Thermal protection and bearing integrated composite material and preparation process thereof

Abstract

This invention discloses a load-bearing and heat-resistant integrated composite material and its preparation process. The composite material, from the inside out, comprises a carbon fiber phenolic resin matrix composite layer, a transition layer, and a high-silica fiber phenolic resin matrix composite layer. An auxiliary material layer is laid on the outer side of the high-silica fiber phenolic resin matrix composite layer. The preparation process includes the following steps: S1: winding pre-forming; S2: hot-pressing curing and demolding; S3: testing. In this application, based on the same resin matrix, high-silica fiber prepreg and carbon fiber prepreg are used in a winding process to achieve the co-curing and molding characteristics of the hybrid fiber reinforced resin matrix composite material, thereby achieving the technical goal of developing and preparing a load-bearing and heat-resistant integrated composite material and improving equipment performance. Based on the winding process, rapid molding of the rotating shell structure can be achieved with high stability. Based on the same resin system, structural deformation and other problems caused by material differences in the hybrid fiber reinforced resin matrix composite material can be reduced.

Description

Technical Field

[0001] This invention belongs to the field of spacecraft material application technology, specifically relating to a load-bearing and heat-resistant integrated composite material and its preparation process. Background Technology

[0002] As the performance of flight equipment continues to improve, the technical requirements for structural load-bearing capacity, thermal protection, and lightweighting are also increasing. Currently, flight equipment often uses different materials to form composite structures to meet various needs. However, due to the significant differences in performance between different materials and the different molding processes, products often have weak points such as interfaces, resulting in poor structural performance. Furthermore, the molding processes are complex and production efficiency is low.

[0003] Lightweight design, load-bearing capacity, and thermal protection are among the most critical performance requirements for aerospace materials and structures. Traditionally, different materials are used to manufacture the load-bearing and thermal protection structures separately, which are then assembled together. Because load-bearing structures often use metals with high density, the equipment is heavy. Furthermore, the significant differences in properties between metals and thermal protection materials result in poor bonding performance, impacting equipment performance.

[0004] Integrated thermal protection composite structures are a new type of structure that combines thermal protection and load-bearing functions, simultaneously fulfilling both load-bearing and thermal protection requirements. Advanced composite materials such as fiber-reinforced resin matrix composites possess lightweight, high strength, and high-temperature resistance properties. Therefore, by integrating various fiber-reinforced resin matrix composites into a single design and molding process, it is possible to develop and produce integrated load-bearing and thermal protection materials and structures.

[0005] Currently, universities, research institutes, and other organizations are developing hybrid fiber composite material design and molding technologies based on various fiber-resin-based composite materials. The aim is to achieve a multi-functional integrated structure with load-bearing, ablation resistance, and heat insulation properties, while further reducing the cost of structural products. Chinese Patent CN112265347A discloses a structural load-bearing-ablation heat-insulating integrated composite material and its preparation method. Using prepregs composed of different fibers and resins, and through methods such as lay-up and co-curing molding, it achieves the design and manufacturing of structural products with integrated load-bearing, ablation resistance, and heat insulation properties. Chinese Patent CN114085524B discloses a structural load-bearing-ablation integrated phthalic anion resin prepreg, composite material, and its preparation method. Based on phthalic anion resin, ablation resistance modifiers, and carbon fibers, it develops a prepreg with integrated load-bearing and ablation resistance properties. Through lay-up, molding, and hot pressing methods, it completes product manufacturing, thereby achieving the product's load-bearing and ablation resistance functions.

[0006] The above technologies mainly have the following problems: 1. Traditional load-bearing and heat-resistant functions use different materials, resulting in poor compatibility between materials, complex molding equipment processes, low production efficiency, and poor structural product stability; 2. Existing composite material products with integrated load-bearing and heat-resistant functions have poor process stability, slow production cycles, and affect product quality and production results. Summary of the Invention

[0007] The purpose of this invention is to provide a load-bearing and heat-resistant integrated composite material and its preparation process, addressing the technical problems described in the background art.

[0008] The technical solution of this invention: A load-bearing and heat-resistant integrated composite material is used to manufacture a load-bearing and heat-resistant integrated rotating body structure. From the inside out, it includes a carbon fiber phenolic resin-based composite material layer, a transition layer, and a high-silica fiber phenolic resin-based composite material layer. An auxiliary material layer is laid on the outside of the high-silica fiber phenolic resin-based composite material layer.

[0009] The carbon fiber phenolic resin-based composite material layer is formed by overlapping and winding carbon fiber phenolic resin-based prepreg tapes, and the carbon fiber phenolic resin base is composed of 65% carbon fiber and 35% phenolic resin by volume.

[0010] The high-silica fiber phenolic resin-based composite material layer is formed by overlapping and winding high-silica fiber phenolic resin-based prepreg tapes. The high-silica fiber phenolic resin base is composed of 65% high-silica fiber and 35% phenolic resin by volume.

[0011] The transition layer is formed by cross-winding of carbon fiber phenolic resin-based prepreg tape and high silica fiber phenolic resin-based prepreg tape.

[0012] The auxiliary material layer includes a release film, a release cloth, and a breathable felt, which are sequentially laid on the outside of the high-silica fiber phenolic resin-based composite material layer.

[0013] A process for preparing a load-bearing, heat-resistant integrated composite material includes the following steps: S1: Winding preforming: For rotating structures, the product is preformed using a winding process and then sent to an autoclave. S2: Hot pressing curing and demolding. After completing step S1, hot pressing curing is carried out using segmented temperature variation and uniform air pressure. After curing, demolding is performed using a demolding machine. S3: Inspection and testing. After completing step S2, the rotating structure is inspected and tested to ensure product qualification.

[0014] In step S1, the winding process includes the following steps: a1: Using carbon fiber phenolic resin-based prepreg tape, an overlap winding process is employed to form a carbon fiber phenolic resin-based composite material layer, thus completing the pre-forming of the load-bearing structure; a2: After completing step a1, a splicing and winding process is used to cross-wrap carbon fiber phenolic resin-based prepreg tape and high silica fiber phenolic resin-based prepreg tape to form a transition layer. a3: After completing step a2, use high-silica fiber phenolic resin-based prepreg tape and adopt an overlapping winding method to continue winding the high-silica fiber phenolic resin-based composite material to complete the preforming of the heat protection structure and finally obtain the load-bearing and heat-resistant integrated rotating structure preform. a4: After completing step a3, lay the release film, release cloth and breathable felt on the outside of the precast part in sequence, wrap and seal it in a vacuum bag, and then send it into the autoclave.

[0015] In step S2, the hot-press curing process is divided into the following stages: b1: First stage: Heating rate 1℃ / min, and heat preservation and pressure holding at 80℃, 100℃ and 120℃ respectively, with curing pressure maintained at 0.6MPa for 30min; b2: Second stage: After completing the first stage, continue to raise the temperature to 160℃, maintain the pressure at 0.6MPa, and hold the temperature and pressure for 180min; b3: Third stage: The cooling rate is 0.8℃ / min, the pressure is maintained at 0.6MPa, and the temperature drops to room temperature; b4: Fourth stage: After complete cooling, open the autoclave, use a demolding machine to demold the product and remove it.

[0016] In step S3, based on visual inspection and non-destructive testing, it is ensured that there are no obvious defects on the surface of the rotating shell structure product, and the feasibility and reliability of the structure and process are verified through static tests.

[0017] In step a2, carbon fiber phenolic resin-based prepreg tape and high silica fiber phenolic resin-based prepreg tape are cross-wound, with each type of prepreg tape being cross-wound at least 2 layers.

[0018] The beneficial effects of this invention are: In this application, high-silica fiber prepreg and carbon fiber prepreg, based on the same resin matrix, are used in a winding molding process to achieve the co-curing and molding characteristics of hybrid fiber reinforced resin matrix composites. This achieves the technical goal of developing and molding an integrated load-bearing and heat-resistant composite material, thereby improving equipment performance. Based on the winding process, rapid molding of the rotating shell structure can be achieved with high stability. Based on the same resin system, structural deformation and other problems caused by material differences in hybrid fiber reinforced resin matrix composites can be reduced, and the technical goal of integrated molding can be achieved, thereby improving production efficiency. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the composite material structure of the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the composite material structure of the present invention. Figure 2 .

[0020] 1-Fiber phenolic resin-based composite material layer, 2-Transition layer, 3-Fiber phenolic resin-based composite material layer, 4-Auxiliary material layer, 11-Carbon fiber phenolic resin-based prepreg tape, 31-Oxygen fiber phenolic resin-based prepreg tape, 41-Release film, 42-Mold release cloth and 43-Breathable felt. Detailed Implementation

[0021] refer to Figures 1-2 A load-bearing and heat-resistant integrated composite material is used to manufacture a load-bearing and heat-resistant integrated rotating body structure. From the inside out, it includes a carbon fiber phenolic resin-based composite material layer 1, a transition layer 2, and a high-silica fiber phenolic resin-based composite material layer 3. An auxiliary material layer 4 is laid on the outside of the high-silica fiber phenolic resin-based composite material layer 3.

[0022] The carbon fiber phenolic resin-based composite material layer 1 is formed by overlapping and winding carbon fiber phenolic resin-based prepreg tape 11. The carbon fiber phenolic resin matrix consists of 65% carbon fiber and 35% phenolic resin by volume. This material, composed of 65% carbon fiber and 35% phenolic resin by volume, possesses characteristics of high temperature resistance, ablation resistance, and structural load-bearing capacity. Used in this application, it can effectively withstand high temperatures. Specifically: With a carbon fiber volume fraction of 65%, it is a high-reinforcing phase content, far exceeding that of ordinary structural composites. It possesses high strength, stiffness, light weight, and strong load-bearing capacity. Phenolic resin itself is heat-resistant, flame-retardant, low-smoke, and low-toxicity; at high temperatures, it forms a dense carbon layer, providing heat insulation, erosion resistance, and resistance to ablation; it can operate in environments of several hundred degrees Celsius or even short-term temperatures of over a thousand degrees Celsius, making it a classic ablation-resistant material.

[0023] The high-silica fiber phenolic resin-based composite material layer 3 is formed by overlapping and winding high-silica fiber phenolic resin-based prepreg tape 31. The high-silica fiber phenolic resin base is composed of 65% high-silica fiber and 35% phenolic resin by volume.

[0024] The high-silica fiber phenolic resin matrix is ​​composed of 65% high-silica fiber and 35% phenolic resin by volume. It possesses characteristics such as ultra-high temperature resistance, ablation resistance, erosion resistance, heat insulation, thermal insulation, chemical stability, and strong corrosion resistance. When used in this application, this material can withstand high temperatures and provide thermal insulation. Specifically: High-silica fibers have a high SiO2 content and can withstand high long-term use temperatures without melting or softening at high temperatures. The phenolic matrix is ​​carbonized at high temperatures to form a dense carbon layer. The two work together to achieve a low ablation rate and good thermal insulation. Furthermore, high-silica fibers have extremely low thermal conductivity, making them a classic high-temperature thermal insulation reinforcement. The high-silica fiber phenolic resin matrix composite layer 3 is formed by overlapping and winding high-silica fiber phenolic resin matrix prepreg tape 31. The overall composite material has low thermal conductivity and is resistant to thermal shock, making it suitable for thermal protection structures.

[0025] The transition layer 2 is formed by cross-winding of carbon fiber phenolic resin-based prepreg tape 11 and high silica fiber phenolic resin-based prepreg tape 31.

[0026] The transition layer 2 can prevent the structural performance from changing in a stepwise manner in the thickness direction, thus avoiding stress concentration or obvious interface phenomena that could affect product performance.

[0027] The auxiliary material layer 4 includes a release film 41, a release cloth 42, and a breathable felt 43, sequentially laid on the outside of the high-silica fiber phenolic resin-based composite material layer 3. The function of the auxiliary material layer 4 is to ensure uniform impregnation, smooth degassing, and curing of the resin under heating and pressurization conditions, and to facilitate smooth demolding of the product with good surface quality, while protecting the mold and the product. Specifically: The separator membrane has the following functions: (1) The barrier resin is directly bonded to the release cloth 42 and the breathable felt 43; (2) Prevent excess resin from seeping into the breathable felt 43, causing waste or sticking to the mold; (3) Ensure that the auxiliary materials can be peeled off as a whole after molding without damaging the surface of the part.

[0028] Release cloth has the following functions: (1) Provides an easy-peel interface, allowing the cured part to be easily separated from the upper auxiliary material; (2) Ensure the product surface is flat, free of sticky material, and free of defects; (3) It has the functions of being breathable and allowing a small amount of resin to pass through, which is beneficial to the molding quality.

[0029] Breathable felt has the following functions: (1) Provide ventilation channels to allow gases and low-molecular-weight volatiles generated during the molding process to be discharged smoothly; (2) Evenly transmit pressure to avoid uneven local pressure leading to insufficient glue, poor oil content, and porosity; (3) Absorb a small amount of excess resin to ensure the internal density of the composite material.

[0030] A process for preparing a load-bearing, heat-resistant integrated composite material includes the following steps: S1: Winding preforming: For rotating structures, the product is preformed using a winding process and then sent to an autoclave. S2: Hot pressing curing and demolding. After completing step S1, hot pressing curing is carried out using segmented temperature variation and uniform air pressure. After curing, demolding is performed using a demolding machine. S3: Inspection and testing. After completing step S2, the rotating structure is inspected and tested to ensure product qualification.

[0031] In step S1, the winding process includes the following steps: a1: Using carbon fiber phenolic resin-based prepreg tape 11, an overlap winding process is used to form carbon fiber phenolic resin-based composite material layer 1, thus completing the pre-forming of the load-bearing structure; a2: After completing step a1, a splicing and winding process is used to cross-wrap the carbon fiber phenolic resin-based prepreg tape 11 and the high silica fiber phenolic resin-based prepreg tape 31 to form a transition layer 2. a3: After completing step a2, use high-silica fiber phenolic resin-based prepreg tape 31 and continue to wind high-silica fiber phenolic resin-based composite material by overlapping winding method to complete the preforming of the heat protection structure and finally obtain the load-bearing and heat-protecting integrated rotating body structure preform. a4: After completing step a3, lay the release film 41, release cloth 42 and breathable felt 43 on the outside of the preform in sequence, and then seal it with a vacuum bag before sending it into the autoclave.

[0032] In step S2, the hot-press curing process is divided into the following stages: b1: First stage: Heating rate 1℃ / min, and heat preservation and pressure holding at 80℃, 100℃ and 120℃ respectively, with curing pressure maintained at 0.6MPa for 30min; b2: Second stage: After completing the first stage, continue to raise the temperature to 160℃, maintain the pressure at 0.6MPa, and hold the temperature and pressure for 180min; b3: Third stage: The cooling rate is 0.8℃ / min, the pressure is maintained at 0.6MPa, and the temperature drops to room temperature; b4: Fourth stage: After complete cooling, open the autoclave, use a demolding machine to demold the product and remove it.

[0033] In step S3, based on visual inspection and non-destructive testing, it is ensured that there are no obvious defects on the surface of the rotating shell structure product, and the feasibility and reliability of the structure and process are verified through static tests.

[0034] In step a2, the carbon fiber phenolic resin-based prepreg tape 11 and the high silica fiber phenolic resin-based prepreg tape 31 are cross-wound, with each type of prepreg tape being cross-wound at least 2 layers.

[0035] In this application, high-silica fiber prepreg and carbon fiber prepreg, based on the same resin matrix, are used in a winding molding process to achieve the co-curing and molding characteristics of hybrid fiber reinforced resin matrix composites. This achieves the technical goal of developing and molding an integrated load-bearing and heat-resistant composite material, thereby improving equipment performance. Based on the winding process, rapid molding of the rotating shell structure can be achieved with high stability. Based on the same resin system, structural deformation and other problems caused by material differences in hybrid fiber reinforced resin matrix composites can be reduced, and the technical goal of integrated molding can be achieved, thereby improving production efficiency.

Claims

1. A load-bearing and heat-resistant integrated composite material for manufacturing a load-bearing and heat-resistant integrated rotating body structure, characterized in that... From the inside out, it includes a carbon fiber phenolic resin-based composite material layer (1), a transition layer (2), and a high silica fiber phenolic resin-based composite material layer (3). An auxiliary material layer (4) is laid on the outside of the high silica fiber phenolic resin-based composite material layer (3).

2. The load-bearing and heat-resistant integrated composite material according to claim 1, characterized in that: The carbon fiber phenolic resin-based composite material layer (1) is formed by overlapping and winding carbon fiber phenolic resin-based prepreg tape (11), and the carbon fiber phenolic resin base is composed of 65% carbon fiber and 35% phenolic resin by volume.

3. The load-bearing and heat-resistant integrated composite material according to claim 2, characterized in that: The high-silica fiber phenolic resin-based composite material layer (3) is formed by overlapping and winding high-silica fiber phenolic resin-based prepreg tape (31), and the high-silica fiber phenolic resin-based composite material is composed of 65% high-silica fiber and 35% phenolic resin by volume.

4. The load-bearing and heat-resistant integrated composite material according to claim 3, characterized in that: The transition layer (2) is formed by cross-winding of carbon fiber phenolic resin-based prepreg tape (11) and high silica fiber phenolic resin-based prepreg tape (31).

5. The load-bearing and heat-resistant integrated composite material according to claim 1, characterized in that: The auxiliary material layer (4) includes a release film (41), a release cloth (42) and a breathable felt (43) that are sequentially laid on the outside of the high silica fiber phenolic resin-based composite material layer (3).

6. The preparation process of the load-bearing and heat-resistant integrated composite material according to any one of claims 1-5, characterized in that: Includes the following steps: S1: Winding preforming: For rotating structures, the product is preformed using a winding process and then sent to an autoclave. S2: Hot pressing curing and demolding. After completing step S1, hot pressing curing is carried out using segmented temperature variation and uniform air pressure. After curing, demolding is performed using a demolding machine. S3: Inspection and testing. After completing step S2, the rotating structure is inspected and tested to ensure product qualification.

7. The preparation process of the load-bearing and heat-resistant integrated composite material according to claim 6, characterized in that: In step S1, the winding process includes the following steps: a1: Using carbon fiber phenolic resin-based prepreg tape (11), a lap-wound winding process is adopted to form a carbon fiber phenolic resin-based composite material layer (1), thus completing the preforming of the load-bearing structure; a2: After completing step a1, a splicing and winding process is used to cross-wrap the carbon fiber phenolic resin-based prepreg tape (11) and the high silica fiber phenolic resin-based prepreg tape (31) to form a transition layer (2). a3: After completing step a2, use high-silica fiber phenolic resin base prepreg tape (31) and adopt the overlapping winding method to continue winding the high-silica fiber phenolic resin base composite material to complete the preforming of the heat protection structure and finally obtain the load-bearing heat protection integrated rotating body structure preform. a4: After completing step a3, lay the release film (41), release cloth (42) and breathable felt (43) on the outside of the preform in sequence, and then seal it with a vacuum bag before sending it into the autoclave.

8. The preparation process of the load-bearing and heat-resistant integrated composite material according to claim 6, characterized in that: In step S2, the hot-press curing process is divided into the following stages: b1: First stage: Heating rate 1℃ / min, and heat preservation and pressure holding at 80℃, 100℃ and 120℃ respectively, with curing pressure maintained at 0.6MPa for 30min; b2: Second stage: After completing the first stage, continue to raise the temperature to 160℃, maintain the pressure at 0.6MPa, and hold the temperature and pressure for 180min; b3: Third stage: The cooling rate is 0.8℃ / min, the pressure is maintained at 0.6MPa, and the temperature drops to room temperature; b4: Fourth stage: After complete cooling, open the autoclave, use a demolding machine to demold the product and remove it.

9. The preparation process of the load-bearing and heat-resistant integrated composite material according to claim 6, characterized in that: In step S3, based on visual inspection and non-destructive testing, it is ensured that there are no obvious defects on the surface of the rotating shell structure product, and the feasibility and reliability of the structure and process are verified through static tests.

10. The preparation process of the load-bearing and heat-resistant integrated composite material according to claim 7, characterized in that: In step a2, the carbon fiber phenolic resin-based prepreg tape (11) and the high silica fiber phenolic resin-based prepreg tape (31) are interwoven, with each type of prepreg tape interwoven at least 2 layers.

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