Quartz fiber felt, process parameter determination method thereof and aerogel felt

Abstract

The invention discloses a quartz fiber felt, a process parameter determination method thereof and an aerogel felt.The method comprises the steps that the lower limit of the number of layers of quartz fiber cloth is determined according to the preset lower limit of tensile breaking strength of the quartz fiber felt, the warp-direction breaking strength of the quartz fiber cloth and the thickness of a tensile sample; according to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz net tire, the preset density of the quartz fiber felt, the surface density of the quartz fiber cloth and the surface density of the quartz net tire, the layer number range of the quartz fiber cloth and the layer number range of the quartz net tire are determined; and determining the layer number of the quartz fiber cloth and the layer number of the quartz net tire according to the layer number lower limit and the layer number range of the quartz fiber cloth and the layer number range of the quartz net tire. Data support can be provided for the preparation process of the quartz fiber felt, so that the prepared quartz fiber felt has the effects of needling molding, good performance and / or good composite manufacturability and the like.

Description

Technical Field

[0001] This application belongs to the technical field of thermal insulation materials, and particularly relates to a quartz fiber felt, a method for determining its process parameters, and an aerogel felt. Background Art

[0002] A quartz fiber felt is a quartz fiber fabric product. Multiple layers of quartz web blanks and multiple layers of quartz fiber cloth are needle-punched and connected into a quartz fiber felt by a needle-punching process. It has the advantages of low density, excellent heat insulation performance, high strength, and large pores, and can be used as a reinforcement for low-density phenolic aerogel composites. However, different structural designs of the quartz web blank and quartz fiber have different effects on the performance of the overall quartz fiber felt product. For example, it may cause problems such as poor formability of the quartz fiber felt. Summary of the Invention

[0003] The embodiments of this application provide a quartz fiber felt, a method for determining its process parameters, and an aerogel felt, thereby providing data support for the subsequent preparation process of the quartz fiber felt, so that the prepared quartz fiber felt can have effects such as good needle-punching formability, good performance, and / or good composite processability.

[0004] Other features and advantages of this application will become apparent through the following detailed description, or be learned in part through the practice of this application.

[0005] The first aspect of the embodiments of this application provides a method for determining the process parameters of a quartz fiber felt, including:

[0006] Determine the lower limit of the number of layers of the quartz fiber cloth according to the preset lower limit of the tensile fracture strength of the quartz fiber felt, the warp fracture strength of the quartz fiber cloth, and the thickness of the tensile specimen;

[0007] Determine the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz web blank according to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz web blank, the preset density of the quartz fiber felt, the areal density of the quartz fiber cloth, and the areal density of the quartz web blank;

[0008] Determine the number of layers of the quartz fiber cloth and the number of layers of the quartz web blank according to the lower limit and range of the number of layers of the quartz fiber cloth, and the range of the number of layers of the quartz web blank.

[0009] Optionally, the determining the lower limit of the number of layers of the quartz fiber cloth according to the preset lower limit of the tensile fracture strength of the quartz fiber felt, the warp fracture strength of the quartz fiber cloth, and the thickness of the tensile specimen includes:

[0010] Determine the lower limit of the number of layers of the quartz fiber cloth based on the following formula according to the preset lower limit of the tensile fracture strength of the quartz fiber felt, the warp fracture strength of the quartz fiber cloth, and the thickness of the tensile specimen:

[0011]

[0012] wherein, n 1min represents the lower limit of the number of layers of the quartz fiber cloth, P represents the lower limit of the tensile fracture strength, D represents the thickness of the tensile specimen, and F represents the warp-wise fracture strength of the quartz fiber cloth.

[0013] Optionally, the lower limit of the tensile fracture strength is n times the target lower limit of the tensile fracture strength, wherein the value range of n is 1.2 - 1.5.

[0014] Optionally, the quartz fiber felt includes at least two of the quartz fiber cloths, and the warp-wise fracture strength of the quartz fiber cloth is the sum of the warp-wise fracture strengths of the various quartz fiber cloths.

[0015] Optionally, determining the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh base according to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz mesh base, the preset density of the quartz fiber felt, the areal density of the quartz fiber cloth, and the areal density of the quartz mesh base includes:

[0016] Based on the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz mesh base, the preset density of the quartz fiber felt, the areal density of the quartz fiber cloth, and the areal density of the quartz mesh base, determine the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh base according to the following formula:

[0017]

[0018] d = (n 1 × d 1 ) + (n 2 × d 2 ); (3)

[0019] wherein, ρ represents the preset density of the quartz fiber felt, ρ s1 represents the areal density of the quartz fiber cloth, ρ s2 represents the areal density of the quartz mesh base, d represents the thickness of the quartz fiber felt, d 1 represents the single-layer thickness of the quartz fiber cloth, d 2 represents the single-layer thickness of the quartz mesh base, n 1 represents the range of the number of layers of the quartz fiber cloth, n 2 represents the range of the number of layers of the quartz mesh base.

[0020] Optionally, determining the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh blank according to the lower limit and range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh blank includes:

[0021] Determining the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh blank according to the lower limit and range of the number of layers of the quartz fiber cloth, the range of the number of layers of the quartz mesh blank, and a preset process parameter rule;

[0022] Wherein, the process parameter rule includes: the number of layers of the quartz fiber cloth is less than or equal to the number of layers of the quartz mesh blank, and / or, when the lower limit of the tensile fracture strength is satisfied, reducing the number of layers of the quartz fiber cloth and increasing the number of layers of the quartz mesh blank.

[0023] The second aspect of the embodiments of the present application provides a quartz fiber felt, and the quartz fiber felt is prepared by using the process parameters determined by any method in the first aspect.

[0024] Optionally, it includes:

[0025] Multiple layers of quartz fiber cloth and multiple layers of quartz mesh blank, the multiple layers of quartz fiber cloth and the multiple layers of quartz mesh blank are stacked, the number of layers of the quartz fiber cloth is less than or equal to the number of layers of the quartz mesh blank, at least one layer of the quartz mesh blank is provided between adjacent two layers of the quartz fiber cloth, and the quartz fiber cloth and the quartz mesh blank are needle-punched and connected.

[0026] The third aspect of the embodiments of the present application provides an aerogel felt, including:

[0027] The quartz fiber felt according to any one of the second aspect, and the quartz fiber felt has fiber gaps;

[0028] An aerogel, filled in the fiber gaps of the quartz fiber felt.

[0029] Optionally, the aerogel is prepared from a phenolic resin material.

[0030] The method for determining the process parameters of the quartz fiber felt provided by the embodiment of the present application determines the lower limit of the number of layers of the quartz fiber cloth according to the preset lower limit of the tensile fracture strength of the quartz fiber felt, the warp fracture strength of the quartz fiber cloth, and the thickness of the tensile specimen; according to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz net tire, the preset density of the quartz fiber felt, the surface density of the quartz fiber cloth, and the surface density of the quartz net tire, determine the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz net tire; according to the lower limit and range of the number of layers of the quartz fiber cloth, and the range of the number of layers of the quartz net tire, determine the number of layers of the quartz fiber cloth and the number of layers of the quartz net tire. Thus, by pre-determining the number of layers of the quartz net tire and quartz fiber in the quartz fiber felt to be prepared, data support is provided for the subsequent preparation process of the quartz fiber felt, so that the prepared quartz fiber felt can have effects such as good needle punching forming, good performance, and / or good composite processability.

[0031] It should be understood that the above general description and the following detailed description are only exemplary and explanatory, and cannot limit the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The drawings herein are incorporated into the specification and form a part of the specification, showing embodiments consistent with the present application, and are used together with the specification to explain the principles of the present application. Obviously, the drawings in the following description are only some embodiments of the present application, and those of ordinary skill in the art can obtain other drawings according to these drawings without creative efforts. In the drawings:

[0033] Figure 1 Shows a flowchart of the method for determining the process parameters of the quartz fiber felt according to the embodiment of the present application;

[0034] Figure 2 Shows a partial cross-sectional structural schematic diagram of the quartz fiber felt according to the embodiment of the present application;

[0035] Figure 3 Shows a partial cross-sectional structural schematic diagram of the aerogel felt according to the embodiment of the present application. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0036] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0037] The block diagrams shown in the drawings are only functional entities and do not necessarily correspond to physically independent entities. That is, these functional entities can be implemented in software form, or implemented in one or more hardware modules or integrated circuits, or implemented in different networks and / or processor devices and / or microcontroller devices.

[0038] The flowcharts shown in the drawings are only illustrative and do not necessarily include all the content and operations / steps, nor do they necessarily have to be executed in the order described. For example, some operations / steps can be decomposed, while some operations / steps can be combined or partially combined, so the actual execution order may change according to the actual situation.

[0039] It should also be noted that the terms "first", "second", etc. in the description, claims and above-mentioned drawings of the present application are used to distinguish similar objects and do not necessarily have to be used to describe a specific order or sequence. It should be understood that the objects so used can be interchanged under appropriate circumstances so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described.

[0040] As used herein, "about", "substantially", "approximately" or "essentially" includes the stated value and the average value within an acceptable deviation range of the specific value, where the acceptable deviation range is determined by a person of ordinary skill in the art considering the measurement being discussed and the error associated with the measurement of the specific quantity (i.e., the limitations of the measurement system).

[0041] In this specification, unless otherwise clearly specified and limited, the terms "installed", "connected" and "coupled" shall 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 directly connected, or indirectly connected through an intermediate member, or the communication inside two elements. For a person of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.

[0042] Quartz fiber felt is a quartz fiber fabric product. Multiple layers of quartz web tires and multiple layers of quartz fiber cloth are needle-punched and connected into quartz fiber felt by a needle-punching process. It has the advantages of low density, excellent heat insulation performance, high strength and large pores, and can be used as a reinforcement for low-density phenolic aerogel composites.

[0043] However, different structural designs of the quartz mesh base and quartz fibers have different effects on the performance of the overall quartz fiber felt product. For example, differences in the types and arrangement methods of the quartz mesh base and quartz fiber cloth will have different effects on the performance of the quartz fiber felt. Therefore, without understanding the relevant principles and material properties, the designed quartz fiber felt may have problems such as inability to be needled into shape, low performance, and poor composite processability. Therefore, it is necessary to pre-determine the structural process parameters of the quartz mesh base and quartz fibers before preparing the quartz fiber felt.

[0044] In view of this, the embodiments of the present application provide a method for determining the process parameters of a quartz fiber felt. To a certain extent, this method can provide data support for the subsequent preparation process of the quartz fiber felt, so that the prepared quartz fiber felt can have effects such as being needled into shape, good performance, and / or good composite processability.

[0045] The method for determining the process parameters of the quartz fiber felt according to the embodiments of the present application will be described below with reference to specific drawings.

[0046] Figure 1 The flowchart of the method for determining the process parameters of the quartz fiber felt according to the embodiments of the present application is shown.

[0047] The first aspect of the embodiments of the present application provides a method for determining the process parameters of a quartz fiber felt, including:

[0048] Step S10. Determine the lower limit of the number of layers of the quartz fiber cloth according to the preset lower limit of the tensile fracture strength of the quartz fiber felt, the warp fracture strength of the quartz fiber cloth, and the thickness of the tensile specimen.

[0049] It should be noted that the main raw materials for preparing the quartz fiber felt in the embodiments of the present application may include fiber cloth and quartz mesh base, such as B-type quartz fiber cloth and quartz mesh base, which are connected by weaving or needling to form a quartz fiber felt.

[0050] It can be understood that for the quartz fiber felt to be prepared, corresponding requirements or standards can be pre-designed for the performance of its product. For example, the lower limit of the tensile fracture strength of the quartz fiber felt is preset. The tensile fracture strength of the quartz fiber felt can refer to the maximum stress that the quartz fiber felt can withstand before being stressed until it breaks. For example, it is required that the tensile fracture strength of the quartz fiber felt at room temperature is greater than or equal to 50 Mpa, that is, the lower limit of the tensile fracture strength is 50 Mpa. Another example is to preset the thickness of the tensile specimen. Among them, the tensile specimen can refer to the quartz fiber felt in the form of a sample for testing in the preparation process of the quartz fiber felt, and its thickness can be the thickness in the Z direction, such as 11 mm.

[0051] It should be noted that the warp breaking strength of the quartz fiber cloth can refer to the tensile strength of the material measured along the main fiber arrangement direction (i.e., the warp direction or the machine direction) during the preparation of the quartz fiber cloth. This warp breaking strength can reflect the maximum stress that the quartz fiber cloth can withstand in the warp direction until it breaks.

[0052] It can be understood that the quartz fiber mat can be formed by laminating multiple layers of quartz fiber cloth and multiple layers of quartz mesh tire and connecting them by needling or weaving. Among them, the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh tire have an important impact on the product performance of the quartz fiber mat. Therefore, it is necessary to pre-determine the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh tire before preparing the quartz fiber mat in the embodiments of the present application.

[0053] Among them, the lower limit of the number of layers of the quartz fiber cloth refers to the minimum value of the number of layers of the quartz fiber cloth in the quartz fiber mat, that is, the quartz fiber mat should at least include the quartz fiber cloth corresponding to this lower limit of the number of layers. For example: if the lower limit of the number of layers of the quartz fiber cloth is 10, then the number of layers of the quartz fiber cloth in the quartz fiber mat needs to be greater than or equal to 10.

[0054] In some embodiments, determining the lower limit of the number of layers of the quartz fiber cloth according to the preset lower limit of the tensile fracture strength of the quartz fiber mat, the warp breaking strength of the quartz fiber cloth, and the thickness of the tensile specimen includes:

[0055] Based on the preset lower limit of the tensile fracture strength of the quartz fiber mat, the warp breaking strength of the quartz fiber cloth, and the thickness of the tensile specimen, determine the lower limit of the number of layers of the quartz fiber cloth based on the following formula:

[0056]

[0057] Among them, n 1min represents the lower limit of the number of layers of the quartz fiber cloth, P represents the preset lower limit of the tensile fracture strength, D represents the thickness of the tensile specimen, and F represents the warp breaking strength of the quartz fiber cloth.

[0058] It should be noted that the tensile fracture strength of the quartz fiber mat is mainly determined by the quartz fiber cloth. After determining the lower limit of the tensile fracture strength, the warp breaking strength of the quartz fiber cloth, and the thickness of the tensile specimen, the lower limit of the number of layers of the quartz fiber cloth in the quartz fiber mat can be determined.

[0059] In some embodiments, the lower limit of the tensile fracture strength is n times the target lower limit of the tensile fracture strength, where the value range of n is 1.2 - 1.5, such as 1.2, 1.3, 1.4, or 1.5.

[0060] It should be noted that during the preparation of the quartz fiber felt, there will more or less be a certain performance loss, for example, a performance loss of about 20%. Therefore, when designing the structure, to ensure that the tensile fracture strength of the quartz fiber felt meets the preset requirements, the tensile fracture strength can be set as n times the target tensile fracture strength, for example, set according to 1.2 - 1.5 times. Among them, the target tensile fracture strength is the tensile fracture strength that is desired to be achieved when producing the quartz fiber felt product. For example, at room temperature, the tensile fracture strength of the quartz fiber felt is greater than or equal to 50 Mpa, that is, the lower limit of the target tensile fracture strength is 50 Mpa.

[0061] In some embodiments, the quartz fiber felt includes at least two of the quartz fiber cloths, and the warp fracture strength of the quartz fiber cloth is the sum of the warp fracture strengths of the various quartz fiber cloths.

[0062] It should be noted that when different quartz glass fiber cloths are distributed in the same quartz fiber felt, it is necessary to calculate separately the warp fracture strengths provided by the different quartz fiber cloths, and the sum of the warp fracture strengths of the various quartz fiber cloths is the warp fracture strength of the quartz fiber cloth in the embodiments of the present application.

[0063] Step S20. Determine the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh base according to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz mesh base, the preset density of the quartz fiber felt, the areal density of the quartz fiber cloth, and the areal density of the quartz mesh base;

[0064] It should be noted that the strength of the quartz fiber felt is provided by the quartz fiber and the quartz mesh base. After determining the tensile fracture strength, the lower limit of the number of layers of the quartz fiber cloth can be calculated through the above formula (1), but the quartz fiber cloths of each layer cannot be needle-punched and connected to each other. It is necessary to use the quartz mesh base as a framework to connect the adjacent two layers of quartz fiber cloths. However, the more the number of layers of the quartz fiber cloth and the quartz mesh base, the greater the density of the quartz fiber felt. But to ensure the heat insulation and / or heat preservation performance of the quartz fiber felt, the pore density in the quartz fiber felt should be limited, and the density is related to the thickness. Therefore, it is necessary to set the density and thickness, and then determine the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh base.

[0065] In the embodiments of the present application, the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz mesh carcass, the density of the quartz fiber mat, the areal density of the quartz fiber cloth, and the areal density of the quartz mesh carcass can be determined in advance according to the performance requirements of the quartz fiber mat, such as heat insulation performance, heat preservation performance, etc. Furthermore, the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh carcass in the quartz fiber mat can be determined based on the above parameters. Among them, the density of the quartz fiber mat can refer to the overall density of the product, the areal density of the quartz fiber cloth can refer to the density of a single layer of quartz fiber cloth, and the areal density of the quartz mesh carcass can refer to the density of a single layer of quartz mesh carcass, for example, 65 g / m 2 .

[0066] It can be understood that tolerances are allowed for parameters such as density and thickness in the embodiments of the present application. For example, the tolerance range of density can be plus or minus 0.06 - 0.09, and the tolerance range of thickness can be plus or minus 0.5, etc. Then, when determining the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh carcass, the number of layers can be increased or decreased within the tolerance ranges of density and thickness to meet the performance requirements of the quartz fiber mat.

[0067] In some embodiments, determining the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh carcass according to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz mesh carcass, the preset density of the quartz fiber mat, the areal density of the quartz fiber cloth, and the areal density of the quartz mesh carcass includes:

[0068] Based on the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz mesh carcass, the preset density of the quartz fiber mat, the areal density of the quartz fiber cloth, and the areal density of the quartz mesh carcass, determine the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh carcass according to the following formula:

[0069]

[0070] d = (n 1 × d 1 ) + (n 2 × d 2 ); (3)

[0071] Where ρ represents the preset density of the quartz fiber mat, ρ s1 represents the areal density of the quartz fiber cloth, ρ s2 represents the areal density of the quartz mesh carcass, d represents the thickness of the quartz fiber mat, d 1 represents the single-layer thickness of the quartz fiber cloth, d 2 represents the single-layer thickness of the quartz mesh carcass, n 1 represents the range of the number of layers of the quartz fiber cloth, and n 2 represents the range of the number of layers of the quartz mesh carcass.

[0072] It can be understood that when solving formulas (2) and (3), a binary linear equation of formulas (2) and (3) can be solved to obtain the layer number range of the quartz mesh carcass, that is, multiplying formula (2) by a corresponding multiple so that the layer number range n of the quartz fiber cloth in formulas (2) and (3) 1 is equal, and subtracting the two formulas can eliminate n 1 , thereby obtaining a multiple equation of n 2 and d 2 . d 2 is a known range value, and the obtained n 2 is a range value. Substituting n 2 into formulas (2) and (3) can obtain n 1 .

[0073] It should be noted that when the quartz mesh carcass is in a natural fluffy state, the single-layer thickness in the natural fluffy state is 0.4 - 0.5 mm. When using the quartz mesh carcass as a skeleton to connect the quartz fiber cloth, the quartz mesh carcass is needled and thus squeezed, so that the thickness of the quartz mesh carcass is reduced to less than 0.1 mm at least, but the quartz mesh carcass is severely squeezed, which will make the density of the quartz mesh carcass larger, and too large density will affect the heat insulation performance of the quartz fiber felt. Therefore, in the embodiment of the present application, the thickness of the quartz mesh carcass in the squeezed state is set to 0.2 - 0.3 mm, such as 0.2 mm, 0.25 mm or 0.3 mm, so as to ensure the heat insulation performance of the quartz fiber felt.

[0074] Step S30. Determine the layer number of the quartz fiber cloth and the layer number of the quartz mesh carcass according to the lower limit of the layer number and the layer number range of the quartz fiber cloth, and the layer number range of the quartz mesh carcass.

[0075] It can be understood that after obtaining the lower limit of the layer number of the quartz fiber cloth based on formula (1), and obtaining the layer number range of the quartz fiber cloth and the layer number range of the quartz mesh carcass based on formulas (2) and (3), an integer layer number of the quartz fiber cloth can be selected and substituted into formula (3) to obtain the corresponding layer number of the quartz mesh carcass, thereby obtaining one or more sets of structural process parameters that meet the performance requirements of the quartz fiber felt. For example: when the layer number of the quartz fiber cloth is 25, the corresponding layer number of the quartz mesh carcass is 29; when the layer number of the quartz fiber cloth is 26, the corresponding layer number of the quartz mesh carcass is 26; when the layer number of the quartz fiber cloth is 27, the corresponding layer number of the quartz mesh carcass is 23; when the layer number of the quartz fiber cloth is 28, the layer number of the quartz mesh carcass is 20, etc.

[0076] In some embodiments, the determining the layer number of the quartz fiber cloth and the layer number of the quartz mesh carcass according to the lower limit of the layer number and the layer number range of the quartz fiber cloth, and the layer number range of the quartz mesh carcass includes:

[0077] Determine the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh core according to the lower limit and range of the number of layers of the quartz fiber cloth, the range of the number of layers of the quartz mesh core, and the preset process parameter rules; wherein, the process parameter rules include: the number of layers of the quartz fiber cloth is less than or equal to the number of layers of the quartz mesh core, and / or, when the lower limit of the tensile fracture strength is satisfied, reduce the number of layers of the quartz fiber cloth and increase the number of layers of the quartz mesh core.

[0078] It should be noted that, in order to improve the reliability of the quartz fiber felt forming process and considering the actual production operation level, after designing the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh core in the quartz fiber needle felt, process parameter rules are further set, so as to obtain a quartz fiber felt with better performance by combining these process parameter rules.

[0079] It can be understood that since quartz fiber cloth with a thickness less than or equal to 0.01 mm is usually not easily connected, the single-layer thickness of the quartz fiber cloth in the embodiments of the present application can be greater than 0.01 mm. When forming a quartz fiber felt with quartz fiber cloth greater than 0.01 mm, since the quartz fiber cloth layers cannot be connected pairwise, the process parameter rule that the number of layers of the quartz fiber cloth is less than or equal to the number of layers of the quartz mesh core is correspondingly set, so that at least one layer of quartz mesh core can be arranged between adjacent layers of quartz fiber cloth, and the quartz mesh core is used as a skeleton to realize the connection between the quartz fiber cloth layers, for example, the quartz fiber cloth is needled on the quartz mesh core.

[0080] It can be understood that the quartz fiber cloth plays a role in strengthening and tensile resistance in the quartz fiber felt, and the quartz mesh core plays a role as a skeleton in the quartz fiber felt to connect the quartz fiber cloth. Therefore, in the case where the tensile fracture strength meets the preset lower limit of tensile fracture, since the strength and tensile resistance of the quartz fiber felt are mainly provided by the quartz fiber cloth, that is, when the number of layers of the quartz fiber cloth has met the preset lower limit of tensile fracture, increasing the number of layers of the mesh core, on the one hand, since the mesh core is short fiber, it can increase the interlayer connection of the quartz fiber cloth, making the interlayer connection tighter, and on the other hand, since there are pores inside the mesh core, the more the number of layers of the mesh core, the fluffier the quartz fiber felt can be, and the more resin can be carried and the more positions for forming cavities, so the heat insulation and heat prevention performance is better. Therefore, the process parameter rule of reducing the number of layers of the quartz fiber cloth and increasing the number of layers of the quartz mesh core is correspondingly set when the lower limit of the tensile fracture strength is satisfied.

[0081] Based on the above disclosed content, the method for determining the process parameters of the quartz fiber felt provided by the embodiments of the present application determines the lower limit of the number of layers of the quartz fiber cloth according to the preset lower limit of the tensile fracture strength of the quartz fiber felt, the warp fracture strength of the quartz fiber cloth, and the thickness of the tensile specimen; according to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz net tire, the preset density of the quartz fiber felt, the surface density of the quartz fiber cloth, and the surface density of the quartz net tire, determine the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz net tire; according to the lower limit and range of the number of layers of the quartz fiber cloth, and the range of the number of layers of the quartz net tire, determine the number of layers of the quartz fiber cloth and the number of layers of the quartz net tire. Thus, by pre-determining the number of layers of the quartz net tire and quartz fiber in the quartz fiber felt to be prepared, it provides data support for the subsequent preparation process of the quartz fiber felt, so that the prepared quartz fiber felt can have effects such as good needle punching forming, good performance, and / or good composite processability.

[0082] For ease of understanding, the following illustrates the specific implementation of the method for determining the process parameters of the quartz fiber felt described in steps S10 - S30 above by way of examples.

[0083] Taking the preparation of the quartz fiber felt with the model number HPFC - 90 as an example, its density requirement is 0.65 g / cm3, the tensile fracture strength at room temperature is greater than or equal to 50 MPa, and the specifications of the quartz fiber cloth and quartz net tire used are shown in Table 1.

[0084] Table 1 Specifications of Quartz Fiber Cloth and Quartz Net Tire

[0085]

[0086] Based on the above design requirements and the specifications of the quartz fiber cloth and quartz net tire, it can be calculated according to formula (1): (1197 N / 25 mm × n 1min ) / 11 mm ≥ 50 MPa × 1.5, then the lower limit n 1min of the number of layers of the quartz fiber cloth is 17.23. In addition, it can be calculated according to formulas (2) and (3): 650000 g / m 3 × 0.011 m × 1 m 2 = n 1 × 210 g / m 2 + n 2 × 65 g / m 2 , 11 m = n 1 × 0.0002 m + n 2 × (0.0002 - 0.0003) m, then the range of the number of layers of the quartz fiber cloth: n 1 = 24.65 - 28.6, the range of the number of layers of the quartz net tire: n 2 = 17.6 - 30.34.

[0087] Based on the above calculations, there are 4 sets of structural process parameters for the quartz fiber felt that meet the requirements: n 1 = 25 / 26 / 27 / 28, n 2 = 29 / 26 / 23 / 20. Combining with the preset process parameter rules, the number of layers of the quartz fiber cloth is 25, and the number of layers of the quartz mesh core is 29. Thus, the structural parameters of the quartz fiber felt prepared based on the above number of layers of the quartz fiber cloth and the number of layers of the quartz mesh core are shown in Table 2.

[0088] Table 2 Structural Parameters of HPFC-T90A Quartz Fiber Felt

[0089]

[0090]

[0091] It can be understood that in order to enhance the ablation resistance of the surface and the heat insulation of the inner layer, the densities of the surface layer and the inner layer can be set differently. Therefore, the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh core can be divided according to the surface layer and the inner layer. For example, the total number of layers of the quartz fiber cloth is 25, the number of layers of the surface layer is 14, the number of layers of the inner layer is 11, the total number of layers of the quartz mesh core is 29, the number of layers of the surface layer is 14, and the number of layers of the inner layer is 15.

[0092] Then, according to the structural design in Table 2, the tensile fracture strength of the obtained quartz fiber felt is: 1197×(14 + 11) / (11×25) = 108.8 MPa, which meets the preset tensile fracture strength requirement.

[0093] Figure 2 Fig. shows a partial cross-sectional structural schematic diagram of the quartz fiber felt in the embodiment of the present application.

[0094] In the second aspect of the embodiment of the present application, a quartz fiber felt is provided, and the quartz fiber felt is prepared by using the process parameters determined by any one of the methods in the first aspect.

[0095] Thus, the quartz fiber felt prepared by using the process parameters determined by any one of the methods in the first aspect can meet the performance requirements of the quartz fiber felt, such as requirements for tensile fracture strength, thickness, density, heat insulation performance, etc.

[0096] In some embodiments, it includes:

[0097] Multiple layers of quartz fiber cloth 1 and multiple layers of quartz mesh core 2, the multiple layers of quartz fiber cloth 1 and the multiple layers of quartz mesh core 2 are stacked, the number of layers of the quartz fiber cloth 1 is less than or equal to the number of layers of the quartz mesh core 2, at least one layer of the quartz mesh core 2 is provided between adjacent two layers of the quartz fiber cloth 1, and the quartz fiber cloth 1 and the quartz mesh core 2 are needle-punched and connected.

[0098] It can be understood that when forming the quartz fiber felt by using the quartz fiber cloth 1, since the quartz fiber cloths 1 cannot be connected pairwise, the number of layers of the quartz fiber cloth 1 is set to be less than or equal to the number of layers of the quartz mesh matrix 2, so that at least one layer of quartz mesh matrix 2 can be arranged between two adjacent layers of quartz fiber cloth 1, and thus the connection of the quartz fiber cloth 1 can be realized based on the quartz mesh matrix 2 as the framework.

[0099] Figure 3 The partial structural schematic diagram of the aerogel adhesive according to the embodiment of the present application is shown. It can be understood that Figure 3 As shown, a resin material is filled between the quartz fiber cloth 1 and the quartz mesh matrix 2, and the resin material forms an aerogel in the quartz fiber cloth 1 and the quartz mesh matrix 2.

[0100] The third aspect of the embodiment of the present application provides an aerogel felt, including:

[0101] The quartz fiber felt according to any one of the second aspect, the quartz fiber felt having fiber gaps;

[0102] An aerogel, filled in the fiber gaps of the quartz fiber felt.

[0103] In some embodiments, the aerogel is prepared from a phenolic resin material.

[0104] It should be noted that the traditional phenolic resin composite material system has low heat insulation performance and can no longer meet the increasingly high heat insulation performance requirements. However, the low-density phenolic aerogel composite material prepared with the quartz fiber felt as the reinforcement and the hybrid phenolic resin as the matrix is integrally formed with the heat insulation and anti-ablation materials, has good heat insulation and anti-ablation performance, can meet the high-temperature environment, and thus the low-density phenolic aerogel composite material has good comprehensive performance.

[0105] It should be noted that the above embodiments are illustrative of the present invention rather than restrictive of the present invention, and those skilled in the art can design alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word "comprising" does not exclude the presence of elements or steps not listed in the claim. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The present invention can be implemented by means of hardware including several different elements and by means of a suitably programmed computer. In the unit claims listing several devices, several of these devices may be embodied by the same item of hardware. The use of the words first, second, and third, etc. does not denote any order. These words can be interpreted as names.

[0106] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included within the protection scope of the present invention.

Claims

1. A method for determining process parameters of quartz fiber felt, characterized in that: include: Determine the lower limit of the number of layers of the quartz fiber cloth according to the preset lower limit of the tensile fracture strength of the quartz fiber felt, the warp fracture strength of the quartz fiber cloth, and the thickness of the tensile specimen; Determine the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh according to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz mesh, the preset density of the quartz fiber felt, the surface density of the quartz fiber cloth and the surface density of the quartz mesh; The number of layers of the quartz fiber cloth and the number of layers of the quartz mesh are determined according to the lower limit and the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh.

2. The method according to claim 1, characterized in that The method of determining the lower limit of the number of layers of the quartz fiber cloth according to the preset lower limit of the tensile fracture strength of the quartz fiber felt, the warp fracture strength of the quartz fiber cloth, and the thickness of the tensile specimen comprises: According to the preset lower limit of tensile strength of the quartz fiber felt, the warp strength of the quartz fiber cloth and the thickness of the tensile specimen, the lower limit of the number of layers of the quartz fiber cloth is determined based on the following formula: Among them, n 1min represents the lower limit of the number of layers of the quartz fiber cloth, P represents the lower limit of the tensile breaking strength, D represents the thickness of the tensile specimen, and F represents the warp breaking strength of the quartz fiber cloth.

3. The method according to claim 2, characterized in that The lower limit of the tensile strength at break is n times the lower limit of the target tensile strength at break, wherein the value range of n is 1.2-1.

5.

4. The method according to claim 2, characterized in that: The quartz fiber felt comprises at least two kinds of the quartz fiber cloths, and the warp breaking strength of the quartz fiber cloths is the sum of the warp breaking strengths of the various quartz fiber cloths.

5. The method according to claim 1, characterized in that The determining of the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh according to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz mesh, the preset density of the quartz fiber felt, the surface density of the quartz fiber cloth and the surface density of the quartz mesh comprises: According to the single-layer thickness of the quartz fiber cloth, the single-layer thickness of the quartz mesh, the preset density of the quartz fiber felt, the surface density of the quartz fiber cloth and the surface density of the quartz mesh, the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh are determined based on the following formula: d=(n1×d1)+(n2×d2); (3) Wherein, ρ represents the preset density of the quartz fiber felt, ρ s1 represents the surface density of the quartz fiber cloth, ρ s2 represents the surface density of the quartz mesh, d represents the thickness of the quartz fiber felt, d1 represents the single-layer thickness of the quartz fiber cloth, d2 represents the single-layer thickness of the quartz mesh, n1 represents the range of the number of layers of the quartz fiber cloth, and n2 represents the range of the number of layers of the quartz mesh.

6. The method according to any one of claims 1 to 5, characterized in that: The determining the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh according to the lower limit and the range of the number of layers of the quartz fiber cloth and the range of the number of layers of the quartz mesh comprises: Determine the number of layers of the quartz fiber cloth and the number of layers of the quartz mesh according to the lower limit and range of the number of layers of the quartz fiber cloth, the range of the number of layers of the quartz mesh and the preset process parameter rules; The process parameter rules include: the number of layers of the quartz fiber cloth is less than or equal to the number of layers of the quartz mesh, and / or, when the lower limit of the tensile fracture strength is met, the number of layers of the quartz fiber cloth is reduced and the number of layers of the quartz mesh is increased.

7. A quartz fiber felt, characterized in that: The quartz fiber felt is prepared using process parameters determined by the method described in any one of claims 1-6.

8. The quartz fiber felt according to claim 7, characterized in that: include: Multilayer quartz fiber cloth and multilayer quartz mesh tire, the multilayer quartz fiber cloth and the multilayer quartz mesh tire are stacked, the number of layers of the quartz fiber cloth is less than or equal to the number of layers of the quartz mesh tire, at least one layer of the quartz mesh tire is arranged between two adjacent layers of the quartz fiber cloth, and the quartz fiber cloth and the quartz mesh tire are connected by needle punching.

9. An aerogel felt, characterized in that: include: The quartz fiber felt described in 7 or 8, wherein the quartz fiber felt has fiber gaps; Aerogel is filled in the fiber gaps of the quartz fiber felt.

10. The aerogel felt according to claim 9, characterized in that: The aerogel is prepared by using phenolic resin material.

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