External heat-proof sandwich structure material with embedded metal layer and preparation method of external heat-proof sandwich structure material

Abstract

The invention provides an outer heat-proof sandwich structure material with an embedded metal layer and a preparation method of the outer heat-proof sandwich structure material. The sandwich structure material comprises a first panel layer, a second panel layer, a third panel layer, an embedded metal layer and an aerogel core layer, wherein the first panel layer, the second panel layer and the third panel layer are compounded together, the embedded metal layer is located between the first panel layer and the second panel layer, and the aerogel core layer is located between the second panel layer and the third panel layer. The invention also relates to a method for preparing the sandwich structure material. The method comprises the following steps: compounding the ceramic panel fabric and sol to prepare ceramic panels as a first panel layer, a second panel layer and a third panel layer; compounding the fiber preform with the sol to prepare an aerogel core layer; and compounding the first panel layer, the second panel layer, the third panel layer, the embedded metal layer and the aerogel core layer to obtain the sandwich structure material. The material has high thermal conductivity, high heat resistance, high strain and high deflection; the method is simple, easy and convenient to operate and free of pollution substances. The method can be used for preparing component products of various shapes and specifications, and has wide application prospects in the environment of the aerospace industry.

Description

Technical Field

[0001] The present invention relates to the field of materials, and in particular to a high-temperature resistant external heat-proof material and a preparation method thereof. Background Art

[0002] Currently, common external heat protection materials can be divided into two categories: high-temperature resistant interlayer materials and thermal insulation tile materials. High-temperature resistant interlayer materials meet the temperature requirements of 1200°C, have a thermal conductivity of less than 0.1W / (m·K), and are excellent in resisting high-speed airflow. However, they are inorganic non-metallic materials and lack electrical conductivity.

[0003] Chinese patent application CN201610816609.5 discloses a method for improving the strain properties of high-temperature resistant sandwich structure insulation materials and the material produced by this method. The strain of the high-temperature resistant sandwich structure produced by this method is up to 4000με. However, after the composite metal layer is added to the insulation material produced by CN201610816609.5, the strain coordination ability of the material decreases sharply. Current methods make it difficult to obtain an internal embedded metal layer external heat-insulating material with a significant decrease in strain coordination ability. For high-temperature resistant sandwich structure insulation materials, the better the strain coordination ability of the material, without significantly affecting the material's temperature resistance and thermal insulation performance, the more suitable it is for use in external heat-insulating systems.

[0004] Therefore, it is very necessary to provide a method for preparing a heat-resistant sandwich structure material with an embedded metal layer and an outer heat-resistant layer without significantly reducing the strain coordination ability. Summary of the Invention

[0005] In order to solve one or more problems, the present invention provides, in the first aspect, a heat-proof sandwich structural material with an embedded metal layer and an outer heat-proof layer, wherein the heat-proof sandwich structural material with an embedded metal layer includes a first panel layer, a second panel layer, a third panel layer, an embedded metal layer located between the first panel layer and the second panel layer, and an aerogel core layer located between the second panel layer and the third panel layer.

[0006] In a second aspect, the present invention provides a method for preparing the sandwich structure material according to the first aspect of the present invention, the method comprising the following steps:

[0007] (1) compounding a ceramic panel fabric with a first precursor sol to prepare ceramic panels as the first panel layer, the second panel layer, and the third panel layer;

[0008] (2) compounding the fiber preform with the second precursor sol to obtain the aerogel core layer;

[0009] (3) Compounding the first panel layer, the second panel layer, the third panel layer, the embedded metal layer and the aerogel core layer to obtain the embedded metal layer sandwich structure external heat protection material.

[0010] Compared with the prior art, the present invention has the following technical advantages:

[0011] (1) The heat-resistant material with an embedded metal layer sandwich structure prepared by the present invention has excellent electrical conductivity.

[0012] (2) The heat-resistant material with an embedded metal layer sandwich structure prepared by the present invention has good strain performance, and the strain is greater than 2000με.

[0013] (3) The method of the present invention is simple, easy to operate, has little pollution to the environment, and the raw materials used, including fibers, sol precursors, etc., are all non-toxic or low-toxic materials: the preparation method used does not produce any substances that pollute the environment.

[0014] (4) The material prepared by the present invention can be used to prepare component products of various shapes and specifications, and has broad application prospects in the fields of aerospace industry and the like. DETAILED DESCRIPTION

[0015] To make the purpose, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the embodiments described are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, other embodiments obtained by ordinary technicians in this field without making creative efforts are all within the scope of protection of the present invention.

[0016] In the first aspect, the present invention provides an inner-buried metal layer and outer-heat-proof sandwich structural material, wherein the inner-buried metal layer and outer-heat-proof sandwich structural material includes a first panel layer, a second panel layer, a third panel layer, an inner-buried metal layer located between the first panel layer and the second panel layer, and an aerogel core layer located between the second panel layer and the third panel layer.

[0017] In some preferred embodiments, the thickness of the second panel layer is 0.1 mm to 2 mm.

[0018] In some preferred embodiments, the embedded metal layer has a thickness of 0.07 mm to 0.3 mm (e.g., 0.07, 0.08, 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.18, 0.20, 0.24, 0.25, 0.28, or 0.30 mm), preferably 0.07 mm to 0.25 mm. If the thickness is too large, the strain capacity of the outer heat shielding material of the sandwich structure with the embedded metal layer will be reduced. If the thickness is too small, the conductivity of the embedded metal layer will be affected.

[0019] In some preferred embodiments, the embedded metal layer is a metal mesh layer or a metal coating. More preferably, the mesh size of the metal mesh layer is 20 to 200 mesh. Further preferably, the embedded metal layer is made of a material selected from any one or more of a combination of highly conductive metal layers such as steel mesh, nickel mesh, and copper mesh.

[0020] In some preferred embodiments, the bonding is achieved by suturing. More preferably, the stitching spacing is 5 mm to 25 mm (e.g., 5, 6, 8, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 22, 23, and 25 mm), preferably 5 mm to 17 mm. If the stitching spacing is too large, the material's strain resistance decreases and the bonding strength between the layers is reduced; if the stitching spacing is too small, the material's thermal insulation capacity decreases.

[0021] In some preferred embodiments, the thickness of the second panel layer is 0.5 mm to 3 mm (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, or 3 mm). In some preferred embodiments, the thickness of the third panel layer is 0.3 mm to 1 mm (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, or 1 mm). If the thickness is too large, the thermal insulation capacity of the material decreases and the strain resistance decreases. If the thickness is too small, the strength of the material decreases, and its anti-scouring performance and load-bearing performance decrease.

[0022] The present invention has no particular requirements for the thickness of the aerogel core layer, and the thickness can be selected according to actual needs. For example, the aerogel thickness can be 5 mm to 30 mm (e.g., 10, 20, or 30 mm). Of course, this thickness can also be smaller or larger.

[0023] In some more preferred embodiments, the strain of the sandwich structure material is greater than 2000 με, preferably 2000 με to 5000 με, such as 2000 με to 4000 με, such as 2000 με, 3000 με or 4000 με, more preferably 2500 με to 5000 με.

[0024] Further preferably, the deflection of the sandwich structure material is 3 mm to 10 mm (for example, 3, 4, 5, 6, 7, 8, 9 or 10 mm).

[0025] In some more preferred embodiments, the sandwich structure material described in the first aspect of the present invention is prepared by the method described below in the second aspect of the present invention.

[0026] In a second aspect, the present invention provides a method for preparing the sandwich structure material according to the first aspect of the present invention, the method comprising the following steps:

[0027] (1) compounding a ceramic panel fabric with a first precursor sol to prepare ceramic panels as the first panel layer, the second panel layer, and the third panel layer;

[0028] (2) compounding the fiber preform with the second precursor sol to obtain the aerogel core layer;

[0029] (3) Compounding the first panel layer, the second panel layer, the third panel layer, the embedded metal layer and the aerogel core layer to obtain the embedded metal layer sandwich structure external heat protection material.

[0030] The present invention does not particularly limit the method for compounding the ceramic panel fabric with the first and second precursor sols, and can be performed using methods known to those skilled in the art, such as the method described in CN201610816609.5. For example, the impregnation of the sol with the plant or preform can be performed under normal pressure, negative pressure, or high pressure, or by brushing, followed by sol gelation at high temperature or room temperature, and finally air-drying or oven-drying.

[0031] For example, the first precursor sol can be a silica sol or an alumina sol; and the second precursor sol can be selected from any one of silica sol, alumina sol, and zirconium dioxide sol. The present invention has no particular limitation on the concentration of the sols. For example, the concentration of the first precursor sol and the second precursor sol can independently be 10% to 40% (e.g., 10, 15, 20, 25, 30, 35, or 40%), preferably 15% to 30%.

[0032] For another example, the ceramic panel fabric can be woven from ceramic yarns such as quartz yarns, alumina yarns or mullite yarns; the fiber preform used in the aerogel core layer can be made from a combination of one or more selected from quartz fibers, alumina fibers or mullite fibers.

[0033] The present invention manufactures an external heat-proof material with high temperature resistance, high strain coordination and excellent electrical conductivity by embedding a metal layer and a second panel layer.

[0034] Currently, existing external heat-shielding materials with embedded metal layers and sandwich structures can meet the requirements for use at 1100°C, with a thermal conductivity coefficient of less than 0.1W / (m·K), and the strain can meet the requirements for use in external heat-shielding systems. However, the strain performance of the external heat-shielding materials with embedded metal layers and sandwich structures will decrease after the metal layer is embedded. After in-depth research, the inventors unexpectedly discovered that by using an external heat-shielding material with embedded metal layers and sandwich structures comprising a high-temperature resistant panel, an embedded metal layer, and an aerogel core layer, the strain performance of the external heat-shielding material with embedded metal layers and sandwich structures can be significantly improved by adjusting the thickness of the panel layer, adjusting the thickness of the embedded metal layer, and adjusting the composite stitching spacing. It is easy to produce an external heat-shielding material with embedded metal layers and sandwich structures having a strain performance greater than 2500με or a controllable strain performance (for example, controlled within a range of 2500με to 4000με).

[0035] In addition, it is noted that, unless otherwise specified, any range described in the present invention includes the end value of the range, any numerical value between the end values, and any sub-range formed by the end value or any numerical value between the end values.

[0036] Example

[0037] The present invention will be further described below with reference to the examples. These examples are merely illustrative of preferred embodiments of the present invention, and the scope of protection of the present invention should not be construed as being limited to these examples. The raw materials involved in each example of the present invention can all be commercially obtained.

[0038] Example 1

[0039] This example prepares an external heat-resistant material with an embedded metal layer sandwich structure. The material uses a high-temperature-resistant ceramic panel fabric woven from quartz fiber yarns. The high-temperature-resistant fiber preform is a quartz fiber preform. The first and second precursor sols are both silica sols (purchased from Shandong Better New Materials Co., Ltd., with a concentration of 20% by mass).

[0040] First, the high-temperature resistant ceramic panel fabric and the first precursor sol were compounded by vacuum pressure impregnation to obtain high-temperature resistant ceramic panels used as the first panel layer (thickness see Table 1 below), the second panel layer (0.5 mm) and the third panel layer (0.5 mm), and then the high-temperature resistant fiber preform and the second precursor sol were compounded by vacuum impregnation to obtain an aerogel core layer material (thickness of 20 mm).

[0041] Then, the prepared first to third panel layers, the embedded metal layer (100-mesh steel mesh) and the aerogel core layer are sewn together to obtain an outer heat-proof material with an embedded metal layer sandwich structure.

[0042] After testing, the performance of the embedded metal layer sandwich structure external heat protection material prepared in this embodiment is as follows: temperature resistance is 1000°C; strain performance is 2200με (ASTM C1341-00), and deflection is 4.2mm (ASTM C1341-00).

[0043] Examples 2 to 8

[0044] Except for the contents listed in Table 1, Examples 2 to 10 were implemented in the same manner as Example 1.

[0045] Example 9

[0046] The process is carried out in substantially the same manner as in Example 1, except that the embedded metal layer is a 0.1 mm thick copper coating sprayed on the first panel layer.

[0047] Example 10

[0048] The process is carried out in a manner substantially the same as in Example 1, except that the second precursor sol is an alumina sol of the same mass concentration, the thickness of the second panel layer is 0.8 mm, the thickness of the third panel layer is 0.3 mm, the aerogel core layer is 15 mm, and the suture spacing is 15 mm.

[0049] Comparative Example 1

[0050] The process is carried out in a manner substantially the same as in Example 1, except that the second panel layer is not omitted, that is, the second panel layer is not sewn on during sewing.

[0051] Comparative Example 2

[0052] The procedure was basically the same as that of Comparative Example 1, except that the suture interval was adjusted to 5 mm.

[0053] Comparative Example 3

[0054] The process was carried out in substantially the same manner as in Example 1, except that the suture spacing was adjusted to 20 mm.

[0055] Comparative Example 4

[0056] The process was carried out in substantially the same manner as in Example 1, except that the metal layer was not sewn.

[0057] Table 1 Process parameters and performances used in the embodiments and comparative examples

[0058]

[0059] *: The embedded metal layer is a copper coating obtained by spraying; “-” means there is no embedded metal layer.

[0060] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, it should be understood by those skilled in the art that the technical solutions described in the embodiments may still be modified, or some of the technical features therein may be replaced with equivalents, and these modifications or replacements do not deviate the essence of the technical solutions from the spirit and scope of the various embodiments of the present invention.

Claims

1. A heat-resistant sandwich structure material with an embedded metal layer and an external heat-resistant layer, characterized by: The embedded metal layer and outer heat-proof sandwich structure material includes a first panel layer, a second panel layer, a third panel layer, an embedded metal layer located between the first panel layer and the second panel layer, and an aerogel core layer located between the second panel layer and the third panel layer.

2. The sandwich structure material according to claim 1, characterized in that: The thickness of the second panel layer is 0.1 mm to 2 mm.

3. The sandwich structure material according to claim 1 or 2, characterized in that: The thickness of the embedded metal layer is 0.07 mm to 0.3 mm.

4. The sandwich structure material according to any one of claims 1 to 3, characterized in that: The embedded metal layer is a metal mesh layer or a metal coating; Preferably, the mesh number of the metal wire mesh layer is 20 mesh to 200 mesh; More preferably, the material of the embedded metal layer is selected from any one or more combinations of steel mesh, nickel mesh and copper mesh.

5. The sandwich structure material according to any one of claims 1 to 4, characterized in that: The compounding is achieved by suturing; Preferably, the suture spacing of the suture is 5 mm to 17 mm.

6. The sandwich structure material according to any one of claims 1 to 5, characterized in that: The thickness of the second panel layer is 0.5 mm to 3 mm; and / or The thickness of the third panel layer is 0.3 mm to 1 mm.

7. The sandwich structure material according to any one of claims 1 to 6, characterized in that: The strain of the sandwich structure material is 2000με to 5000με, and the deflection is 3mm to 10mm.

8. A method for preparing the sandwich structure material according to any one of claims 1 to 7, characterized in that: The method comprises the following steps: The method comprises the following steps: (1) compounding a ceramic panel fabric with a first precursor sol to prepare ceramic panels as the first panel layer, the second panel layer, and the third panel layer; (2) compounding the fiber preform with the second precursor sol to obtain the aerogel core layer; (3) Compounding the first panel layer, the second panel layer, the third panel layer, the embedded metal layer and the aerogel core layer to obtain the embedded metal layer sandwich structure external heat protection material.

9. The method according to claim 8, characterized in that: The first precursor sol is a silica sol or an alumina sol; and / or The second precursor sol is selected from any one of silica sol, alumina sol and zirconium dioxide sol.

10. The method according to any one of claims 8 or 9, characterized in that: The ceramic panel fabric is woven from ceramic yarns; preferably, the ceramic yarns are selected from the group consisting of quartz yarns, alumina yarns, and mullite yarns; and / or The fiber preform used in the aerogel core layer is made of a combination of one or more selected from quartz fiber, alumina fiber or mullite fiber.

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