Asymmetric carbon fiber profiled puncture fabric and preparation method thereof

Abstract

The present invention provides an asymmetric carbon fiber profiled puncture fabric and a preparation method thereof, wherein the asymmetric carbon fiber profiled puncture fabric comprises a carbon fiber cloth and a Z-direction fiber bundle; the Z-direction fiber bundle forms the asymmetric carbon fiber profiled puncture fabric by puncturing several layers of the carbon fiber cloth in the X-Y direction; the distribution of the Z-direction fiber bundle in the X-Y direction includes n distribution areas from the center of the carbon fiber cloth to the outside in sequence, wherein n is an integer ≥ 2, and the spacing of the Z-direction fiber bundle in the i-th distribution area is less than the spacing of the Z-direction fiber bundle in the i-1st distribution area, and i is an integer from 1 to n. The present invention can improve the overall carbon fiber cloth to be more uniformly stressed during the puncture and fiber replacement process, and finally obtain an asymmetric carbon fiber profiled puncture fabric product with small wrinkles of the carbon fiber cloth and less internal metal debris.

Description

Technical Field

[0001] The invention relates to the technical field of carbon fiber puncture fabrics, in particular to an asymmetric carbon fiber profile puncture fabric and a preparation method thereof. Background Art

[0002] With the development of new spacecraft in the fields of future aerospace, hypersonic and deep space exploration, spacecraft will face extremely high temperature airflow and gas friction during flight, and the surface of the spacecraft will be burned and eroded, seriously affecting its performance and life. Higher requirements are put forward for advanced composite materials, and composite materials reinforced by asymmetric carbon fiber contoured puncture fabrics can effectively disperse and transmit the huge high temperature generated by high-speed airflow friction, reduce the ablation of high-speed aircraft heat protection materials, improve the heat protection performance of ablation-resistant composite materials, and improve the technical indicators of high-speed aircraft.

[0003] Therefore, the preparation technology of composite materials reinforced with asymmetric carbon fiber contoured puncture fabrics has become a key technology that must be overcome in the research and development of new aircraft at home and abroad. Summary of the invention

[0004] In order to solve the above technical problems, the present invention provides an asymmetric carbon fiber profiled puncture fabric and a preparation method thereof. By setting the spacing between the middle puncture needles to be large and the spacing between the outer puncture needles to be small, the wrinkles of the carbon fiber cloth can be reduced, and an asymmetric carbon fiber profiled puncture fabric with excellent performance can be obtained.

[0005] To achieve this object, the present invention adopts the following technical solutions:

[0006] In a first aspect, the present invention provides an asymmetric carbon fiber profiled puncture fabric, wherein the asymmetric carbon fiber profiled puncture fabric comprises a carbon fiber cloth and a Z-direction fiber bundle;

[0007] The Z-direction fiber bundle forms the asymmetric carbon fiber contoured puncture fabric by puncturing several layers of the carbon fiber cloth in the XY directions;

[0008] The distribution of the Z-direction fiber bundles in the XY directions includes n distribution areas from the center of the carbon fiber cloth to the outside, wherein n is an integer ≥ 2, and the spacing of the Z-direction fiber bundles in the i-th distribution area is less than the spacing of the Z-direction fiber bundles in the i-1th distribution area, and i is an integer from 1 to n.

[0009] It is worth noting that during the puncture and fiber replacement process of the carbon fiber cloth, the friction in the middle is large. By setting the spacing between the middle puncture needles to be large and the spacing between the outer puncture needles to be small, the overall carbon fiber cloth can be subjected to more uniform force during the puncture and fiber replacement process, and ultimately an asymmetric carbon fiber contoured puncture fabric with small carbon fiber cloth wrinkles and less internal metal debris can be obtained.

[0010] Preferably, the spacing of the Z-direction fiber bundles in the i-th distribution area is 0.1 to 0.2 mm smaller than the spacing of the Z-direction fiber bundles in the i-1 distribution area, for example, it may be 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, 0.18 mm, 0.19 mm or 0.2 mm, etc.

[0011] The distribution of the Z-direction fiber bundles in the XY direction includes three distribution areas from the center of the carbon fiber cloth to the outside, wherein the spacing between the Z-direction fiber bundles in the first distribution area is 1.8-2.0 mm, for example, it can be 1.8 mm, 1.82 mm, 1.83 mm, 1.84 mm, 1.85 mm, 1.89 mm, 1.90 mm, 1.92 mm, 1.93 mm, 1.94 mm, 1.95 mm, 1.98 mm or 2.0 mm; the spacing between the Z-direction fiber bundles in the second distribution area is 1.6-1.8 mm, for example It can be 1.6mm, 1.62mm, 1.63mm, 1.64mm, 1.65mm, 1.68mm, 1.69mm, 1.7mm, 1.72mm, 1.75mm, 1.78mm or 1.8mm, etc.; the spacing between the Z-direction fiber bundles in the third distribution area is 1.4-1.6mm, for example, it can be 1.4mm, 1.41mm, 1.42mm, 1.45mm, 1.48mm, 1.5mm, 1.52mm, 1.55mm, 1.58mm or 1.6mm, etc.

[0012] Preferably, the wrinkle width of the carbon fiber cloth in the XY direction in the asymmetric carbon fiber profiled puncture fabric is ≤50 mm, for example, it can be 50 mm, 49 mm, 48 mm, 45 mm or 40 mm, and / or the size of the metal debris in the asymmetric carbon fiber profiled puncture fabric is ≤3 mm and the number of metal debris with a size ≥1 mm is ≤3, for example, it can be 3, 2, 1 or 0, etc.

[0013] Preferably, the asymmetric carbon fiber contoured puncture fabric comprises a first X-direction segment, a second Y-direction segment and a third arc-shaped segment connected; the second Y-direction segment comprises a first sub-Y-direction segment and a second sub-Y-direction segment; two ends of the first sub-Y-direction segment are respectively connected to the first end of the first X-direction segment and the first end of the third arc-shaped segment; two ends of the second sub-Y-direction segment are respectively connected to the second end of the first X-direction segment and the second end of the third arc-shaped segment.

[0014] The first sub-Y-direction section and the second sub-Y-direction section are directions that form a certain angle with the X-direction, but they are not required to be parallel or symmetrical.

[0015] Preferably, the dimensions of the asymmetric carbon fiber profiled puncture fabric are ≥ maximum length 300 mm×maximum width 120 mm×maximum height 100 mm.

[0016] Preferably, the interlayer density of the asymmetric carbon fiber profiled puncture fabric is ≥40 layers / cm, for example, it can be 40 layers / cm, 41 layers / cm, 42 layers / cm, 43 layers / cm, 45 layers / cm, 48 layers / cm or 50 layers / cm, etc.; and / or, the Z-direction spacing of the asymmetric carbon fiber profiled puncture fabric is 1.4-2.0 mm, for example, it can be 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm or 2.0 mm, etc.

[0017] Preferably, the volume density of the asymmetric carbon fiber profiled puncture fabric is ≥ 0.85 g / cm 3 , for example, it can be 0.85 g / cm 3 , 0.86g / cm 3 , 0.87g / cm 3 , 0.88g / cm 3 , 0.89g / cm 3 , 0.90g / cm 3 、0.91g / cm 3 or 0.92g / cm 3 wait.

[0018] Preferably, the ply angle of the carbon fiber cloth in the X direction is 0° to 90°, for example, 0°, 30°, 45°, 60° or 90°.

[0019] The penetration mode of the Z-direction fiber bundle in the present invention is two-strand bidirectional penetration.

[0020] In a second aspect, the present invention provides a method for preparing the asymmetric carbon fiber contoured puncture fabric according to the first aspect, the preparation method comprising:

[0021] The puncture needles are distributed in n distribution areas in the XY direction from the center of the carbon fiber cloth to the outside, forming a needle array. Where n is an integer ≥ 2, and the spacing of the puncture needles in the i-th distribution area is less than the spacing of the puncture needles in the i-1th distribution area, and i is an integer from 1 to n;

[0022] Then, the puncture steel needle is passed through several layers of carbon fiber cloth, and after pressurization and densification and Z-direction fiber bundle replacement of the steel needle, the asymmetric carbon fiber contour puncture fabric is obtained.

[0023] The preparation method provided in the second aspect of the present invention can obtain a product in which the overall carbon fiber cloth is subjected to more uniform force during puncture and fiber replacement.

[0024] Preferably, the spacing between the puncture needles in the i-th distribution area is 0.1 to 0.2 mm smaller than the spacing between the puncture needles in the i-1 distribution area, for example, it can be 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, 0.16 mm, 0.17 mm, 0.18 mm, 0.19 mm or 0.2 mm, etc.

[0025] Preferably, the specification of the carbon fiber in the carbon fiber cloth is any one of 3K, 6K, 12K, 24K or 48K or a combination of at least two thereof, and / or the specification of the Z-direction fiber bundle is any one of 1K, 3K or 6K or a combination of at least two thereof.

[0026] Compared with the prior art, the present invention has at least the following beneficial effects:

[0027] The structural design and preparation method of the asymmetric carbon fiber profiled puncture fabric provided by the present invention can obtain a carbon fiber profiled puncture fabric product with an asymmetric structure, and the overall carbon fiber cloth is more evenly stressed during the puncture and fiber replacement process. The carbon fiber cloth in the final product has small wrinkles and less internal metal debris, and has broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 Schematic diagram of the asymmetric carbon fiber contoured puncture fabric provided in Example 1 of the present invention.

[0029] In the figure, 1 is the first X-direction segment; 21 is the first sub-Y-direction segment; 22 is the second sub-Y-direction segment; 3 is the third arc segment. DETAILED DESCRIPTION

[0030] For the convenience of understanding the present invention, the present invention lists the following embodiments. It should be understood by those skilled in the art that the embodiments are only to help understand the present invention and should not be regarded as specific limitations of the present invention.

[0031] It should be understood that, in the description of the present invention, the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, the terms "first", "second", etc. are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0032] It should be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "disposed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood by specific circumstances.

[0033] Example 1

[0034] This embodiment provides an asymmetric carbon fiber profiled puncture fabric, wherein the asymmetric carbon fiber profiled puncture fabric comprises a carbon fiber cloth and a Z-direction fiber bundle;

[0035] The Z-direction fiber bundle forms the asymmetric carbon fiber contoured puncture fabric by puncturing several layers of the carbon fiber cloth in the XY directions;

[0036] The distribution of the Z-direction fiber bundles in the XY directions includes three distribution areas from the center of the carbon fiber cloth to the outside, wherein the spacing between the Z-direction fiber bundles in the first distribution area is 2.0 mm; the spacing between the Z-direction fiber bundles in the second distribution area is 1.8 mm; and the spacing between the Z-direction fiber bundles in the third distribution area is 1.6 mm.

[0037] See also Figure 1The asymmetric carbon fiber contoured puncture fabric includes a first X-direction segment 1, a second Y-direction segment and a third arc-shaped segment 3 which are connected; the second Y-direction segment includes a first sub-Y-direction segment 21 and a second sub-Y-direction segment 22; two ends of the first sub-Y-direction segment 21 are respectively connected to the first end of the first X-direction segment 1 and the first end of the third arc-shaped segment 3; two ends of the second sub-Y-direction segment 22 are respectively connected to the second end of the first X-direction segment 1 and the second end of the third arc-shaped segment 3.

[0038] The interlayer density of the asymmetric carbon fiber profiled puncture fabric is 42 layers / cm, and the volume density of the asymmetric carbon fiber profiled puncture fabric is 0.95 g / cm 3 The carbon fiber cloth is laid at 0° in the X direction.

[0039] This embodiment also provides a method for preparing the above-mentioned asymmetric carbon fiber contoured puncture fabric, the preparation method comprising:

[0040] The puncture steel needles are distributed in three distribution areas in the XY direction from the center of the carbon fiber cloth to the outside to form a steel needle array;

[0041] Then, the puncture steel needle is passed through several layers of carbon fiber cloth, and after pressurization and densification and Z-direction fiber bundle replacement of the steel needle, the asymmetric carbon fiber contour puncture fabric is obtained.

[0042] The spacing of the puncture steel needles in the i-th distribution area is 0.2 mm smaller than the spacing of the puncture steel needles in the i-1th distribution area. The specification of the carbon fiber in the carbon fiber cloth is 3K; the specification of the Z-direction fiber bundle is 1K.

[0043] Example 2

[0044] The difference between this embodiment and embodiment 1 is that the spacing between the Z-direction fiber bundles in the first distribution area is 1.8 mm; the spacing between the Z-direction fiber bundles in the second distribution area is 1.6 mm; and the spacing between the Z-direction fiber bundles in the third distribution area is 1.4 mm.

[0045] The interlayer density of the asymmetric carbon fiber profiled puncture fabric is 43 layers / cm, and the volume density of the asymmetric carbon fiber profiled puncture fabric is 0.85 g / cm 3 The carbon fiber cloth is laid at 60° in the X direction;

[0046] The spacing of the puncture steel needles in the i-th distribution area is 0.2 mm smaller than the spacing of the puncture steel needles in the i-1th distribution area. The specification of the carbon fiber in the carbon fiber cloth is 12K; the specification of the Z-direction fiber bundle is 3K.

[0047] The rest are the same as in Example 1 and will not be described again.

[0048] Example 3

[0049] The difference between this embodiment and embodiment 1 is that the spacing between the Z-direction fiber bundles in the first distribution area is 1.8 mm; the spacing between the Z-direction fiber bundles in the second distribution area is 1.65 mm; the spacing between the Z-direction fiber bundles in the third distribution area is 1.5 mm;

[0050] The interlayer density of the asymmetric carbon fiber profiled puncture fabric is 42 layers / cm, and the volume density of the asymmetric carbon fiber profiled puncture fabric is 0.90 g / cm 3 The carbon fiber cloth is laid at 90° in the X direction;

[0051] The spacing of the puncture steel needles in the i-th distribution area is 0.15 mm smaller than the spacing of the puncture steel needles in the i-1th distribution area. The specification of the carbon fiber in the carbon fiber cloth is 12K; the specification of the Z-direction fiber bundle is 3K.

[0052] The rest are the same as in Example 1 and will not be described again.

[0053] Example 4

[0054] The only difference between this embodiment and Embodiment 1 is that the distribution of the Z-direction fiber bundles in the XY directions includes two distribution areas from the center of the carbon fiber cloth to the outside, wherein the spacing between the Z-direction fiber bundles in the first distribution area is 2.0 mm; the spacing between the Z-direction fiber bundles in the second distribution area is 1.8 mm, and the rest is the same as Embodiment 1 and will not be repeated here.

[0055] Example 5

[0056] The only difference between this embodiment and Embodiment 1 is that: the spacing between the Z-direction fiber bundles in the first distribution area is 1.8 mm; the spacing between the Z-direction fiber bundles in the second distribution area is 1.7 mm; the spacing between the Z-direction fiber bundles in the third distribution area is 1.6 mm, and the spacing between the puncture needles in the i-th distribution area is 0.1 mm smaller than the spacing between the puncture needles in the i-1th distribution area. The rest is the same as Embodiment 1 and will not be repeated here.

[0057] Example 6

[0058] The only difference between this embodiment and Embodiment 1 is that: the spacing between the Z-direction fiber bundles in the first distribution area is 2.0 mm; the spacing between the Z-direction fiber bundles in the second distribution area is 1.6 mm; the spacing between the Z-direction fiber bundles in the third distribution area is 1.2 mm, and the spacing between the puncture needles in the i-th distribution area is 0.4 mm smaller than the spacing between the puncture needles in the i-1th distribution area. The rest is the same as Embodiment 1 and will not be repeated here.

[0059] Comparative Example 1

[0060] This comparative example provides an asymmetric carbon fiber profiled puncture fabric. The asymmetric carbon fiber profiled puncture fabric is the same as Example 1 except that no partitions are set and the spacing between fiber bundles in the Z direction is 2.0 mm, and the rest is not repeated here.

[0061] Comparative Example 2

[0062] This comparative example provides an asymmetric carbon fiber profiled puncture fabric, which is the same as Example 1 except that no partitions are set and the spacing between fiber bundles in the Z direction is 1.6 mm, and the rest is not repeated here.

[0063] Test method: observe the wrinkle width of the carbon fiber cloth in the XY direction in the asymmetric carbon fiber profiled puncture fabric, record the largest wrinkle width (≤45mm is the standard), and count the number of metal debris with a size of ≤3mm and a size of ≥1mm in the asymmetric carbon fiber profiled puncture fabric (≤3 is the standard).

[0064] The test results of the above embodiments and comparative examples are shown in Table 1.

[0065] Table 1

[0066]

[0067]

[0068] From Table 1, we can see the following points:

[0069] (1) It can be seen from Examples 1 to 3 that the asymmetric carbon fiber contoured puncture fabric provided by the present invention has small wrinkles and few internal metal debris, wherein the wrinkle width of the carbon fiber fabric is ≤36 mm, the number of metal debris is ≤1, and the performance is excellent;

[0070] (2) Combining Example 1 and Examples 4 to 6, it can be seen that in Example 1, the distribution of the Z-direction fiber bundle in the XY direction includes three distribution areas from the center of the carbon fiber cloth to the outside, and the spacing range of the Z-direction fiber bundle in each distribution area is preferably set. Compared with Example 4, only the chain distribution areas are set, and the difference between the spacing of the puncture steel needles in the i-th distribution area and the spacing of the puncture steel needles in the i-1 distribution area in Examples 5 to 6 is not within the preferred range, the maximum fold width of the asymmetric carbon fiber profiled puncture fabric finally obtained in Example 1 is only 35 mm, and there is no metal debris, while the number of metal debris in Example 4 is 2, and the maximum fold width of the asymmetric carbon fiber profiled puncture fabric in Examples 5 to 6 is 42 mm and 39 mm, respectively, and the number of metal debris is 3 and 2, respectively. This shows that the present invention further preferably sets the number of partitions and the difference between the spacing of the puncture steel needles in the i-th distribution area and the spacing of the puncture steel needles in the i-1 distribution area within a specific range, which can further improve the product quality of the asymmetric carbon fiber profiled puncture fabric;

[0071] (3) It can be seen from the combination of Example 1 and Comparative Examples 1-2 that no partition is set in Comparative Examples 1-2, which ultimately leads to large wrinkles in the asymmetric carbon fiber contoured puncture fabric and a lot of metal debris inside, making it difficult to meet product requirements.

[0072] The present invention illustrates the detailed features of the present invention through the above embodiments, but the present invention is not limited to the above detailed features, that is, it does not mean that the present invention must rely on the above detailed features to be implemented. Those skilled in the art should understand that any improvement to the present invention, equivalent replacement of the technical features selected by the present invention, addition of auxiliary technical features, selection of specific methods, etc., all fall within the protection scope and disclosure scope of the present invention.

Claims

1. An asymmetric carbon fiber profiled puncture fabric, characterized in that: The asymmetric carbon fiber contoured puncture fabric comprises carbon fiber cloth and Z-direction fiber bundles; The Z-direction fiber bundle forms the asymmetric carbon fiber contoured puncture fabric by puncturing several layers of the carbon fiber cloth in the XY directions; The distribution of the Z-direction fiber bundles in the XY directions includes three distribution areas from the center of the carbon fiber cloth to the outside, wherein the spacing between the Z-direction fiber bundles in the first distribution area is 1.8-2.0 mm; the spacing between the Z-direction fiber bundles in the second distribution area is 1.6-1.8 mm; and the spacing between the Z-direction fiber bundles in the third distribution area is 1.4-1.6 mm.

2. The asymmetric carbon fiber profiled puncture fabric according to claim 1, characterized in that: The wrinkle width of the carbon fiber cloth in the asymmetric carbon fiber profiled puncture fabric in the XY direction is ≤50mm, and / or the size of metal debris in the asymmetric carbon fiber profiled puncture fabric is ≤3mm and the number of metal debris with a size ≥1mm is ≤3.

3. The asymmetric carbon fiber profiled puncture fabric according to claim 1, characterized in that: The asymmetric carbon fiber contoured puncture fabric comprises a first X-direction section, a second Y-direction section and a third arc-shaped section connected; The second Y-direction section includes a first sub-Y-direction section and a second sub-Y-direction section; Two ends of the first sub-Y-direction section are respectively connected to the first end of the first X-direction section and the first end of the third arc-shaped section; Two ends of the second sub-Y-direction segment are respectively connected to the second end of the first X-direction segment and the second end of the third arc segment.

4. The asymmetric carbon fiber profiled puncture fabric according to claim 1, characterized in that: The interlayer density of the asymmetric carbon fiber profiled puncture fabric is ≥40 layers / cm, and / or the Z-direction spacing of the asymmetric carbon fiber profiled puncture fabric is 1.4-2.0 mm.

5. The asymmetric carbon fiber profiled puncture fabric according to claim 1, characterized in that: The volume density of the asymmetric carbon fiber profiled puncture fabric is ≥0.85 g / cm 3 .

6. The asymmetric carbon fiber profiled puncture fabric according to claim 1, characterized in that: The ply angle of the carbon fiber cloth in the X direction is 0° to 90°.

7. A method for preparing the asymmetric carbon fiber profiled puncture fabric according to any one of claims 1 to 6, characterized in that: The preparation method comprises: The puncture needles are distributed in n distribution areas in the XY direction from the center of the carbon fiber cloth to the outside, forming a steel needle array; wherein n is 3, and the spacing of the puncture needles in the i-th distribution area is less than the spacing of the puncture needles in the i-1th distribution area, and i is an integer from 1 to n; Then, the puncture steel needle is passed through several layers of carbon fiber cloth, and after pressurization and densification and Z-direction fiber bundle replacement of the steel needle, the asymmetric carbon fiber contour puncture fabric is obtained.

8. The preparation method according to claim 7, characterized in that: The spacing between the puncture needles in the i-th distribution area is 0.1~0.2mm smaller than the spacing between the puncture needles in the i-1-th distribution area.

9. The preparation method according to claim 7, characterized in that: The specification of the carbon fiber in the carbon fiber cloth is any one of 3K, 6K, 12K, 24K or 48K or a combination of at least two thereof; and / or the specification of the Z-direction fiber bundle is any one of 1K, 3K or 6K or a combination of at least two thereof.

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