阅读说明：本技术 一种基于树脂基碳泡沫的隔热瓦及其制备方法 (Heat insulation tile based on resin-based carbon foam and preparation method thereof ) 是由 程小全 庄淇凯 于 2021-09-15 设计创作，主要内容包括：本发明公布一种基于树脂基碳泡沫的隔热瓦及其制备方法。所述隔热瓦的结构包括隔热层、外面板、密封板、底面板；所述隔热层具备隔热功能；所述外面板起到表面增强的作用,保护内部结构免受气流冲蚀以及表面冲击损伤,所述密封板与所述底面板是一层致密的耐高温薄板,共同紧密包裹所述隔热层,阻挡氧气进入,避免碳泡沫氧化；所述底面板与主结构连接。本发明的隔热层,具备与隔热陶瓷相近的密度和热导率,但模量和强度更高,长期使用温度也更高；通过设计所述外面板、密封板与底面板,解决了树脂基碳泡沫易氧化的问题,增加了隔热瓦的刚度、强度和抗冲击性能；树脂基碳泡沫的造价低廉,可以大量生产,使得隔热瓦的应用成本较低,应用面更广。(The invention discloses a heat insulation tile based on resin-based carbon foam and a preparation method thereof. The structure of the heat insulation tile comprises a heat insulation layer, an outer panel, a sealing plate and a bottom panel; the heat insulation layer has a heat insulation function; the outer panel plays a role in surface enhancement and protects the internal structure from air flow erosion and surface impact damage, the sealing plate and the bottom panel are a layer of compact high-temperature-resistant thin plate and tightly wrap the heat insulation layer together to prevent oxygen from entering and avoid carbon foam oxidation; the bottom panel is connected to the main structure. The thermal insulation layer has the density and the thermal conductivity similar to those of thermal insulation ceramic, but has higher modulus and strength and higher long-term use temperature; by designing the outer panel, the sealing plate and the bottom panel, the problem that resin-based carbon foam is easy to oxidize is solved, and the rigidity, the strength and the shock resistance of the heat insulation tile are improved; the resin-based carbon foam has low manufacturing cost and can be produced in large quantities, so that the application cost of the heat insulation tile is low, and the application range is wider.)

1. The heat insulation tile based on the resin-based carbon foam is characterized by comprising a heat insulation layer (1), an outer panel (2), a sealing plate (3) and a bottom panel (4), wherein the heat insulation layer (1) has a heat insulation function, the outer panel (2) has a surface reinforcing function and protects an internal structure from air flow erosion and surface impact damage, and the sealing plate (3) and the bottom panel (4) jointly and tightly wrap the heat insulation layer (1) to prevent oxygen from entering and prevent carbon foam from being oxidized; the outer panel (2) covers the sealing plate (3).

2. A heat-insulating tile according to claim 1, characterized in that said sealing plate (3) and said bottom panel (4) are each a layer of dense high-temperature-resistant thin plate; preferably, the high temperature is the temperature of less than or equal to 1400 ℃; preferably, the thickness of the thin plate is more than 0 and less than or equal to 5 mm.

3. A tile according to claim 1, characterised in that said bottom panel (4) is connected to the main structure (5) by means of an adhesive connection when the ambient temperature of the tile is greater than 600 ℃, or by means of an adhesive connection or by making holes in the tile, mechanically, such as expansion bolts, when the ambient temperature of the tile is less than 600 ℃, for example less than 400 ℃.

4. The insulating tile according to claim 1, characterized in that the insulating layer (1) is made of resin-based carbon foam satisfying the following performance requirements: density 0.10-0.25g/cm³The thermal conductivity at normal temperature is 0.05W/(m.K), the thermal conductivity at 2000 ℃ is less than 1W/(m.K), the Young modulus is 100-.

5. The heat insulating tile according to claim 1, characterized in that the outer panel (2) is in the form of a laminate of one of a resin, a ceramic, a metal, a fiber-reinforced composite, a C/C composite or a sandwich of one of a honeycomb sandwich, a foam sandwich, a corrugated sandwich, a lattice made of metal, ceramic, carbon/carbon material.

6. An insulating tile according to claim 1, characterized in that a sealing plate (3) is wrapped around all but the bottom surface of the insulating layer (1) and is connected to the outer panel (2) by gluing (21) or co-curing (22).

7. The insulating tile according to claim 6, characterized in that the glue joint (21), i.e. the sealing plate (3), is cured and then cured with the outer panel (2), and the co-curing (22), i.e. the sealing plate (3) is co-cured with the outer panel (2).

8. The insulating tile according to claim 1, characterized in that the bottom panel (4) is in the form of a laminate of one of a resin, a ceramic, a metal, a fiber-reinforced composite, a C/C composite or a sandwich of one of a honeycomb sandwich, a foam sandwich, a corrugated sandwich, a lattice made of metal, ceramic, carbon/carbon material.

9. A heat insulating tile according to claim 3, characterized in that the size of the heat insulating tile depends on the deformation of the main structure (5), the size of the heat insulating tile being the same as the main structure (5) when the total bending deflection of the main structure (5) is less than 1 mm.

10. A method of making a resin based carbon foam based insulation tile according to any one of claims 1 to 9, comprising the steps of:

step 1: the heat insulation layer (1) is processed into a required shape according to design requirements, and is mechanically processed and formed by a single resin-based carbon foam blank or a plurality of blanks after being spliced; the splicing method is that the resin-based carbon foam at the splicing position is processed into one of the following configurations: comprises a step lap joint (31), a concave-convex lap joint (32), a hasp lap joint (33) and an oblique lap joint (34), and the joints are bonded by high-temperature-resistant adhesives;

step 2: when the outer panel (2) and the sealing plate (3) are used for processing the sealing plate (3) and the outer panel (2) for composite molding, glue joint or co-curing is adopted, and a mold is used on the outer surface of the outer panel (2) and the inner part of the sealing plate (3) during molding so as to obtain a required shape; when the material of the sealing plate (3) is not a ceramic matrix composite material, the resin-based carbon foam of the heat insulation layer (1) is used as an internal mold of the sealing plate (3) and is cured and molded together with the sealing plate (3); when the material of the sealing plate (3) is ceramic matrix composite material, the resin-based carbon foam of the heat insulation layer (1) can not be used as an internal mold;

and step 3: packaging the heat insulation layer (1), putting the heat insulation layer (1) into the sealing plate (3), filling the gap with high-temperature adhesive, and fixing the heat insulation layer (1); the bottom panel (4) and the heat insulation layer (1) are compounded and connected in a gluing mode, and vacuumizing needs to be kept during gluing and curing.

Technical Field

The invention relates to the field of thermal protection, in particular to a heat insulation tile based on resin-based carbon foam and a preparation method thereof.

Background

In recent 20 years, resin-based carbon foam has become one of the hot spots in the aspects of the preparation technology, the application, the development and the research of light high-temperature-resistant heat insulation materials. The density of the resin-based carbon foam in China is 0.10-0.25g/cm³The thermal conductivity at normal temperature is 0.05W/(m.K), the thermal conductivity at 2000 ℃ is less than 1W/(m.K), the Young modulus is 100-. Compared with high-performance ceramic heat insulation materials, the resin-based carbon foam has similar density and heat conductivity, higher modulus and strength and higher temperature resistance. Resin-based carbon foams thus have great potential for aerospace applications, such as thermal shielding for aircraft structures, engine intake ducts and jet nozzles, where aerodynamic heating is severe. The cost of the resin-based carbon foam is lower than that of high-performance heat-insulating materials such as ceramics, silica aerogel and the like, and the resin-based carbon foam has a great application prospect in the civil field.

Resin-based carbon foams have an oxidation problem and begin to oxidize at 400 c in an aerobic environment, and therefore, resin-based carbon foams generally require an anti-oxidation treatment in practical use. The traditional anti-oxidation treatment comprises two processes of vapor deposition and surface coating, wherein the vapor deposition process has poor anti-oxidation effect, can obviously increase the thermal conductivity of the material and seriously weaken the heat-insulating property of the material; the surface coating is easy to fall off or damage and is difficult to use for a long time.

Resin-based carbon foams also present surface protection problems in applications. The resin-based carbon foam has a porous structure, the surface of which is easily damaged and not smooth, and the resin-based carbon foam is easily eroded in a high-speed airflow, so that a protective panel matched with the resin-based carbon foam needs to be designed.

Disclosure of Invention

Aiming at the problems in the prior art, the resin-based carbon foam is used as a heat insulation material, an anti-oxidation packaging structure and a protection panel matched with the heat insulation material are designed, and the synthesized structure is used as a heat insulation tile, has the characteristics of good heat insulation effect, light weight, high temperature resistance, erosion resistance and reusability, can replace the traditional ceramic tile to be applied to a hypersonic aircraft or an aerospace shuttle, and simultaneously provides a reliable solution for other applications needing high-temperature heat insulation.

The technical scheme adopted by the invention is as follows:

a heat insulation tile based on resin-based carbon foam comprises a heat insulation layer 1, an outer panel 2, a sealing plate 3 and a bottom panel 4. The heat insulation layer 1 has a heat insulation function, and the outer panel 2 plays a role in surface enhancement and protects the internal structure from air flow erosion and surface impact damage. The sealing plate 3 and the bottom panel 4 are tightly wrapped on the heat insulation layer 1 together to prevent oxygen from entering and avoid carbon foam oxidation. The outer panel 2 covers the sealing plate 3.

The sealing plate 3 and the bottom plate 4 are respectively a layer of compact high-temperature-resistant thin plate. Preferably, the high temperature is 1400 ℃ or less. Preferably, the thickness of the thin plate is more than 0 and less than or equal to 5 mm.

The bottom panel 4 is connected with the main structure 5, when the temperature of the working environment of the heat insulation tile is higher than 600 ℃, the connection mode selects adhesive connection, when the temperature of the working environment of the heat insulation tile is lower than 600 ℃, especially lower than 400 ℃, besides the adhesive connection, the heat insulation tile can be perforated and mechanically connected, such as expansion bolts. The heat insulation tile can be designed into any shape according to actual requirements, and any heat insulation tile conforming to the structure form is within the protection scope of the invention.

The heat insulation layer 1 is made of resin-based carbon foam and must meet the following performance requirements: density 0.10-0.25g/cm³The thermal conductivity at normal temperature is 0.05W/(m.K), the thermal conductivity at 2000 ℃ is less than 1W/(m.K), the Young modulus is 100-.

The outer panel 2 is in the form of a laminate or a sandwich structure, the material of the laminate can be one of resin, ceramic, metal, fiber reinforced composite material and C/C composite material, and the sandwich structure can be one of a honeycomb sandwich structure, a foam sandwich structure, a corrugated plate sandwich structure and a lattice structure made of metal, ceramic and carbon/carbon material. The material selection of the outer panel 2 depends on the design requirements of the insulating tile.

The sealing plate 3 is a thin plate, and preferably, the thickness of the thin plate is greater than 0 and less than or equal to 5 mm. The sealing plate 3 wraps all the surfaces of the heat insulation layer 1 except the bottom surface, and the connection mode with the outer panel 2 can be glue joint 21 or co-curing 22, as shown in fig. 2. The adhesive bonding 21 is that the sealing plate 3 is cured and formed and then is bonded and cured with the outer panel 2, and the co-curing 22 is that the sealing plate 3 and the outer panel 2 are co-cured and formed.

The bottom surface of the heat insulation layer 1 is covered with a bottom panel 4. The bottom panel 4 is in the form of a laminate or a sandwich structure, the material of the laminate can be one of resin, ceramic, metal, fiber reinforced composite material and C/C composite material, and the sandwich structure can be one of a honeycomb sandwich structure, a foam sandwich structure, a corrugated plate sandwich structure and a lattice structure made of metal, ceramic and carbon/carbon material. Since the operating temperature is lower than that of the outer panel 2, the material should be selected according to the operating temperature.

The preparation method of the heat insulation tile comprises the following steps:

step 1: and (4) processing the heat insulation layer 1. The heat insulation layer 1 is processed into a required shape according to design requirements, can be mechanically processed and formed by a single resin-based carbon foam blank, and can also be mechanically processed and formed by splicing a plurality of blanks (suitable for large-size heat insulation tiles). The splicing method is that the resin-based carbon foam at the splicing part can be processed into a certain configuration as shown in figure 3, the configuration comprises a step lap joint 31, a concave-convex lap joint 32, a hasp lap joint 33 and an inclined lap joint 34, and the joints are bonded by high-temperature-resistant adhesives.

Step 2: the outer panel 2 and the sealing plate 3 are machined. When the sealing plate 3 and the outer panel 2 are formed in a composite mode, glue joint or co-curing can be adopted, and a mold is required to be used on the outer surface of the outer panel 2 and the inner portion of the sealing plate 3 during forming so as to obtain a required shape. When the material of the sealing plate 3 is not a ceramic matrix composite material, the resin-based carbon foam of the heat insulation layer 1 can be used as an internal mold of the sealing plate 3 and is cured and molded together with the sealing plate 3; when the sealing plate 3 material is a ceramic matrix composite, the resin-based carbon foam of the thermal insulation layer 1 may not function as an internal mold.

And step 3: and encapsulating the thermal insulation layer 1. Placing the heat insulation layer 1 into the sealing plate 3, filling the gap with a high-temperature adhesive, and fixing the heat insulation layer 1; the bottom panel 4 and the heat insulation layer 1 are combined in a gluing connection mode, and vacuumizing needs to be kept during gluing curing.

The size of the heat insulation tile depends on the deformation of the main structure 5, when the total bending deflection of the main structure 5 is less than 1mm, the size of the heat insulation tile can be the same as that of the main structure 5, a complete heat insulation barrier is formed, and therefore the heat bridge effect at the joint can be effectively reduced. Since the resin-based carbon foam of the thermal insulation layer 1 can adopt a splicing process, the size of the thermal insulation tile is not limited by the size of raw materials and the process, and only depends on the configuration, deformation and size of the main structure 5. For example, the primary structure is an aircraft primary structure.

Compared with the prior heat insulation tile, the invention has the beneficial effects that: the resin-based carbon foam is used as the heat insulation layer, has the density and the heat conductivity similar to those of heat insulation ceramics, but has higher modulus and strength and higher long-term use temperature; by designing the outer panel 2, the sealing plate 3 and the bottom panel 4, the problem that resin-based carbon foam is easy to oxidize is solved, and the rigidity, strength and impact resistance of the heat insulation tile are improved; the resin-based carbon foam has low manufacturing cost and can be produced in large quantities, so that the application cost of the heat insulation tile is low, and the application range is wider.

Drawings

FIG. 1 is a schematic view of the internal structure of a lightweight high temperature resistant heat insulating tile based on resin-based carbon foam;

FIG. 2 is a schematic view of a composite process of an outer panel and a sealing plate;

FIG. 3 is a schematic view of a resin-based carbon foam splice configuration;

fig. 4 is a schematic view of an embodiment of a resin-based carbon foam insulation tile.

Wherein: 1-a heat insulation layer; 2-an outer panel; 3-sealing the plate; 4-a bottom panel; 5-main structure; 21-gluing; 22-co-curing; 31-step lapping; 32-concave-convex lapping; 33-lap-joint of the hasps; 34-obliquely lapping; 41-example insulating tiles; 42-aircraft primary structural surface; 411 — example insulation; 412-an embodiment exception panel; 413-example seal plate; 414 example bottom panel; 4121-sandwich panel; 4122-sandwich structure sandwich; 4131-boss; 4132-groove.

Detailed Description

The invention is described in detail below with reference to the drawings and examples, which are provided for reference and illustration only and are not intended to be limiting of the invention.

Application example 1, a thermal insulating tile based on resin-based carbon foam for large surface area of air-to-air shuttle vehicles, as shown in fig. 1, has a structure comprising: 1) the size is 300mm multiplied by 30mm, the material is 0.15g/cm³A heat insulating layer 1 made of resin-based carbon foam having a normal temperature thermal conductivity of 0.05W/(m.K), a Young's modulus of 170MPa, and a compressive strength of 1.1 MPa; 2) an outer panel 2 made of a quartz fiber reinforced ceramic matrix composite laminate having a thickness of 4 mm; 3) a sealing plate 3 made of a quartz fiber reinforced ceramic matrix composite laminated plate with a thickness of 1 mm;

4) a bottom panel 4 made of carbon fiber reinforced bismaleimide resin matrix composite material with the thickness of 1 mm; 5) a primary structure 5 belonging to a part of the skin of an aircraft.

The preparation method comprises the following steps: 1) processing the resin-based carbon foam blank with the size of 320mm multiplied by 35mm into the heat insulation layer 1 with the size of 300mm multiplied by 30mm by a numerical control machine tool; 2) manufacturing a box body metal mold with the overall dimension of 300mm multiplied by 30mm, tightly covering 1mm of quartz fiber prepreg containing a ceramic precursor on 5 outer surfaces of the box body metal mold through demolding cloth, leaving one surface with the dimension of 300mm multiplied by 300mm uncovered, covering one surface with the dimension of 300mm multiplied by 300mm of quartz fiber prepreg containing a ceramic precursor of 4mm on one surface with the dimension of 1mm of the prepreg with the dimension of 300mm multiplied by 300mm, then integrally packaging a vacuum bag, and putting the vacuum bag into an autoclave for curing molding at 200 ℃ for 10 h; 3) taking out the metal mold after molding to obtain a co-cured outer panel 2 and sealing plate 3 preform; 4) putting the prefabricated body into a nitrogen atmosphere furnace at 650 ℃ for firing for 24 hours, and fully reacting the ceramic precursor to obtain the final structure of the co-cured outer panel 2 and the sealing plate 3; 5) putting the processed heat insulation layer 1 into the sealing plate 3, and filling a gap with a high-temperature-resistant adhesive; 6) covering one surface of the carbon fiber reinforced bismaleimide resin matrix composite prepreg exposed out of the resin matrix carbon foam, wrapping a vacuum bag, and curing for 10 hours at 250 ℃ in an autoclave to form the bottom panel 4; 7) and preparing a normal-temperature curing high-temperature-resistant adhesive, uniformly coating the adhesive on the outer surface of the bottom panel 4, covering the heat-insulating tile on the outer surface of the main structure 5, ensuring that the bottom panel 4 contains a glue surface and is in contact with the outer surface of the main structure 5, and finishing the installation of the heat-insulating tile after curing for 36 hours at normal temperature.

Application example 2, a heat insulating tile based on resin-based carbon foam applied to the surface of a reusable hypersonic aircraft, as shown in fig. 4, an example heat insulating tile 41 is a hexagonal three-dimensional curved surface configuration with a side length of 600mm, and is densely arranged on the main structure surface 42 of the aircraft at a gap of 0.2mm, and the connection mode is mechanical connection, and the structure of the example heat insulating tile 41 includes: 1) the density was 0.15g/cm³Example insulating layer 411 made of resin-based carbon foam having a normal temperature thermal conductivity of 0.05W/(m · K), a young's modulus of 170MPa, and a compressive strength of 1.1 MPa; 2) example sandwich construction panel 412, sandwich construction panel 4121 is made of SiC/SiC composite, sandwich construction sandwich 4122 is made of carbonized coal based carbon foam; 3) an embodiment seal plate 413 of SiC/SiC composite material having bosses 4131 attached to provide mechanical attachment, said bosses 4131 being disposed on three adjacent sides of a hexagonal insulating tile, the other three sides being recessed 4132 to avoid interference of said bosses 4131 with other said embodiment insulating tiles 41 during installation; 4) an example bottom panel 414 made of a carbon fiber reinforced bismaleimide resin matrix composite.

The preparation method comprises the following steps: 1) splicing 4 blocks of 350mm multiplied by 60mm resin-based carbon foam into a blank of 700mm multiplied by 60mm, processing the joint into the shape shown in the figure 3 oblique lapping 34, and bonding the joint by using a high-temperature adhesive; 2) machining a resin-based carbon foam blank into a shape required by the thermal insulation layer 411 of the embodiment, wherein the thickness of the thermal insulation layer is 40 mm; 3) splicing 4 carbonized coal-based carbon foams with the thickness of 350mm multiplied by 20mm into a blank with the thickness of 700mm multiplied by 20mm, processing the joint into the shape shown in the figure 3 oblique lapping 34, and bonding the joint by using a high-temperature adhesive; 4) machining a coal-based carbon foam blank into a shape required by the sandwich structure sandwich 4122, wherein the thickness is 15 mm; 5) preparing the boss 4131 by using a box-shaped mold, wherein the material is quartz fiber prepreg containing a ceramic precursor; 6) manufacturing a box metal mold with the same shape and size as the thermal insulation layer 411 of the embodiment, tightly covering 1mm of quartz fiber prepreg containing a ceramic precursor on 5 outer surfaces of the box metal mold through demolding cloth, leaving one surface with the size of 300mm multiplied by 300mm uncovered, covering one surface with the size of 300mm multiplied by 300mm of 1mm of quartz fiber prepreg containing a ceramic precursor on one surface with the size of 300mm multiplied by 300mm of 1mm of the prepreg, covering the thermal insulation layer 411 of the embodiment on the outer surface of 4mm of the prepreg, covering the 5mm of quartz fiber prepreg containing a ceramic precursor on the outer surface of the thermal insulation layer 411 of the embodiment, integrally packaging a vacuum bag, and putting the vacuum bag into an autoclave for curing molding at 200 ℃ for 10 hours; 7) after molding, taking out the metal mold, and adhering the prefabricated boss 4131 by using an adhesive to obtain a co-cured prefabricated body of the embodiment outer panel 412 and the embodiment sealing plate 413; 8) putting the prefabricated body into a nitrogen atmosphere furnace at 650 ℃ for firing for 24 hours, and fully reacting the ceramic precursor to obtain the final structures of the co-cured panel 2 outside the embodiment and the sealing plate 3 outside the embodiment; 9) placing the processed embodiment heat insulation layer 411 into the embodiment sealing plate 413, and filling a gap with a high temperature resistant adhesive; 10) and covering one side of the carbon fiber reinforced bismaleimide resin matrix composite prepreg exposed out of the resin matrix carbon foam, wrapping a vacuum bag, and curing for 10 hours at 250 ℃ in an autoclave.

The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the present invention. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.