A composite material for 200ka lightning protection and a preparation method and application thereof

Abstract

The application provides a composite material for 200kA lightning protection and a preparation method and application thereof. The composite material comprises a carbon fiber structure layer, an insulation protection layer and an ultralinearly arranged carbon nanotube film prepreg layer which are sequentially stacked; the thickness of the ultralinearly arranged carbon nanotube film prepreg layer is 30-120 mu m. The application prepares a composite material with excellent surface state and high conductivity, which can be used for lightning protection of 200kA level.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of lightning protection of composite materials, and particularly relates to a composite material for 200kA-level lightning protection and a preparation method and application thereof. BACKGROUND

[0002] At present, carbon fiber composite materials will be more widely applied to future large passenger aircraft. Compared with metal materials, carbon fiber composite materials have the characteristics of light weight and high strength, can effectively reduce the self weight of the aircraft, and improve the load ratio. However, carbon fiber composite materials are poor in electrical conductivity, and are prone to structural damage after being struck by lightning, which may cause air disasters. At present, the mainstream lightning protection technology is to apply a copper mesh with high electrical conductivity on the surface of the carbon fiber composite material structure. When lightning strikes, the lightning current is conducted on the surface of the composite material, so as to avoid the generation of high Joule heat in the composite material to cause structural damage. Although the copper mesh can improve the lightning protection performance of the composite material, it also has the disadvantage of obvious weight increase.

[0003] In order to solve the urgent demand for lightweight lightning protection materials of future large passenger aircraft, lightweight carbon nanotube film lightning protection material systems have attracted widespread attention from researchers. CN104789175A uses a certain thickness (30-250 μm) of insulating heat-conducting ablation-resistant adhesive to paste the conductive film on the surface of the continuous carbon fiber laminated composite material product, so as to prevent the conduction of the electric current to the continuous carbon fiber laminated composite material product and improve the lightning protection effect of the conductive film.

[0004] However, the above patent only relates to a 100kA-level carbon nanotube lightning protection system, and fails to study a 200kA-level lightning protection material system.

[0005] Therefore, it is urgent to design a new lightning protection material which can be used in a 200kA-level lightning protection material system. SUMMARY

[0006] In view of the deficiencies of the prior art, the purpose of the present application is to provide a composite material for 200kA-level lightning protection and a preparation method and application thereof. The present application prepares a composite material with excellent surface state and high electrical conductivity, which can be used in a 200kA-level lightning protection.

[0007] In order to achieve the purpose of the present application, the following technical solutions are adopted:

[0008] In a first aspect, the present application provides a composite material for 200kA-level lightning protection, which comprises a carbon fiber structure layer, an insulating protection layer and a super-aligned carbon nanotube film prepreg layer which are sequentially laminated.

[0009] The thickness of the super-aligned carbon nanotube film prepreg layer is 30-120 μm, for example, 30 μm, 50 μm, 70 μm, 90 μm, 100 μm or 120 μm, etc.

[0010] In the present application, if the thickness of the super-aligned carbon nanotube film prepreg layer is too small, the lightning protection capability is weak, and the composite plate is broken down; if the thickness of the super-aligned carbon nanotube film prepreg layer is too large, the carbon nanotubes are not easy to infiltrate, and the adhesion of the protective layer is poor.

[0011] As a preferred technical solution of the present application, the super-aligned carbon nanotube film prepreg layer comprises at least 1500 layers, for example, 1500 layers, 2000 layers, 2500 layers, 3000 layers, 3500 layers, 4000 layers or 4500 layers, etc., preferably 1500-3000 layers, and further preferably 2000 layers.

[0012] As a preferred technical solution of the present application, the super-aligned carbon nanotube film prepreg layer is composed of a super-aligned carbon nanotube film and a thermosetting resin.

[0013] Preferably, the thermosetting resin comprises any one or a combination of at least two of a polyimide resin, a phthalonitrile resin or a phenolic cyanate ester resin.

[0014] As a preferred technical solution of the present application, the super-aligned carbon nanotube film is prepared from a carbon nanotube array.

[0015] Preferably, the thickness of the super-aligned carbon nanotube film is 40-100 μm, for example, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm or 90 μm, etc., and preferably 40-60 μm.

[0016] Preferably, in the carbon nanotube array, the diameter of the carbon nanotubes is 10-20 nm, for example, 10 nm, 15 nm or 20 nm, etc., and the height of the carbon nanotube array is 200-1000 μm, for example, 200 μm, 500 μm, 750 μm or 1000 μm, etc., and preferably 300 μm.

[0017] As a preferred technical solution of the present application, the single-layer thickness of the carbon fiber structure layer is 80-150 μm, for example, 80 μm, 100 μm, 125 μm or 150 μm, etc., and preferably 200 μm.

[0018] Preferably, the number of layers of the carbon fiber structure layer is 15-30 layers, for example, 15 layers, 20 layers, 25 layers or 30 layers, etc.

[0019] Preferably, the material of the insulating protective layer comprises any one or a combination of two or more of glass fiber prepreg, aramid fiber prepreg, PBO fiber prepreg or polyimide fiber prepreg.

[0020] Preferably, the single-layer thickness of the insulating protective layer is 50-400 μm, for example, it can be 50 μm, 100 μm, 200 μm, 300 μm or 400 μm, etc., preferably 50-100 μm.

[0021] Preferably, the number of layers of the insulating protective layer is 1-5 layers, for example, it can be 1 layer, 2 layers, 3 layers, 4 layers or 5 layers, etc.

[0022] In a second aspect, the present application provides a preparation method of the composite material according to the first aspect, the preparation method comprising the following steps:

[0023] The carbon fiber prepreg is placed at the bottom of the mold, and then the insulating prepreg and the super-aligned carbon nanotube film prepreg are stacked in sequence, and after curing and forming, the composite material for 200 kA lightning protection is obtained.

[0024] As a preferred technical solution of the present application, the preparation method of the super-aligned carbon nanotube film prepreg comprises:

[0025] (a) pre-curing the thermosetting resin, then coating the pre-cured thermosetting resin on the release paper to obtain a film;

[0026] (b) placing the super-aligned carbon nanotube film between the two films, and making the side of the release paper with the thermosetting resin contact the super-aligned carbon nanotube film, then performing infiltration treatment to obtain the super-aligned carbon nanotube film prepreg.

[0027] In the present application, the purpose of pre-curing the thermosetting resin is to improve the operability of the carbon nanotube film after pre-impregnation. When manually or mechanically operating, the prepreg is in a semi-solid state and has certain viscosity.

[0028] As a preferred technical solution of the present application, the pre-cured thermosetting resin of step (a) is in a semi-solid state at room temperature.

[0029] Preferably, the viscosity of the pre-cured thermosetting resin of step (a) is 10-20 Pa·s, for example, it can be 10 Pa·s, 12 Pa·s, 14 Pa·s, 16 Pa·s, 18 Pa·s or 20 Pa·s, etc.

[0030] Preferably, the coating method of step (a) comprises manual coating or film coating machine coating.

[0031] Preferably, the pressure during the infiltration treatment of step (b) is 2-3 MPa, for example, it can be 2 MPa, 2.3 MPa, 2.5 MPa, 2.8 MPa or 3 MPa, etc.

[0032] Preferably, the temperature during the infiltration treatment of step (b) is 80-100℃, for example, it can be 80℃, 85℃, 90℃, 95℃ or 100℃, etc.

[0033] Preferably, the method for preparing the composite material comprises the following steps:

[0034] As a preferred technical solution of the present application, the preparation method comprises the following steps:

[0035] (1) Pre-solidify the thermosetting resin so that the pre-solidified thermosetting resin is semi-solid at room temperature with a viscosity of 10-20 Pa·s, then coat the pre-solidified thermosetting resin on the release paper to obtain a film;

[0036] Place the super-aligned carbon nanotube film between the two films, and make the side of the release paper with thermosetting resin contact the super-aligned carbon nanotube film, then perform infiltration treatment at 2-3 MPa and 80-100℃ to obtain a super-aligned carbon nanotube film prepreg;

[0037] (2) Preheat the mold at 40-60℃ (for example, it can be 40℃, 50℃ or 60℃, etc.) for 1-3 h (for example, it can be 1 h, 2 h or 3 h, etc.), then place the carbon fiber prepreg at the bottom of the preheated mold, lay 15-30 layers, then lay 1-5 layers of insulating prepreg and 1500-3000 layers of super-aligned carbon nanotube film prepreg on the carbon fiber prepreg in turn, and then close the mold upper mold and baffle and fix the bolts;

[0038] (3) Place the mold on the molding machine at 60-100℃ (for example, it can be 60℃, 70℃, 80℃, 90℃ or 100℃, etc.) for 20-40 min (for example, it can be 20 min, 30 min or 40 min, etc.), then cure at 100-200℃ (for example, it can be 100℃, 200℃ or 300℃, etc.) and 2-3 MPa (for example, it can be 2 MPa, 2.5 MPa or 3 MPa, etc.) for 1-2 h (for example, it can be 1 h, 1.5 h or 2 h, etc.), and then cool to room temperature after curing to obtain the composite material for 200 kA lightning protection.

[0039] In a third aspect, the present application provides a use of the composite material as described in the first aspect in the preparation of lightning protection materials.

[0040] The numerical ranges recited herein are inclusive of the endpoints and of any range that would be formed by the inclusion of any of the recited points. To the extent that any numerical ranges are recited herein by endpoints, all

[0041] Compared with the prior art, the present application has the following beneficial effects:

[0042] (1) The composite material prepared by the present application has excellent surface state and high conductivity, and can be used for lightning protection of 200kA level.

[0043] (2) The preparation method provided by the present application improves the wettability of carbon nanotubes, enhances the bonding force between the carbon nanotubes and the insulating protective layer, and improves the lightning protection capacity of the composite material to 200Ka. Compared with the traditional copper mesh, the weight of the lightning protection layer can be reduced. BRIEF DESCRIPTION OF DRAWINGS

[0044] Figure 1 The optical photograph of the composite material prepared in Example 1 in the present application after being subjected to 200kA level lightning impact.

[0045] Figure 2 The non-destructive flaw detection c scan graph of the composite material prepared in Example 1 in the present application after being subjected to 200kA level lightning impact.

[0046] Figure 3 The non-destructive flaw detection b scan graph of the composite material prepared in Example 1 in the present application after being subjected to 200kA level lightning impact.

[0047] Figure 4 The optical photograph of the composite material prepared in Example 2 in the present application after being subjected to 200kA level lightning impact.

[0048] Figure 5 The non-destructive flaw detection c scan graph of the composite material prepared in Example 2 in the present application after being subjected to 200kA level lightning impact.

[0049] Figure 6 The non-destructive flaw detection b scan graph of the composite material prepared in Example 2 in the present application after being subjected to 200kA level lightning impact.

[0050] Figure 7 The optical photograph of the composite material prepared in Comparative Example 1 in the present application after being subjected to 200kA level lightning impact.

[0051] Figure 8 The non-destructive flaw detection c scan graph of the composite material prepared in Comparative Example 1 in the present application after being subjected to 200kA level lightning impact.

[0052] Figure 9The b-scan of the composite material prepared in the present application Comparative Example 1 after 200 kA level lightning impact.

[0053] Figure 10 The optical photograph of the composite material prepared in the present application Comparative Example 2 after 200 kA level lightning impact.

[0054] Figure 11 The c-scan of the composite material prepared in the present application Comparative Example 2 after 200 kA level lightning impact.

[0055] Figure 12 The b-scan of the composite material prepared in the present application Comparative Example 2 after 200 kA level lightning impact.

[0056] Figure 13 The surface morphology of the composite material prepared in the present application Comparative Example 3. DETAILED DESCRIPTION

[0057] The technical solutions of the present application will be further described below through specific embodiments. Those skilled in the art should understand that the embodiments are only used to help understand the present application and should not be regarded as specific limitations on the present application.

[0058] In the following embodiments, room temperature refers to 25℃.

[0059] Example 1

[0060] The present embodiment provides a composite material for 200 kA level lightning protection, which comprises a carbon fiber structure layer, an insulating protection layer and a super-aligned carbon nanotube film prepreg layer arranged in sequence.

[0061] The thickness of the super-aligned carbon nanotube film prepreg layer is 30 μm, the super-aligned carbon nanotube film prepreg layer is 1500 layers, the super-aligned carbon nanotube film prepreg layer is composed of a super-aligned carbon nanotube film and a thermosetting resin (i.e. TDE85 epoxy resin), the number of layers of the carbon fiber structure layer is 24 layers, and the total thickness is 2.2 mm, the material of the insulating protection layer is glass fiber prepreg, the single layer thickness of the insulating protection layer is 300 μm, and the number of layers of the insulating protection layer is 3 layers.

[0062] The present embodiment also provides a preparation method of the above-mentioned composite material for 200 kA level lightning protection, which comprises the following steps:

[0063] (1) pre-curing the thermosetting resin so that the pre-cured thermosetting resin is semi-solid at room temperature and has a viscosity of 15 Pa·s at 80℃, and then manually coating the pre-cured thermosetting resin on a release paper to obtain a film;

[0064] The super-aligned carbon nanotube film is placed between two said adhesive films, and the side of the release paper with the thermosetting resin is contacted with the super-aligned carbon nanotube film, and then the resin is infiltrated into the carbon nanotube by a compounding machine at 2.5 MPa and 90°C to obtain a super-aligned carbon nanotube film prepreg;

[0065] (2) The mold is preheated at 50°C for 2 h, then the carbon fiber prepreg is placed at the bottom of the preheated mold, 24 layers are laid, then 3 layers of insulating prepreg and 1500 layers of super-aligned carbon nanotube film prepreg are laid in turn on the carbon fiber prepreg, and then the mold upper mold and baffle are closed and fixed by bolts;

[0066] (3) The mold is placed on the molding machine at 80°C for 30 min, then cured at 150°C and 2.5 MPa for 1 h, and cooled to room temperature after curing;

[0067] (4) The mold is disassembled and the processed sample is taken out, thereby obtaining the composite material for 200 kA lightning protection.

[0068] Example 2

[0069] The embodiment provides a composite material for 200 kA lightning protection, which comprises a carbon fiber structure layer, an insulating protection layer and a super-aligned carbon nanotube film prepreg layer which are sequentially stacked.

[0070] The thickness of the super-aligned carbon nanotube film prepreg layer is 40 μm, the super-aligned carbon nanotube film prepreg layer is 2000 layers, the super-aligned carbon nanotube film prepreg layer is composed of a super-aligned carbon nanotube film and a thermosetting resin (i.e. a polyimide resin), the number of layers of the carbon fiber structure layer is 24 layers, and the total thickness is 2.2 mm, the material of the insulating protection layer is glass fiber prepreg, the single-layer thickness of the insulating protection layer is 300 μm, and the number of layers of the insulating protection layer is 3 layers.

[0071] The embodiment also provides a preparation method of the composite material for 200 kA lightning protection, and the preparation method comprises the following steps:

[0072] (1) The thermosetting resin is pre-cured, so that the pre-cured thermosetting resin is semi-solid at room temperature and has a viscosity of 15 Pa·s at 80°C, then the pre-cured thermosetting resin is manually coated on the release paper to obtain an adhesive film;

[0073] The super-aligned carbon nanotube film is placed between two said adhesive films, and the side of the release paper with the thermosetting resin is in contact with the super-aligned carbon nanotube film, and then the resin is infiltrated into the carbon nanotubes by a compounding machine at 2.5 MPa and 90°C to obtain a super-aligned carbon nanotube film prepreg;

[0074] (2) The mold is preheated at 50°C for 2 h, then the carbon fiber prepreg is placed at the bottom of the preheated mold, 24 layers are laid, then 3 layers of insulating prepreg and 2000 layers of super-aligned carbon nanotube film prepreg are laid in turn on the carbon fiber prepreg, and then the mold upper mold and baffle are closed and fixed by bolts;

[0075] (3) The mold is placed on the molding machine at 80°C for 30 min, then cured at 150°C and 2.5 MPa for 1 h, and cooled to room temperature after curing;

[0076] (4) The mold is disassembled and the processed sample is taken out, thereby obtaining the composite material for 200kA lightning protection.

[0077] Example 3

[0078] The embodiment provides a composite material for 200kA lightning protection, which comprises a carbon fiber structure layer, an insulating protection layer and a super-aligned carbon nanotube film prepreg layer which are sequentially stacked.

[0079] The thickness of the super-aligned carbon nanotube film prepreg layer is 30 μm, the super-aligned carbon nanotube film prepreg layer is 1500 layers, the super-aligned carbon nanotube film prepreg layer is composed of a super-aligned carbon nanotube film and a thermosetting resin (i.e. phthalonitrile resin), the number of layers of the carbon fiber structure layer is 10 layers, and the total thickness is 0.9 μm, the material of the insulating protection layer is glass fiber prepreg, the thickness of a single layer of the insulating protection layer is 100 μm, and the number of layers of the insulating protection layer is 1 layer.

[0080] The embodiment also provides a preparation method of the composite material for 200kA lightning protection, and the preparation method comprises the following steps:

[0081] (1) The thermosetting resin is pre-cured to make the pre-cured thermosetting resin be in a semi-solid state at room temperature and have a viscosity of 15 Pa·s at 80°C, and then the pre-cured thermosetting resin is manually coated on a release paper to obtain an adhesive film;

[0082] The super-aligned carbon nanotube film is placed between two said adhesive films, and the side of the release paper with the thermosetting resin is in contact with the super-aligned carbon nanotube film, and then the resin is infiltrated into the carbon nanotubes by a compounding machine at 2.5 MPa and 90°C to obtain a super-aligned carbon nanotube film prepreg;

[0083] (2) Preheat the mold for 3h at 40℃, then place the carbon fiber prepreg at the bottom of the preheated mold, lay 10 layers, then lay 1 layer of insulating prepreg and 1500 layers of the super-aligned carbon nanotube film prepreg on the carbon fiber prepreg in turn, then close the mold upper mold and baffle, and fix with bolts;

[0084] (3) Place the mold on the molding machine at 60℃ for 40min, then cure at 100℃, 2MPa for 2h, and cool to room temperature after curing;

[0085] (4) Disassemble the mold and take out the processed sample to obtain the composite material for 200kA lightning protection.

[0086] Example 4

[0087] The embodiment provides a composite material for 200kA lightning protection, the composite material comprising a carbon fiber structure layer, an insulating protection layer and a super-aligned carbon nanotube film prepreg layer which are sequentially stacked.

[0088] The thickness of the super-aligned carbon nanotube film prepreg layer is 120μm, the super-aligned carbon nanotube film prepreg layer is 6000 layers, the super-aligned carbon nanotube film prepreg layer is composed of a super-aligned carbon nanotube film and a thermosetting resin (i.e. a phenolic cyanate ester resin), the number of layers of the carbon fiber structure layer is 30 layers, and the total thickness is 4.5mm, the material of the insulating protection layer is glass fiber prepreg, the single layer thickness of the insulating protection layer is 400μm, and the number of layers of the insulating protection layer is 4 layers.

[0089] The embodiment also provides a preparation method of the composite material for 200kA lightning protection.

[0090] (1) Pre-cure the thermosetting resin so that the pre-cured thermosetting resin is semi-solid at room temperature and has a viscosity of 15Pa·s at 80℃, then manually coat the pre-cured thermosetting resin on release paper to obtain a glue film;

[0091] Place the super-aligned carbon nanotube film between two glue films, and make the side of the release paper with the thermosetting resin contact the super-aligned carbon nanotube film, then make the resin infiltrate the carbon nanotube by a compounding machine at 2.5Mpa and 90℃ to obtain a super-aligned carbon nanotube film prepreg;

[0092] (2) Preheat the mold at 60°C for 1 h, then place the carbon fiber prepreg at the bottom of the preheated mold, lay 30 layers, then lay 4 layers of insulating prepreg and 6000 layers of the super-aligned carbon nanotube film prepreg on the carbon fiber prepreg in turn, and then close the mold, the baffle, and fix the bolt;

[0093] (3) Place the mold on the molding machine at 100°C for 20 min, then cure at 200°C and 3 MPa for 2 h, and cool to room temperature after curing;

[0094] (4) Disassemble the mold and take out the processed sample to obtain the composite material for 200 kA lightning protection.

[0095] Example 5

[0096] The difference between this example and Example 1 is that the thermosetting resin is not pre-cured in step (1).

[0097] The rest of the preparation method and parameters remain the same as in Example 1.

[0098] The difference between this example and Example 1 is that the temperature of the infiltration treatment in step (1) is 40°C.

[0099] (Temperature is too small)

[0100] The rest of the preparation method and parameters remain the same as in Example 1.

[0101] Example 7

[0102] The difference between this example and Example 1 is that the temperature of the infiltration treatment in step (1) is 120°C.

[0103] (Temperature is too large)

[0104] The rest of the preparation method and parameters remain the same as in Example 1.

[0105] Comparative Example 1

[0106] The difference between this comparative example and Example 1 is that the composite material only includes a carbon fiber structure layer, i.e., step (1) is not performed, and the insulating prepreg and the super-aligned carbon nanotube film prepreg are not laid in step (2).

[0107] The rest of the preparation method and parameters remain the same as in Example 1.

[0108] Comparative Example 2

[0109] The difference between this comparative example and Example 1 is that the super-aligned carbon nanotube film prepreg layer is 1000 layers, i.e., the thickness of the super-aligned carbon nanotube film prepreg layer is 20 μm.

[0110] The rest of the preparation method and parameters are consistent with Example 1.

[0111] Comparative Example 3

[0112] The difference between this comparative example and Example 2 is that the super-aligned carbon nanotube film is only a finished film, and no prepreg processing is performed.

[0113] The rest of the preparation method and parameters are consistent with Example 2.

[0114] Comparative Example 4

[0115] The difference between this comparative example and Example 1 is that the thickness of the super-aligned carbon nanotube film prepreg layer is 150 μm.

[0116] The rest of the preparation method and parameters are consistent with Example 1.

[0117] Performance test

[0118] The composite materials prepared in the above examples and comparative examples are subjected to 200 kA lightning impact test, and ultrasonic waves are used to evaluate the damage to the composite materials, and the bending strength of the composite materials is tested.

[0119] The test results are shown in Figures 1-13 and Table 1.

[0120] Figure 1 , Figure 2 and Figure 3 respectively show the optical photograph, non-destructive testing c-scan and non-destructive testing b-scan of the composite material prepared in Example 1 after 200 kA level lightning impact. As can be seen from the figures, there is no obvious change on the surface of the carbon fiber after lightning impact test, which shows that the composite material can be used for lightning protection.

[0121] Figure 4 , Figure 5 and Figure 6 respectively show the optical photograph, non-destructive testing c-scan and non-destructive testing b-scan of the composite material prepared in Example 2 after 200 kA level lightning impact. As can be seen from the figures, there is no obvious change on the surface of the carbon fiber after lightning impact test, which shows that the composite material can be used for lightning protection.

[0122] Figure 7 , Figure 8 and Figure 9 respectively show the optical photograph, non-destructive testing c-scan and non-destructive testing b-scan of the composite material prepared in Comparative Example 1 after 200 kA level lightning impact. As can be seen from the figures, the surface of the carbon fiber is seriously ablated after lightning impact test, which shows that the material is not suitable for 200 kA level lightning protection.

[0123] Figure 10 , Figure 11 and Figure 12 respectively show the optical photo, non-destructive c-scan and non-destructive b-scan of the composite material prepared in Comparative Example 2 after 200kA level lightning impact, from which it can be seen that the carbon fiber surface is seriously ablated after lightning impact test, indicating that the material is not suitable for 200kA level lightning protection.

[0124] Figure 13 shows the surface morphology of the composite material prepared in Comparative Example 3, from which it can be seen that the carbon nanotube surface of the composite material is seriously lacking in glue, which does not have engineering application prospect.

[0125] Table 1

[0126]

[0127]

[0128] Analysis:

[0129] From the above table, the present application prepares a composite material with excellent surface state and high conductivity, which can be used for 200kA level lightning protection.

[0130] From Example 1 and Example 5, if the thermosetting resin is not pre-solidified, the prepared composite material has poor operability, the resin has high flowability during curing, which easily causes surface lack of glue and does not play a protective role.

[0131] From Example 1 and Examples 6-7, if the temperature of the infiltration treatment is too low, the resin and the carbon nanotube have poor wettability, causing local lack of glue and defects, resulting in breakdown of the composite material; if the temperature of the infiltration treatment is too high, the carbon nanotube prepreg will be cured, causing surface cracking during curing and forming cracks that cause lightning breakdown.

[0132] From Example 1 and Comparative Example 1, if the composite material only includes a carbon fiber structure layer, the carbon fiber surface is seriously ablated after lightning impact test, and ultrasonic flaw detection shows that the carbon fiber composite material produces a crack in the longitudinal direction.

[0133] From Example 1 and Comparative Example 2, if the thickness of the aligned carbon nanotube film prepreg layer is too thin, the carbon fiber surface is seriously ablated after lightning impact test, and ultrasonic flaw detection shows that the carbon fiber composite material produces a crack in the longitudinal direction.

[0134] From Example 1 and Comparative Example 3, if the aligned carbon nanotube film is not pre-impregnated, the prepared composite material has a serious lack of glue on the surface of the carbon nanotube, which does not have engineering application prospect.

[0135] From Example 1 and Comparative Example 4, if the thickness of the super-aligned carbon nanotube film prepreg layer is too thick, the carbon nanotubes cannot be infiltrated, resulting in internal lack of glue, poor mechanical strength of the protective layer, and easy damage of the protective layer under lightning strike, failing to achieve the protection effect.

[0136] Applicant declares that the process of the present application is illustrated by the above examples, but the present application is not limited to the above process steps, i.e. it does not mean that the present application must rely on the above process steps to be implemented. It should be understood by those skilled in the art that any improvement of the present application, equivalent replacement of the raw materials selected by the present application, addition of auxiliary ingredients, selection of specific methods, etc. fall within the protection scope and disclosure scope of the present application.

Claims

1. A composite material for 200kA lightning protection, characterized in that, The composite material comprises a carbon fiber structural layer, an insulating protective layer, and a super-aligned carbon nanotube film prepreg layer stacked sequentially. The super-aligned carbon nanotube film prepreg layer is composed of a super-aligned carbon nanotube film and a thermosetting resin; The super-aligned carbon nanotube film prepreg layer comprises at least 1500 layers of super-aligned carbon nanotube film prepreg. The preparation method of the super-aligned carbon nanotube film prepreg includes: (a) Pre-curing the thermosetting resin and then coating the pre-cured thermosetting resin onto release paper to obtain an adhesive film; (b) Place the super-aligned carbon nanotube film between the two adhesive films, and make the release paper side with thermosetting resin in contact with the super-aligned carbon nanotube film, and then perform an impregnation treatment to obtain the super-aligned carbon nanotube film prepreg. The temperature for the immersion treatment is 80-100℃; The thickness of the super-aligned carbon nanotube film prepreg layer is 30-120 μm.

2. The composite material according to claim 1, characterized in that, The super-aligned carbon nanotube film prepreg layer comprises 1500-3000 layers.

3. The composite material according to claim 1, characterized in that, The super-aligned carbon nanotube film prepreg layer comprises 2000 layers.

4. The composite material according to claim 1, characterized in that, The thermosetting resin includes any one or a combination of at least two of polyimide resin, phthalonitrile resin, or phenolic cyanate ester resin.

5. The composite material according to claim 1, characterized in that, The super-aligned carbon nanotube film was prepared by a carbon nanotube array.

6. The composite material according to claim 1, characterized in that, The thickness of the super-aligned carbon nanotube film is 40-100 μm.

7. The composite material according to claim 1, characterized in that, The thickness of the super-aligned carbon nanotube film is 40-60 μm.

8. The composite material according to claim 5, characterized in that, In the carbon nanotube array, the diameter of the carbon nanotubes is 10-20 nm, and the height of the carbon nanotube array is 200-1000 μm.

9. The composite material according to claim 1, characterized in that, The carbon fiber structural layer has 15-30 layers.

10. The composite material according to claim 9, characterized in that, The thickness of a single layer in the carbon fiber structure is 80-150 μm.

11. The composite material according to claim 9, characterized in that, The thickness of a single layer in the carbon fiber structure is 200 μm.

12. The composite material according to claim 1, characterized in that, The material of the insulating protective layer includes any one or a combination of at least two of glass fiber prepreg, aramid fiber prepreg, PBO fiber prepreg, or polyimide fiber prepreg.

13. The composite material according to claim 1, characterized in that, The number of insulating protective layers is 1-5.

14. The composite material according to claim 13, characterized in that, The thickness of a single layer in the insulating protective layer is 50-400 μm.

15. The composite material according to claim 13, characterized in that, The thickness of a single layer in the insulating protective layer is 50-100 μm.

16. A method for preparing a composite material according to any one of claims 1-15, characterized in that, The preparation method includes the following steps: Carbon fiber prepreg is placed at the bottom of the mold, and then insulating prepreg and super-aligned carbon nanotube film prepreg are stacked in sequence. After curing, the composite material for 200kA lightning protection is obtained. The preparation method of the super-aligned carbon nanotube film prepreg includes: (a) Pre-curing the thermosetting resin and then coating the pre-cured thermosetting resin onto release paper to obtain an adhesive film; (b) Place the super-aligned carbon nanotube film between the two adhesive films, and make the release paper side with thermosetting resin in contact with the super-aligned carbon nanotube film, and then perform an impregnation treatment to obtain the super-aligned carbon nanotube film prepreg. The temperature during the immersion treatment in step (b) is 80-100℃.

17. The preparation method according to claim 16, characterized in that, The pre-cured thermosetting resin described in step (a) is semi-solid at room temperature.

18. The preparation method according to claim 16, characterized in that, The viscosity of the pre-cured thermosetting resin in step (a) is 10-20 Pa·s.

19. The preparation method according to claim 16, characterized in that, The coating method described in step (a) includes manual coating or coating machine coating.

20. The preparation method according to claim 16, characterized in that, The pressure during the impregnation treatment in step (b) is 2-3 MPa.

21. The preparation method according to claim 16, characterized in that, The impregnation process described in step (b) can be performed by manual impregnation or by a laminating machine.

22. The preparation method according to claim 16, characterized in that, The preparation method includes the following steps: (1) The thermosetting resin is pre-cured so that the pre-cured thermosetting resin is semi-solid at room temperature and has a viscosity of 10-20 Pa·s. Then the pre-cured thermosetting resin is coated on release paper to obtain an adhesive film. A super-aligned carbon nanotube film is placed between two adhesive films, with the release paper containing thermosetting resin in contact with the super-aligned carbon nanotube film. Then, it is impregnated at 2-3 MPa and 80-100°C to obtain a super-aligned carbon nanotube film prepreg. (2) At 40-60℃, preheat the mold for 1-3 hours, then place the carbon fiber prepreg at the bottom of the preheated mold and lay 15-30 layers, then lay 1-5 layers of insulating prepreg and 1500-3000 layers of super-aligned carbon nanotube film prepreg on the carbon fiber prepreg, then close the upper mold and baffle, and fix it with bolts; (3) Place the mold on a molding machine at 60-100℃ for 20-40 minutes, and then cure it at 100-200℃ and 2-3MPa for 1-2 hours. After curing, cool it to room temperature to obtain the composite material for 200kA lightning protection.

23. The use of a composite material as described in any one of claims 1-15 in the preparation of lightning protection materials.

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