A flexible high-temperature resistant composite thermal protection component and its manufacturing method

Abstract

This invention discloses a flexible high-temperature resistant composite thermal protection component and its manufacturing method. The component includes an ablation-resistant layer and a flame-retardant aluminum foil composite fiberglass cloth layer. The ablation-resistant layer is formed by coating a polyester fiber felt with an aerogel impregnation liquid and curing it to form an aerogel felt. The flexible high-temperature resistant composite thermal protection component produced by this invention has excellent aging resistance, is lightweight, and can withstand long-term heat insulation at medium and high temperatures. It can maintain its position for 1100 seconds at an ambient temperature of 230~260℃, while the outer surface temperature of the heat-resistant instrument remains below 55℃.

Description

Technical Field

[0001] This invention relates to heat-insulating products for equipment and pipelines used in aircraft propulsion systems, specifically to a flexible composite thermal protection component and its manufacturing method. Background Technology

[0002] Thermal protective sleeves and suits for instrument electrical connectors are suitable for short-term heat insulation under high heat flux (high temperature). In recent years, many aircraft models have proposed long-term heat insulation requirements, and traditional thermal insulation materials must be significantly thickened to meet these requirements. However, due to limited space within the cabin, narrow spaces are not suitable for the assembly of thicker materials. Furthermore, the weight of the thermal insulation material is also a consideration for aircraft. Second, existing thermal protective sleeves and suits for instrument electrical connectors are made using cable thermal protection coatings. These coatings are made by grinding modified polyurethane resin with inorganic and organic fillers. Polyurethane is sensitive to humidity, and prolonged exposure to humid and hot environments can easily lead to accelerated water degradation, aging, and moisture absorption, resulting in sticky products. Third, some models require an aging resistance of at least 30 years, increasing the risk of moisture damage during packaging, transportation, storage, and handling. Fourth, organic solvents are added during the production of thermal protective sleeves and suits for instrument electrical connectors for dilution. Although the residual amount of organic solvents is within acceptable limits, it increases the company's investment in environmental protection facilities and equipment. Meanwhile, for certain special sections, the quality loss rate must not exceed 1%. In summary, it is imperative to design and develop an integrated composite heat-resistant protective component that is flexible, has excellent aging resistance, is lightweight, can withstand long-term heat insulation at medium and high temperatures, is low-cost, and environmentally friendly. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a flexible high-temperature resistant composite thermal protection component for equipment and pipelines used in aircraft propulsion systems, and to provide a method for manufacturing the protective component.

[0004] To solve the above-mentioned technical problems, the technical solution of the present invention regarding the flexible high-temperature resistant composite thermal protection component is: a flexible high-temperature resistant composite thermal protection component, comprising an ablation-resistant layer and an outermost flame-retardant aluminum foil composite glass fiber cloth layer, wherein the ablation-resistant layer is formed by coating a polyester fiber felt with an aerogel impregnation liquid and curing it.

[0005] Furthermore, it also includes a low thermal conductivity layer made of type B quartz glass fiber cloth.

[0006] In one embodiment, the aerogel is prepared by adding an organosilane modifier to a modified ZrO2-SiO2 precursor sol, followed by aging and drying to obtain a high-temperature resistant modified ZrO2-SiO2 composite aerogel. The specific preparation method includes the following steps: S1. Mixing tetraethyl orthosilicate, an organosilane modifier, and ethanol, then adding water and an acid catalyst for hydrolysis to obtain solution A; S2. Mixing zirconium oxychloride, water, and ethanol, and hydrolyzing to obtain solution B; S3. Adding solution B to solution A and stirring to obtain a modified ZrO2-SiO2 precursor sol; S4. Adding a coagulant and a modifier to the modified ZrO2-SiO2 precursor sol to obtain a modified ZrO2-SiO2 composite wet gel; S5. Aging and drying the modified ZrO2-SiO2 composite wet gel to obtain a high-temperature resistant modified ZrO2-SiO2 composite aerogel.

[0007] In one embodiment, the thickness of the ablation-resistant layer is 3.9 mm, and the thickness of the flame-retardant aluminum foil composite glass fiber cloth layer is 0.1 mm.

[0008] In one embodiment, the thickness of the low thermal conductivity layer is 0.4 mm, the thickness of the ablation-resistant layer is 4.8 mm, and the thickness of the flame-retardant aluminum foil composite glass fiber cloth layer is 0.1 mm.

[0009] In one embodiment, the thickness of the low thermal conductivity layer is 4.6 mm, the thickness of the ablation-resistant layer is 1.5 mm, and the thickness of the flame-retardant aluminum foil composite glass fiber cloth layer is 0.1 mm.

[0010] The present invention relates to a method for manufacturing a flexible high-temperature resistant composite thermal protection component, comprising the following steps: ① making a mold; ② cutting type B quartz fiberglass cloth, aerogel felt, and flame-retardant aluminum foil composite fiberglass cloth into sheets according to the mold unfolding diagram; ③ assembling type B quartz fiberglass cloth, aerogel felt, and flame-retardant aluminum foil composite fiberglass cloth according to a layered structure; ④ first sewing type B quartz fiberglass cloth and aerogel felt together with Kevlar thread to form a component, and then baking it to remove volatiles. The overlap width of the Kevlar thread stitching is 10-20mm, the baking time is 30-60min, and the baking temperature is 270-300℃; ⑤ baking the flame-retardant aluminum foil composite fiberglass cloth to remove volatiles. The baking time is 200-300s, and the baking temperature is 200-250℃; ⑥ wrapping the flame-retardant aluminum foil composite fiberglass cloth over the component from step ④, and then sewing the edges together with Kevlar thread.

[0011] The flexible, high-temperature resistant composite thermal protection component produced using this invention exhibits excellent aging resistance, is lightweight, and can withstand long-term heat insulation at medium and high temperatures. It can maintain its insulation for 1100 seconds at an ambient temperature of 230-260℃, while the outer surface temperature of the heat-resistant instrument remains below 55℃. Because the three materials—Type B quartz fiberglass cloth, aerogel felt, and flame-retardant aluminum foil composite fiberglass cloth—are lightweight and flexible, facilitating construction, the combination of these three materials results in low vacuum mass loss under high-temperature heating conditions. Tests have shown that even after baking at 400℃, the mass loss rate is less than 0.1%, and no oily or suspended matter is generated to contaminate the instrument. Compared to traditional multi-layered sleeves or protective components, this invention reduces the number of layers and requires fewer types of materials, thus greatly simplifying the manufacturing process and meeting the heat protection requirements of specific aircraft models. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the flexible high-temperature resistant composite thermal protection component in Example 1;

[0013] Figure 2 This is a schematic diagram of the flexible high-temperature resistant composite thermal protection component in Example 2;

[0014] Figure 3 This is a schematic diagram of the flexible high-temperature resistant composite thermal protection component in Example 3;

[0015] The attached figures are labeled as follows:

[0016] 1—Low thermal conductivity layer; 2—Ablation resistant layer

[0017] 3—Flame-retardant aluminum foil composite glass fiber cloth layer. Detailed Implementation

[0018] Various exemplary embodiments of the present invention will now be described in detail. This detailed description should not be considered as a limitation of the present invention, but rather as a more detailed description of certain aspects, features, and embodiments of the present invention. Example 1

[0019] like Figure 1 As shown, a flexible high-temperature resistant composite thermal protection component is composed of three layers of different materials. From the inside out, they are a low thermal conductivity layer 1, an ablation resistant layer 2, and a flame-retardant aluminum foil composite fiberglass cloth layer 3. The edges are stitched together layer by layer with Kevlar thread.

[0020] The specific steps are as follows:

[0021] (1) Making molds

[0022] The client's design department provides dimensional drawings of the instruments, meters, and equipment that need protection, and molds are manufactured according to the drawings;

[0023] (2) Cut the low thermal conductivity layer 1, the ablation resistant layer 2, and the flame-retardant aluminum foil composite glass fiber cloth layer 3.

[0024] The ablation-resistant layer 2 is formed by coating a polyester fiber felt with an aerogel impregnation solution and curing it. The preparation method of the aerogel includes the following steps: 1) mixing tetraethyl orthosilicate, an organosilane modifier, and ethanol, then adding water and an acid catalyst for hydrolysis to obtain solution A; 2) mixing zirconium oxychloride, water, and ethanol, and hydrolyzing to obtain solution B; 3) adding solution B to solution A and stirring to obtain a modified ZrO2-SiO2 precursor sol; 4) adding a coagulant and a modifier to the modified ZrO2-SiO2 precursor sol to obtain a modified ZrO2-SiO2 composite wet gel; 5) aging and drying the modified ZrO2-SiO2 composite wet gel to obtain a high-temperature resistant modified ZrO2-SiO2 composite aerogel.

[0025] Cut the B-type quartz fiberglass cloth for making the low thermal conductivity layer 1, the aerogel felt for making the ablation resistant layer 2, and the flame-retardant aluminum foil composite fiberglass cloth according to the mold unfolding diagram; both the B-type quartz fiberglass cloth and the flame-retardant aluminum foil composite fiberglass cloth are purchased directly from the market. The B-type quartz fiberglass cloth refers to quartz fiberglass cloth with a silica content of more than 99%, an epoxy impregnating agent, and a thickness of 0.1mm. The flame-retardant aluminum foil composite fiberglass cloth is a common material in building insulation materials, consisting of an anti-corrosion coating + 7-micron aluminum foil + 13×14 (1cm horizontal 13 yarns and vertical 14 yarns weaving density) fiberglass cloth + polyethylene;

[0026] (3) Covering and molding on the mold

[0027] Four layers of type B quartz glass fiber cloth (each layer is about 0.1 mm thick, and the total thickness is about 0.4 mm) and 16 layers of aerogel felt (each layer is about 0.3 mm thick, and the total thickness is about 4.8 mm) are sequentially wrapped on the mold.

[0028] (4) Suturing

[0029] The edges are stitched together with Kevlar thread to form the components;

[0030] (5) Baking

[0031] Place the sewn components in an oven to remove volatiles for 30-60 minutes at a temperature of 270-300°C; arrange flame-retardant aluminum foil composite glass fiber in an oven to remove volatiles for 200-300 seconds at a temperature of 200-250°C.

[0032] (6) Covering

[0033] Wrap a layer of flame-retardant aluminum foil composite fiberglass cloth (approximately 0.1 mm thick) around the baked component;

[0034] (7) Suturing

[0035] Kevlar thread is used to sew the edges together to obtain a flexible, high-temperature resistant composite thermal protection component.

[0036] The following table illustrates the hierarchical structure and temperature test results of the flexible high-temperature resistant composite thermal protection component obtained in this embodiment:

[0037]

[0038] The flexible high-temperature resistant composite thermal protection component provided in this embodiment has undergone the above thermal testing, with the temperature rise on the outer surface of the instrument ≤65℃. The key to achieving such thermal insulation is the 16-layer aerogel felt in the ablation-resistant layer 2. This is because the high-temperature resistant modified ZrO2-SiO2 composite aerogel used in this aerogel felt has the following characteristics:

[0039] 1) The temperature resistance is significantly improved. Due to the severe agglomeration damage caused by the abundant and highly active hydroxyl groups on the aerogel surface, the mesoporous structure of the aerogel is preserved, and the number of Si-O-Zr bonds is significantly increased, which significantly increases the phase transition temperature of the aerogel. After calcination at 1000℃, the crystallinity and crystal facet types are significantly reduced. These factors significantly improve the high-temperature stability of the material. After heat treatment in an aerobic environment at 1000℃, the high-temperature modified ZrO2-SiO2 composite aerogel has an optimal specific surface area of ​​259.6 m2 / g and an optimal pore volume of 1.51 cm3 / g.

[0040] 2) Excellent physical properties, low thermal conductivity, and good high-temperature insulation performance: The ZrO2-SiO2 composite aerogel modified with organosilane exhibits significantly improved physical properties due to the altered cross-linking degree of the three-dimensional network structure caused by the introduction of Si-C. The optimal density is as low as 0.124 g / cm3, while the optimal pore volume reaches 3.30 cm3 / g. This superior physical structure and properties enhance the aerogel's thermal insulation performance. The lowest thermal conductivity of the high-temperature modified ZrO2-SiO2 composite aerogel is 0.023 W / m at both room temperature and 1000℃. -1 K -1 and 0.042Wm -1 K -1 ;

[0041] 3) High hydrophobicity: Organosilanes are modified to introduce hydrophobic functional groups into the material and the hydroxyl groups are almost gone. Therefore, the material has low surface energy. The high-temperature modified ZrO2-SiO2 composite aerogel has a contact angle of more than 120° and high hydrophobicity, which can be used in harsh humid and high-temperature environments. Example 2

[0042] like Figure 2 As shown, a flexible high-temperature resistant composite thermal protection component consists of two layers, from the inside out: an ablation-resistant layer 2 and a flame-retardant aluminum foil composite fiberglass cloth layer 3, with the edges stitched together layer by layer using Kevlar thread.

[0043] The specific steps are as follows:

[0044] (1) Making molds

[0045] The client's design department provides dimensional drawings of the instruments, meters, and equipment that need protection, and molds are manufactured according to the drawings;

[0046] (2) Cut the ablation-resistant layer 2 and the flame-retardant aluminum foil composite glass fiber cloth layer 3.

[0047] Cut the aerogel felt for making the ablation-resistant layer 2 according to the mold unfolding diagram, and cut the flame-retardant aluminum foil composite glass fiber cloth; select the optimal solution and control the generation of excess material; the types of aerogel felt and flame-retardant aluminum foil composite glass fiber cloth are the same as in Example 1;

[0048] (3) Covering and molding on the mold

[0049] Thirteen layers of aerogel felt (each layer is about 0.1 mm thick, and the total thickness is about 3.9 mm) were wrapped around the mold.

[0050] (4) Suturing

[0051] The edges are stitched together with Kevlar thread to form the components;

[0052] (5) Baking

[0053] Place the sewn components in an oven to remove volatiles for 30-60 minutes at a temperature of 270-300°C; arrange flame-retardant aluminum foil composite glass fiber in an oven to remove volatiles for 200-300 seconds at a temperature of 200-250°C.

[0054] (6) Covering

[0055] Wrap a layer of flame-retardant aluminum foil composite fiberglass cloth (approximately 0.1 mm thick) around the baked component;

[0056] (7) Suturing

[0057] Kevlar thread is used to sew the edges together to obtain a flexible, high-temperature resistant composite thermal protection component.

[0058] The following table illustrates the hierarchical structure and temperature test results of the flexible high-temperature resistant composite thermal protection component obtained in this embodiment:

[0059]

[0060] The flexible high-temperature resistant composite thermal protection component provided in this embodiment has undergone the above thermal testing, and the temperature rise on the outer surface of the instrument is ≤55℃. Similar to Embodiment 1, the reason why this embodiment can achieve such a thermal insulation effect is mainly due to the 13-layer aerogel felt of the ablation-resistant layer 2, for details of which can be found in Embodiment 1. Example 3

[0061] like Figure 3 As shown, a flexible high-temperature resistant composite thermal protection component consists of four layers, from the inside out: a low thermal conductivity layer 1, an ablation-resistant layer 2, a low thermal conductivity layer 3, and a flame-retardant aluminum foil composite fiberglass cloth layer 4. The edges are stitched together layer by layer with Kevlar thread.

[0062] The specific steps are as follows:

[0063] (1) Making molds

[0064] The client's design department provides dimensional drawings of the instruments, meters, and equipment that need protection, and molds are manufactured according to the drawings;

[0065] (2) Cut the low thermal conductivity layer 1, the ablation resistant layer 2, and the flame-retardant aluminum foil composite glass fiber cloth layer 3.

[0066] Cut the type B quartz glass fiber cloth for making the low thermal conductivity layer 1, the aerogel felt for making the ablation resistant layer 2, and the flame-retardant aluminum foil composite glass fiber cloth according to the mold unfolding diagram; select the optimal solution and control the generation of excess; the types of type B quartz glass fiber cloth, aerogel felt and flame-retardant aluminum foil composite glass fiber cloth are the same as those in Example 1.

[0067] (3) Covering and molding on the mold

[0068] The mold is sequentially covered with 44 layers of type B quartz glass fiber cloth (each layer is about 0.1 mm thick, and the total thickness is about 4.4 mm), 5 layers of aerogel felt (each layer is about 0.3 mm thick, and the total thickness is about 1.5 mm), and 2 layers of quartz glass fiber cloth (the total thickness is about 0.2 mm).

[0069] (4) Suturing

[0070] The edges are stitched together with Kevlar thread to form the components;

[0071] (5) Baking

[0072] Place the sewn components in an oven to remove volatiles for 30-60 minutes at a temperature of 270-300°C; arrange flame-retardant aluminum foil composite glass fiber in an oven to remove volatiles for 200-300 seconds at a temperature of 200-250°C.

[0073] (6) Covering

[0074] Wrap a layer of flame-retardant aluminum foil composite fiberglass cloth (approximately 0.1 mm thick) around the baked component;

[0075] (7) Suturing

[0076] Kevlar thread is used to sew the edges together to obtain a flexible, high-temperature resistant composite thermal protection component.

[0077] The following table illustrates the hierarchical structure and temperature test results of the flexible high-temperature resistant composite thermal protection component obtained in this embodiment:

[0078]

[0079] The flexible high-temperature resistant composite thermal protection component provided in this embodiment uses a large amount of type B quartz glass fiber cloth (a total of 46 layers) and a small amount of aerogel felt (5 layers). After the above thermal test, the temperature rise of the outer surface of the instrument is ≤180℃.

[0080] The above embodiments are preferred implementations of the present invention. In addition, the present invention can be implemented in other ways. Any obvious substitutions without departing from the concept of the present technical solution are within the protection scope of the present invention.

[0081] To facilitate understanding by those skilled in the art of the improvements of this invention over the prior art, some of the accompanying drawings and descriptions have been simplified, and for clarity, some other elements have been omitted from this application. Those skilled in the art should realize that these omitted elements may also constitute the content of this invention.

Claims

1. A flexible high-temperature resistant composite thermal protection component, characterized in that: The protective component is divided into two layers according to different materials, including an ablation-resistant layer (2) and an outermost flame-retardant aluminum foil composite glass fiber cloth layer (3). The ablation-resistant layer (2) is formed by coating aerogel impregnation liquid onto the surface of polyester fiber felt and curing it to form an aerogel felt. The aerogel is prepared by adding organosilane modifier to prepare modified ZrO2-SiO2 precursor sol, and then aging and drying to obtain high-temperature resistant modified ZrO2-SiO2 composite aerogel.

2. The flexible high-temperature resistant composite thermal protection component according to claim 1, characterized in that: The thickness of the ablation-resistant layer (2) is 3.9 mm, and the thickness of the flame-retardant aluminum foil composite glass fiber cloth layer (3) is 0.1 mm.

3. A flexible high-temperature resistant composite thermal protection component, characterized in that: The protective component is divided into three layers according to different materials. From the inside out, they are a low thermal conductivity layer (1), an ablation resistant layer (2), and a flame-retardant aluminum foil composite glass fiber cloth layer (3). The low thermal conductivity layer (1) is a low thermal conductivity layer (1) made of type B quartz glass fiber cloth. The ablation resistant layer (2) is formed by coating a polyester fiber felt with an aerogel impregnation liquid after surface treatment and curing. The aerogel is prepared by adding an organosilane modifier to prepare a modified ZrO2-SiO2 precursor sol, and then aging and drying to obtain a high-temperature resistant modified ZrO2-SiO2 composite aerogel.

4. The flexible high-temperature resistant composite thermal protection component according to claim 3, characterized in that: The thickness of the low thermal conductivity layer (1) is 0.4 mm, the thickness of the ablation resistant layer (2) is 4.8 mm, and the thickness of the flame-retardant aluminum foil composite glass fiber cloth layer (3) is 0.1 mm.

5. A flexible high-temperature resistant composite thermal protection component, characterized in that: The protective component is divided into four layers according to different materials. From the inside out, they are a low thermal conductivity layer (1), an ablation resistant layer (2), a low thermal conductivity layer (3), and a flame-retardant aluminum foil composite glass fiber cloth layer (4). The low thermal conductivity layer (1) is a low thermal conductivity layer (1) made of type B quartz glass fiber cloth. The ablation resistant layer (2) is formed by coating a polyester fiber felt with an aerogel impregnation liquid after surface treatment and curing. The aerogel is prepared by adding an organosilane modifier to prepare a modified ZrO2-SiO2 precursor sol, and then aging and drying to obtain a high-temperature resistant modified ZrO2-SiO2 composite aerogel.

6. The flexible high-temperature resistant composite thermal protection component according to claim 5, characterized in that: The total thickness of the low thermal conductivity layer (1) is 4.6 mm, the thickness of the ablation resistant layer (2) is 1.5 mm, and the thickness of the flame-retardant aluminum foil composite glass fiber cloth layer (3) is 0.1 mm.

7. The method for manufacturing the flexible high-temperature resistant composite thermal protection component as described in any one of claims 3 to 6, characterized in that, Includes the following steps: S1. The low thermal conductivity layer (1) and the ablation resistant layer (2) are first sewn together with Kevlar thread to form an assembly, and then placed in an oven to remove volatiles. The baking time is 30~60min and the baking temperature is 270~300℃. S2. Place the flame-retardant aluminum foil composite fiberglass cloth separately in an oven to remove volatiles. The baking time is 200~300s and the baking temperature is 200~250℃. S3. Sew the baked flame-retardant aluminum foil composite fiberglass cloth to the components in step 1).

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