Three-dimensional woven part composite nano ceramic fiber insulation board

Abstract

The utility model relates to a three-dimensional woven part composite nano ceramic fiber insulation board which comprises organic coating glass fabric I, a nano ceramic fiber needled felt I, a three-dimensional woven part framework, a nano ceramic fiber needled felt II and organic coating glass fabric II which are sequentially arranged from top to bottom. The three-dimensional woven part framework comprises an upper surface layer, a connecting layer and a lower surface layer which are respectively woven by fibers; the connecting layer is composed of a plurality of wire harnesses; the upper surface layer is connected with the lower surface layer through the connecting layer, and the connecting layer provides support for the upper surface layer and the lower surface layer; the outer surfaces of the upper surface layer, the connecting layer and the lower surface layer are coated with resin; the organic coating glass fabric I, the nano ceramic fiber needled felt I, the three-dimensional woven part framework, the nano ceramic fiber needled felt II and the organic coating glass fabric II are sewn and fixed through high-temperature-resistant suture lines. The three-dimensional woven part composite nano ceramic fiber insulation board has the advantages of being low in volume density, resistant to high temperature, low in heat conduction and high in strength.

Description

Technical Field

[0001] The utility model belongs to the technical field of heat insulation materials, and relates to a three-dimensional woven composite nano-ceramic fiber insulation board. Background Technique

[0002] Energy consumption and carbon emissions are major issues faced in the 21st century. The core goal of China's dual-carbon strategy is to reduce energy consumption and lower CO2 emissions to address global climate change. The effective application of thermal insulation materials in the fields of construction, industrial production, transportation, etc. is an important way to save energy and reduce carbon emissions.

[0003] Currently, the existing thermal insulation materials mainly include organic thermal insulation materials and inorganic thermal insulation materials. Among them, organic thermal insulation materials are mainly represented by melamine foam, polyurethane foam, polystyrene foam, phenolic foam, etc. These thermal insulation materials have good thermal insulation performance at room temperature. However, due to their defects such as easy combustion, non-fireproof, or the release of toxic smoke when burning due to the addition of flame retardants, and poor weather stability, their applications in the fields of construction, transportation, as well as high-temperature equipment and scenarios are restricted.

[0004] Inorganic thermal insulation materials mainly include four types: rock wool boards, silica aerogel composite glass fiber / ceramic fiber felts, vacuum insulation panels, and silicon carbide insulation boards.

[0005] Among them, CN109610663A records that the rock wool board is prepared from basalt, slag, industrial waste, etc. through melting, centrifugal spinning, and solidification molding, and is widely used in the thermal insulation of building facades and some industrial equipment after being compounded with a grid board and a binder. Its thermal conductivity is relatively low (up to 0.025 - 0.031W / (m·K)), and its fireproof performance is excellent. However, its bulk density is relatively large (up to 159 - 165kg / m 3 )), especially during use, it poses a greater threat to the health of construction workers and will also cause a great environmental safety risk after service.

[0006] The preparation processes of silica aerogel composite glass fiber mats and silica aerogel composite ceramic fiber mats are similar. Generally, glass fiber mats or ceramic fiber mats are prepared by compounding silica aerogel materials inside their mat bodies through supercritical or normal temperature and pressure processes. CN105367038B records that silica aerogel composite glass fiber / ceramic fiber mats have excellent heat insulation performance, with a thermal conductivity as low as 0.008 - 0.015 W / (m·K), and also have good mechanical strength. Patent CN209794765U discloses a three-dimensional hollow aerogel heat insulation and preservation board. In this patent, silica aerogel or its fiber reinforcement is filled in the voids between the skeletons woven by fiber bundles to obtain a three-dimensional hollow aerogel heat insulation and preservation board; Patent CN209307237U discloses a three-dimensional hollow woven part-reinforced silica aerogel composite material. In this patent, silica aerogel is filled in a three-dimensional hollow woven skeleton coated with silicone resin coatings on the upper and lower surfaces, which has strong mechanical strength and certain heat resistance and heat protection performance. However, it is difficult for the above materials to solve the problem of silica aerogel powder falling off, and silica aerogel is usually prone to the collapse of pore structure or phase transformation at high temperatures (>600 °C), which affects its heat insulation performance and overall stability, and its fire protection performance is also limited.

[0007] CN109844392B records that vacuum insulation panels are usually made of inorganic fiber materials as the core material, wrapped with an air barrier film on the outside and maintaining a vacuum state inside, which are high-efficiency insulation panels with the lowest thermal conductivity currently (as low as 0.002 - 0.004 W / (m·K)). Patent CN110566759A discloses a multi-layer core material supported by a woven fiber skeleton and the prepared vacuum insulation panel. In this patent, a woven fiber skeleton is used as the support layer of the core material to prepare a vacuum insulation panel, which increases the compressive performance and service life of the vacuum insulation panel. However, the manufacturing process of the above vacuum insulation panel materials is harsh, the production cost is high, and the temperature range of the applicable scenarios is narrow, which limits their application in the fields of construction, industrial heat insulation, etc.

[0008] Silicon carbide heat insulation boards are made by dry pressing silicon carbide powder, silicon carbide fiber or silicon carbide aerogel and other basic forms into plates or by compounding them with glass fiber / ceramic fiber mats. Since silicon carbide has good high-temperature resistance (it can withstand high temperatures of 1200 °C) and good infrared light shielding properties, it has been applied to some high-temperature heat insulation fields. However, due to the relatively high thermal conductivity of silicon carbide at room temperature (as high as 100 - 200 W / (m·K)), its application in the fields of construction, transportation, etc. is greatly limited.

[0009] Therefore, it is of great significance to study a three-dimensional woven part-reinforced nano-ceramic fiber heat insulation board to solve the problems existing in the prior art. Utility Model Content

[0010] The purpose of the present utility model is to solve the problems existing in the prior art and provide a three-dimensional woven composite nano-ceramic fiber thermal insulation board.

[0011] To achieve the above object, the technical solution adopted by the present utility model is as follows:

[0012] A three-dimensional woven composite nano-ceramic fiber thermal insulation board, comprising an organic-coated fiberglass cloth I, a nano-ceramic fiber needle punched felt I, a three-dimensional woven skeleton, a nano-ceramic fiber needle punched felt II, and an organic-coated fiberglass cloth II, which are arranged in sequence from top to bottom;

[0013] The three-dimensional woven skeleton includes an upper surface layer woven by fibers, a connecting layer woven by fibers, and a lower surface layer woven by fibers; the connecting layer is composed of a plurality of wire bundles; the upper surface layer is connected to the lower surface layer through the connecting layer, and the connecting layer provides support for the upper surface layer and the lower surface layer; the outer surfaces of the upper surface layer, the connecting layer, and the lower surface layer are wrapped with resin; the fiber is glass fiber, ceramic fiber, carbon fiber or aramid fiber; the resin is epoxy resin, polyimide resin or cyanate resin;

[0014] Specifically, the three-dimensional woven skeleton is a space three-dimensional skeleton formed by simultaneously weaving fibers in the X, Y, and Z directions using three-dimensional weaving technology to form a preform, and then through resin impregnation and post-curing treatment; the fibers are woven in the X and Y directions to form the upper surface layer and the lower surface layer, and a hollow structure is simultaneously woven in the Z direction. The woven wire bundles in the Z direction bridge and support the upper surface layer and the lower surface layer;

[0015] The organic-coated fiberglass cloth I, the nano-ceramic fiber needle punched felt I, the three-dimensional woven skeleton, the nano-ceramic fiber needle punched felt II, and the organic-coated fiberglass cloth II are stitched and fixed by high-temperature resistant sewing threads; the high-temperature resistant sewing threads are yarns with a softening temperature > 800 °C;

[0016] The organic-coated fiberglass cloth I and the organic-coated fiberglass cloth II are fiberglass cloths with an organic coating on the surface; the organic coating is an organic coating with a decomposition temperature > 200 °C. In the scenario where the temperature ≤ 200 °C, the organic coating provides the function of reducing air heat convection. After the temperature > 200 °C, as the temperature rises, the fiberglass in the fiberglass cloth gradually softens and melts together, replacing the organic coating to play the role of reducing air heat convection.

[0017] As a preferred technical solution:

[0018] For the three-dimensional woven composite nano-ceramic fiber thermal insulation board as described above, the thickness of each of the nano-ceramic fiber needle punched felt I and the nano-ceramic fiber needle punched felt II is 1 - 50 mm, the softening temperature > 1300 °C, and the needle pitch of the needles for preparing the nano-ceramic fiber needle punched felt I and the nano-ceramic fiber needle punched felt II is 30 - 90 needles / cm 2, the ceramic nanofiber bulk material of the nano-ceramic fiber needle punched felt endows it with the properties of high temperature resistance and low thermal conductivity, while the needling process effectively compensates for the defect of insufficient mechanical strength of the ceramic nanofiber bulk material. At the same time, the finished thickness and bulk density of the nano-ceramic fiber felt can be adjusted through the needling process, thereby regulating the balance of heat insulation, temperature resistance and light weight of the finished product;

[0019] The preparation process of the nano-ceramic fiber needle punched felt is as follows: the nano-ceramic fiber membrane is subjected to web laying, needling and cutting to obtain the nano-ceramic fiber needle punched felt, and the needle pitch of the needling is 30 - 90 needles / cm 2 . The main components of its ceramic fiber are silicon dioxide and aluminum trioxide, and the content of aluminum trioxide is 30 - 70 wt%.

[0020] For a three-dimensional woven composite nano-ceramic fiber thermal insulation board as described above, the diameter range of the nano-ceramic fiber is 0.3 - 1 μm.

[0021] For a three-dimensional woven composite nano-ceramic fiber thermal insulation board as described above, the organic coating is a polytetrafluoroethylene coating or a silicone rubber coating.

[0022] For a three-dimensional woven composite nano-ceramic fiber thermal insulation board as described above, the thickness of each of the organic coated fiberglass cloth I and the organic coated fiberglass cloth II is 0.3 - 3 mm.

[0023] For a three-dimensional woven composite nano-ceramic fiber thermal insulation board as described above, the thickness of the three-dimensional woven part skeleton is 5 - 500 mm.

[0024] For a three-dimensional woven composite nano-ceramic fiber thermal insulation board as described above, the high-temperature suture is a high-temperature suture twisted from one of high silica fiber, aluminum silicate fiber, quartz fiber and alumina fiber. Twisting the above fibers into a high-temperature suture is a prior art. For example, patents CN114717700 A and CN113846448A disclose alumina fiber yarn and high silica yarn. When the high-temperature suture stitches and fixes the organic coated fiberglass cloth I, the nano-ceramic fiber needle punched felt I, the three-dimensional woven part skeleton, the nano-ceramic fiber needle punched felt II and the organic coated fiberglass cloth II, the needle pitch of the high-temperature suture is 5 - 50 mm, which plays a role in fixing the overall structure and strengthening.

[0025] For a three-dimensional woven composite nano-ceramic fiber thermal insulation board as described above, when the high-temperature suture stitches and fixes the organic coated fiberglass cloth I, the nano-ceramic fiber needle punched felt I, the three-dimensional woven part skeleton, the nano-ceramic fiber needle punched felt II and the organic coated fiberglass cloth II, the high-temperature suture passes through the connecting layer of the three-dimensional woven part skeleton, further dividing and refining the internal space of the three-dimensional woven composite nano-ceramic fiber thermal insulation board, hindering air heat convection and reducing the thermal conductivity.

[0026] A three-dimensional braided composite nano-ceramic fiber thermal insulation board as described above, with multiple wire bundles distributed at intervals, and the shapes of the wire bundles being "I", "S", or "V" shapes.

[0027] A three-dimensional braided composite nano-ceramic fiber thermal insulation board as described above, with multiple wire bundles divided into n wire bundle groups; each wire bundle group includes two fiber bundles, and the two fiber bundles cross-lap to form an "X" shape.

[0028] Beneficial effects:

[0029] (1) The three-dimensional braided composite nano-ceramic fiber thermal insulation board of the present utility model has properties such as high temperature resistance, low thermal conductivity, and high strength. Moreover, the material preparation process is simple, expanding the application range of nano-ceramic fiber materials, being easy to be applied on a large scale, and being particularly suitable for heat insulation scenarios with lightweight, high temperature resistance, and fire prevention requirements in building materials, transportation, etc.

[0030] (2) The three-dimensional braided composite nano-ceramic fiber thermal insulation board of the present utility model has a low bulk density and high strength; during weaving, the organic-coated fiberglass cloth I, nano-ceramic fiber needle punched felt I, three-dimensional braided part skeleton, nano-ceramic fiber needle punched felt II, and organic-coated fiberglass cloth II are stitched into an integrated shape through high-temperature resistant sewing threads. The three-dimensional braided part skeleton has a good mechanical strengthening and toughening effect in the composite material. At the same time, the hollow structure inside the three-dimensional braided part skeleton, combined with the characteristics of the low bulk density of the nano-ceramic fiber itself, further endows the overall composite material with a low bulk density.

[0031] (3) In the three-dimensional braided composite nano-ceramic fiber thermal insulation board of the present utility model, the ceramic nano-fiber bulk material of the nano-ceramic fiber needle punched felt endows it with high temperature resistance and low thermal conductivity; the hollow structure inside the three-dimensional braided part skeleton significantly reduces the heat conduction of the solid medium, and the outer organic-coated fiberglass cloth also forms a closed space to block air transmission, further reducing the contribution of air heat convection to the overall heat transfer of the composite material.

[0032] (4) The three-dimensional braided composite nano-ceramic fiber thermal insulation board of the present utility model is stitched by high-temperature resistant sewing threads for the lamination of multiple layers. While shaping and strengthening the longitudinal direction of the composite thermal insulation board, it also effectively improves its transverse shear strength; at the same time, the sewing thread passing through the middle of the three-dimensional braided part skeleton at a certain stitch spacing further divides and refines the internal space, hindering air heat convection and reducing the thermal conductivity. Description of the drawings

[0033] Figure 1 It is a schematic structural diagram of a three-dimensional braided composite nano-ceramic fiber thermal insulation board of the present utility model;

[0034] Among them, 1 is a three-dimensional braided part skeleton, 2 is a nano-ceramic fiber needle-punched felt I, 3 is a nano-ceramic fiber needle-punched felt II, 4 is an organic-coated fiberglass cloth I, 5 is an organic-coated fiberglass cloth II, and 6 is a high-temperature resistant suture thread. Specific embodiments

[0035] The following further elaborates on the present utility model in conjunction with specific embodiments. It should be understood that these embodiments are only used to illustrate the present utility model and not to limit the scope of the present utility model. In addition, it should be understood that after reading the content taught by the present utility model, those skilled in the art can make various changes or modifications to the present utility model, and these equivalent forms also fall within the scope defined by the appended claims of this application.

[0036] The test methods related to the performance indicators of the present utility model are as follows:

[0037] Thermal conductivity at 25°C: Tested according to the standard of GB / T10295 - 2008;

[0038] Thermal conductivity at 600°C: Tested according to the standard of GB / T10294 - 2008;

[0039] Compressive strength: Refer to GB 8811 - 88. The specific test method is as follows: Gradually apply pressure from 0 Pa to the yield of the material (that is, the compressive stress reaches the peak and then decreases), and test at a compressive rate of 1 mm / min, detecting the dimensional change of the sample in the compression direction and the corresponding compressive stress; Deformation rate = (initial dimension - dimension after applying stress) / initial dimension.

[0040] A three-dimensional braided part composite nano-ceramic fiber insulation board, as Figure 1 shown, includes an organic-coated fiberglass cloth I 4, a nano-ceramic fiber needle-punched felt I 2, a three-dimensional braided part skeleton 1, a nano-ceramic fiber needle-punched felt II 3, and an organic-coated fiberglass cloth II 5 arranged in sequence from top to bottom;

[0041] The organic-coated fiberglass cloth I 4 and the organic-coated fiberglass cloth II 5 are fiberglass cloths with an organic coating on the surface; the thickness of each of the organic-coated fiberglass cloth I 4 and the organic-coated fiberglass cloth II 5 is 0.3 - 3 mm; the organic coating is a polytetrafluoroethylene coating or a silicone rubber coating, and its decomposition temperature > 200°C;

[0042] The thickness of each of the nano-ceramic fiber needle-punched felt I 2 and the nano-ceramic fiber needle-punched felt II 3 is 1 - 50 mm, and the softening temperature > 1300°C; the diameter range of the nano-ceramic fiber is 0.3 - 1 μm;

[0043] The three-dimensional braided part skeleton 1 includes a fiber-braided upper surface layer, a fiber-braided connection layer, and a fiber-braided lower surface layer; the connection layer is composed of multiple wire bundles; the multiple wire bundles are distributed at intervals, and the shape of the wire bundle is one of "I", "S", or "V" shapes, or the multiple wire bundles are divided into n wire bundle groups, each wire bundle group includes two wire bundles, and the two wire bundles cross-lap to form an "X" shape; the upper surface layer is connected to the lower surface layer through the connection layer, and the connection layer provides support for the upper surface layer and the lower surface layer; the outer surfaces of the upper surface layer, the connection layer, and the lower surface layer are wrapped with epoxy resin, polyimide resin, or cyanate resin; the fiber is glass fiber, ceramic fiber, carbon fiber, or aramid fiber; the thickness of the three-dimensional braided part skeleton 1 is 5-500 mm;

[0044] The organic-coated glass fiber cloth I 4, the nano-ceramic fiber needle-punched felt I 2, the three-dimensional braided part skeleton 1, the nano-ceramic fiber needle-punched felt II 3, and the organic-coated glass fiber cloth II 5 are stitched and fixed by a high-temperature resistant suture 6. When stitching and fixing, the high-temperature resistant suture 6 passes through the connection layer of the three-dimensional braided part skeleton 1; the high-temperature resistant suture 6 is a high-temperature resistant suture 6 twisted from one of high silica fiber, aluminum silicate fiber, quartz fiber, and alumina fiber, and its softening temperature > 800 °C.

[0045] The following uses specific embodiments to illustrate a three-dimensional braided part composite nano-ceramic fiber thermal insulation board of the present utility model, which is specifically as follows:

[0046] A three-dimensional braided part composite nano-ceramic fiber thermal insulation board includes an organic-coated glass fiber cloth I, a nano-ceramic fiber needle-punched felt I, a three-dimensional braided part skeleton, a nano-ceramic fiber needle-punched felt II, and an organic-coated glass fiber cloth II arranged in sequence from top to bottom.

[0047] The three-dimensional braided part skeleton is a 3D glass fiber braided skeleton cloth of Suzhou Chengjia Textile New Material Technology Co., Ltd.; the three-dimensional braided part skeleton includes a glass fiber-braided upper surface layer, a glass fiber-braided connection layer, and a glass fiber-braided lower surface layer; the connection layer is composed of multiple wire bundles, the diameter of a single wire bundle is 2 ± 0.5 mm, the multiple wire bundles are distributed at intervals, and the distance between any two adjacent wire bundles is 20 ± 2 mm; the shape of the wire bundle is an "S" shape; the upper surface layer is connected to the lower surface layer through the connection layer, and the connection layer provides support for the upper surface layer and the lower surface layer; the outer surfaces of the upper surface layer, the connection layer, and the lower surface layer are wrapped with epoxy resin; the thickness of the three-dimensional braided part skeleton is 20 mm;

[0048] The organic-coated glass fiber cloth I and the organic-coated glass fiber cloth II are glass fiber cloths coated with a polytetrafluoroethylene coating on the surface (PTFE Teflon glass fiber single-sided coating cloth of Taixing Sanheng Composite Materials Co., Ltd.); the thickness of each of the organic-coated glass fiber cloth I and the organic-coated glass fiber cloth II is 1 mm;

[0049] The nano-ceramic fiber needle punched felt I and the nano-ceramic fiber needle punched felt II are products of Jiaxing FuruiBang New Material Technology Co., Ltd.; the bulk density of each of the nano-ceramic fiber needle punched felt I and the nano-ceramic fiber needle punched felt II is 80 kg / m 3 , and the thickness is 15 mm; the nano-ceramic fiber includes 65 wt% of aluminum oxide, 25 wt% of silicon dioxide, and 10 wt% of trace components (including CaO, TiO2, ZrO2); the diameter range of the nano-ceramic fiber is 0.5 - 0.9 μm;

[0050] The organic coated fiberglass cloth I, the nano-ceramic fiber needle punched felt I, the three-dimensional braided part skeleton, the nano-ceramic fiber needle punched felt II, and the organic coated fiberglass cloth II are stitched and fixed by high-temperature resistant sewing threads. When stitching and fixing, the high-temperature resistant sewing threads pass through the connecting layer of the three-dimensional braided part skeleton; the high-temperature resistant sewing thread is a high-silica wire with a diameter of 1 mm from Wuhan Shimeier Energy Saving Technology Co., Ltd.

[0051] The bulk density of the three-dimensional braided part composite nano-ceramic fiber thermal insulation board is 40 kg / m 3 , the thermal conductivity at 25 °C is 0.045 W / (m·K), the thermal conductivity at 600 °C is 0.13 W / (m·K), there is no open flame, no smoke, no visible deformation to the naked eye, and the structure does not collapse when the butane torch flame is directly sprayed for 1 min, and the compressive strength of the material with 40% deformation is 0.15 MPa.

Claims

1. A three-dimensional woven composite nano-ceramic fiber thermal insulation board, characterized in that, It includes an organic-coated fiberglass cloth I, a nano-ceramic fiber needle-punched felt I, a three-dimensional braided part skeleton, a nano-ceramic fiber needle-punched felt II, and an organic-coated fiberglass cloth II, which are arranged in sequence from top to bottom; The three-dimensional braided part skeleton includes a fiber-braided upper surface layer, a fiber-braided connection layer, and a fiber-braided lower surface layer; the connection layer is composed of multiple wire bundles; the upper surface layer is connected to the lower surface layer through the connection layer, and the connection layer provides support for the upper surface layer and the lower surface layer; the outer surfaces of the upper surface layer, the connection layer, and the lower surface layer are wrapped with a resin coating; The fiber is glass fiber, ceramic fiber, carbon fiber, or aramid fiber; the resin is epoxy resin, polyimide resin, or cyanate resin; The organic-coated fiberglass cloth I, the nano-ceramic fiber needle-punched felt I, the three-dimensional braided part skeleton, the nano-ceramic fiber needle-punched felt II, and the organic-coated fiberglass cloth II are stitched and fixed by a high-temperature resistant suture; the high-temperature resistant suture is a yarn with a softening temperature > 800 °C; The organic-coated fiberglass cloth I and the organic-coated fiberglass cloth II are fiberglass cloths with an organic coating on the surface; the organic coating is an organic coating with a decomposition temperature > 200 °C.

2. The three-dimensional braided composite nano-ceramic fiber thermal insulation board according to claim 1, characterized in that The thickness of each of the nano-ceramic fiber needle-punched felt I and the nano-ceramic fiber needle-punched felt II is 1 - 50 mm, and the softening temperature > 1300 °C.

3. The three-dimensional braided composite nano-ceramic fiber thermal insulation board according to claim 2, wherein The diameter range of the nano-ceramic fiber is 0.3 - 1 μm.

4. The three-dimensional woven composite nano-ceramic fiber thermal insulation board according to claim 1, characterized in that The organic coating is a polytetrafluoroethylene coating or a silicone rubber coating.

5. The three-dimensional braided composite nano-ceramic fiber thermal insulation board according to claim 4, characterized in that, The thickness of each of the organic-coated fiberglass cloth I and the organic-coated fiberglass cloth II is 0.3 - 3 mm.

6. A three-dimensional woven composite nano-ceramic fiber insulation board according to claim 1, characterized in that, The thickness of the three-dimensional braided part skeleton is 5 - 500 mm.

7. A three-dimensional woven composite nano-ceramic fiber thermal insulation board according to claim 1, characterized in that, The high-temperature resistant suture is a high-temperature resistant suture twisted from one of high silica fiber, aluminum silicate fiber, quartz fiber, and alumina fiber.

8. A three-dimensional woven composite nano-ceramic fiber thermal insulation board according to claim 1, characterized in that, When the high-temperature resistant suture stitches and fixes the organic-coated fiberglass cloth I, the nano-ceramic fiber needle-punched felt I, the three-dimensional braided part skeleton, the nano-ceramic fiber needle-punched felt II, and the organic-coated fiberglass cloth II, the high-temperature resistant suture passes through the connection layer of the three-dimensional braided part skeleton.

9. A three-dimensional woven composite nano-ceramic fiber thermal insulation board according to claim 1, characterized in that The multiple wire bundles are distributed at intervals, and the shape of the wire bundle is "I", "S", or "V" shape.

10. A three-dimensional woven composite nano-ceramic fiber thermal insulation board according to claim 1, characterized in that, The multiple wire bundles are divided into n wire bundle groups; each wire bundle group includes two wire bundles, and the two wire bundles cross and overlap to form an "X" shape.

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