invention, equivalent substitutions of selected components of the present invention, addition of auxiliary components, selection of specific modes, etc., are within the scope of the present invention and the scope of the disclosure.

Claims (44)

1. A gradient density preform, wherein the gradient density preform comprises a first layer, a second layer, and a third layer;
the density of the first layer is more than or equal to the density of the second layer, and the density of the second layer is more than or equal to the density of the third layer;
The second layer includes a first density region, a second density region, and a second layer transition region transitioning from the first density region to the second density region;
the first density region and the second density region of the second layer are different in density;
And the first density area and the second density area of the second layer transition area are connected in a layering way in a wedge-shaped mode, and the first density area with high density is pressed against the second density area with low density.
2. The gradient density preform of claim 1, wherein the thickness of the first layer is 5-10% of the total thickness of the gradient density preform.
3. The gradient density preform of claim 1, wherein the first layer has a bulk density of 0.60-1.0 g/cm 3.
4. The gradient density preform of claim 1, wherein the first layer comprises a third density region, a fourth density region, and a first layer transition region transitioning from the third density region to the fourth density region.
5. The gradient density preform of claim 4, wherein the first layer transition zone comprises a first sub-layer and a second sub-layer stacked in sequence from top to bottom.
6. The gradient density preform of claim 5, wherein the density of the first sub-layer is higher than the density of the second sub-layer.
7. The gradient density preform of claim 5, wherein the density of the first sub-layer is comparable to the density of the third density region.
8. The gradient density preform of claim 5, wherein the density of the second sub-layer is comparable to the density of the fourth density region.
9. The gradient density preform of claim 5, wherein the thickness of the first sub-layer comprises 25-50% of the thickness of the first layer.
10. The gradient density preform of claim 4, wherein the first layer transition zone has a width of 30-60 mm.
11. The gradient density preform of claim 1, wherein the thickness of the second layer is 15-30% of the total thickness of the gradient density preform.
12. The gradient density preform of claim 1, wherein the second layer has a bulk density of 0.25 to 0.58g/cm 3.
13. The gradient density preform of claim 1, wherein the second layer transition zone has a width of 30-60 mm.
14. The gradient density preform of claim 1, wherein the first density region in the second layer has a bulk density of 0.25 to 0.40g/cm 3.
15. The gradient density preform of claim 1, wherein the second density region in the second layer has a bulk density of 0.42 to 0.58g/cm 3.
16. The gradient density preform of claim 1, wherein the third layer has a bulk density of 0.08-0.20 g/cm 3.
17. The gradient density preform of claim 1, wherein the thickness of the third layer is 40-80% of the total thickness of the gradient density preform.
18. The gradient density preform of claim 1, wherein the gradient density preform is a fiber preform.
19. The gradient density preform of claim 18, wherein the gradient density preform is any one or a combination of at least two of carbon fiber, silicon carbide fiber, quartz fiber, glass fiber, silica rich fiber, or basalt fiber.
20. A method of preparing a gradient density preform according to any one of claims 1 to 19, comprising: forming a first layer, a second layer and a third layer by adopting a three-coordinate scanning technology and adopting different needling depths and needling densities to prepare a gradient density preform;
and the second layer transition region in the second layer is used for carrying out layering connection on the cloth layers of the first density region and the second density region in a wedge-shaped mode, and the first density region with high density is pressed against the second density region with low density.
21. The method of making according to claim 20, wherein the first layer comprises two layers of fiber cloth and one layer of fiber web felt or the first layer comprises one layer of fiber cloth and one layer of fiber web felt.
22. The method of claim 20, wherein the first layer has a needling density of 25 to 35 needles/cm 2.
23. The method of claim 20, wherein the first layer has a needle penetration depth of 15-20 mm.
24. The method of manufacturing according to claim 20, wherein the first layer comprises a third density region, a fourth density region, and a first layer transition region transitioning from the third density region to the fourth density region;
And the first layer transition area carries out overlapping, crossed and laminated needling on the cloth layers in the third density area and the fourth density area.
25. The method of claim 20, wherein the first layer of fiber cloth is a five-satin fabric.
26. The method of claim 20, wherein the mass per unit area of the fiber cloth in the first layer is 220-360 g/m 2.
27. The method of claim 20, wherein the fibrous web mat in the first layer has a mass per unit area of 60 to 200g/m 2.
28. The method of claim 20, wherein the first density region of the second layer comprises a layer of fibrous cloth and a layer of fibrous web felt.
29. The method of claim 20, wherein the fibrous web mat of the first density zone in the second layer has a mass per unit area of 130 to 170g/m 2.
30. The method of claim 20, wherein the second density region in the second layer comprises two layers of fiber cloth and one layer of fiber web felt or the second density region in the second layer comprises one layer of fiber cloth and one layer of fiber web felt.
31. The method of claim 20, wherein the second density region of the second layer has a web felt mass per unit area of 60 to 85g/m 2.
32. The method of claim 20, wherein the needling density in the second layer is 15 to 25 needles/cm 2.
33. The method of claim 20, wherein the second layer has a needle penetration depth of 13-17 mm.
34. The method of claim 20, wherein the second layer of fiber cloth is a five-satin fabric.
35. The method of claim 20, wherein the mass per unit area of the fiber cloth in the second layer is 280-300 g/m 2.
36. The method of claim 20, wherein the second layer transition region is further treated with stitching.
37. The method of claim 36, wherein the means for suturing comprises single strand bi-directional suturing.
38. The method of claim 36, wherein the seam spacing is 2-10 mm in the weft direction x 2-10 mm in the warp direction.
39. The method of claim 38, wherein the stitching process is spaced apart by 3mm weft x 6mm warp.
40. The method of claim 20, wherein the third layer is needled with a quartz fiber web mat.
41. The method of claim 20, wherein the third layer has a needling density of 5 to 10 needles/cm 2.
42. The method of claim 20, wherein the third layer has a needling depth of 11-15 mm.
43. The method of manufacturing according to claim 20, characterized in that the method of manufacturing comprises:
Forming a first layer, a second layer and a third layer by adopting a three-coordinate scanning technology and adopting different needling depths and needling densities to prepare a gradient density preform;
The forming a first layer includes: adopting fiber cloth and a fiber net felt, wherein the needling density is 25-35 needles/cm 2, the needling depth is 15-20 mm, overlapping, cross lamination and needling are carried out on the cloth layers in the third density area and the fourth density area in the transition area of the first layer, the unit area mass of the fiber cloth in the first layer is 220-360 g/m 2, and the unit area mass of the fiber net felt is 60-200 g/m 2;
Forming the second layer includes: forming a first density region of a second layer, wherein the first density region comprises fiber cloth and fiber net felt, and the unit area mass of the fiber net felt in the first density region is 130-170 g/m 2; the second density region comprises fiber cloth and fiber net felt, and the unit area mass of the fiber net felt in the second density region is 60-85 g/m 2; the needling density in the second layer is 15-25 needles/cm 2, and the needling depth is 13-17 mm; the unit area mass of the fiber cloth in the second layer is 280-300 g/m 2; layering and connecting the cloth layers of the first density area and the second density area in a wedge-shaped mode in the second layer transition area, and pressing the first density area with high density to the second density area with low density;
forming the third layer includes: and (3) performing needling molding by adopting a quartz fiber net felt, wherein the needling density is 5-10 needles/cm 2, and the needling depth is 11-15 mm.
44. A thermal insulation material, characterized in that it is manufactured using the gradient density preform according to any one of claims 1 to 19.
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