A composite insulating panel having a high modulus of elasticity

Abstract

The utility model provides a kind of composite insulating board of high elastic modulus, it is related to electrical insulating material technical field, including upper dense panel, lower dense panel and corrugated core layer, the corrugated core layer is located between the upper dense panel and lower dense panel, the corrugated core layer is three-dimensional continuous undulation structure, the inside integration of the corrugated core layer is reinforced framework, the reinforced framework is multistage fiber mesh structure, and the main fiber bundle of its reinforced framework is woven along the curved surface trend of the corrugated core layer, the peak of the corrugated core layer is embedded with bionic reinforcing node at wave trough vertex;The utility model is combined by four core structure innovation points of "three-dimensional corrugated sandwich structure", "multistage bionic fiber reinforced framework", "gradient interface and self-repair system" and "bionic node local reinforcement", and constructs a kind of full-scale optimized composite insulating board.

Description

Technical Field

[0001] This utility model relates to the field of electrical insulation materials technology, and in particular to a composite insulation board with high elastic modulus. Background Technology

[0002] In fields such as high-voltage electrical equipment, rail transit insulation systems, and aerospace electrical components, extremely high comprehensive performance requirements are placed on the insulation materials of structural support components: excellent electrical insulation performance is required, along with high elastic modulus to resist deformation and good impact and damage tolerance to ensure long-term reliability. Existing composite insulation boards mostly use laminates, glass fiber reinforced epoxy resin boards (FR-4), or simple unidirectional fiber reinforcement structures, which mainly have the following shortcomings:

[0003] First, the extensive use of unidirectional continuous fiber reinforcement in pursuit of high modulus leads to significant anisotropy in the material, resulting in a sharp decrease in stiffness and strength in non-principal stress directions, making it difficult to withstand complex stress states. Second, the weak interfacial bonding strength between the reinforcing fibers and the resin matrix easily becomes a stress concentration point and a microcrack initiation source, leading to premature delamination failure and low damage tolerance. Furthermore, the traditional insulation board has a simple structural design, lacking active design of load transfer paths and damage suppression mechanisms. Once cracks or damage occur, they can easily propagate rapidly, causing the entire component to fail. Therefore, we propose a composite insulation board with high elastic modulus. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies. First, the extensive use of unidirectional continuous fiber reinforcement in pursuit of high modulus leads to significant anisotropy in the material, resulting in a sharp decrease in stiffness and strength in non-principal stress directions, making it difficult to withstand complex stress states. Second, the weak interfacial bonding strength between the reinforcing fibers and the resin matrix easily becomes a stress concentration point and a microcrack initiation source, leading to premature delamination failure and low damage tolerance. Furthermore, the traditional insulation board has a simple structural design, lacking active design of load transfer paths and damage suppression mechanisms. Once cracks or damage occur, they can easily propagate rapidly, leading to the failure of the entire component.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A high-elasticity modulus composite insulation board includes an upper dense panel, a lower dense panel, and a corrugated core layer. The corrugated core layer is located between the upper and lower dense panels and has a three-dimensional continuous undulating structure. An integrated reinforcing skeleton is incorporated within the corrugated core layer. The reinforcing skeleton is a multi-level fiber mesh structure, with its main fiber bundles woven along the curved surface of the corrugated core layer. Biomimetic reinforcing nodes are embedded at the crests and troughs of the corrugated core layer, and these biomimetic reinforcing nodes have a porous mesh structure inside. The upper and lower dense panels are bonded to the corrugated core layer as a single unit using a resin composite bonding agent.

[0007] Furthermore, the reinforcing skeleton includes a main fiber bundle woven at ±45° along the main stress direction of the corrugated core surface, and a secondary fiber network formed by leading out from the intersection of the main fiber bundles and weaving them together, with nanofiber bridges connected at the nodes of the secondary fiber network.

[0008] Furthermore, the main fiber bundle of the reinforcing skeleton is a high-modulus carbon fiber bundle, the secondary fiber web is an aramid fiber web, and the nanofiber bridge is a nanocellulose whisker.

[0009] Furthermore, the biomimetic reinforcement node is a 3D printed metal or high-modulus ceramic component with microtexture on its outer surface. The multiple extension arms of the biomimetic reinforcement node are interwoven and anchored with the main fiber bundles and resin matrix of the surrounding reinforcing skeleton.

[0010] Furthermore, microcapsules are uniformly dispersed within the resin composite material bonded to the upper dense panel, the lower dense panel, and the corrugated core layer. The outer shell of the microcapsules is a brittle polymer, and the interior is filled with a repair agent. A gradient interface transition layer is provided between the main fiber bundles and resin matrix of the reinforcing skeleton.

[0011] Furthermore, the corrugated wavelength, wave height, and corrugated angle of the corrugated core layer vary periodically or gradiently along the length of the plate.

[0012] Furthermore, in the expected high stress concentration areas of the composite insulation board, the corrugation density of the corrugated core layer and the distribution density of the reinforcing skeleton main fiber bundles are greater than in other areas.

[0013] Compared with the prior art, the beneficial effects of this utility model are:

[0014] This invention organically combines four core structural innovations: a three-dimensional corrugated sandwich structure, a multi-level biomimetic fiber-reinforced skeleton, a gradient interface and self-healing system, and local reinforcement of biomimetic nodes. This results in a composite insulation board optimized across all scales. The design not only optimizes macroscopic mechanical properties and improves isotropy through the corrugated core layer and biomimetic nodes, but also achieves microscopic reinforcement and toughening through a multi-level fiber network and gradient interface. Furthermore, it introduces self-healing capabilities. The final product maintains excellent electrical insulation performance while achieving high and balanced elastic modulus, superior impact toughness, high damage tolerance, and long-life reliability. It is particularly suitable for fields with extreme requirements for mechanical properties and insulation reliability. Attached Figure Description

[0015] Figure 1 A schematic diagram of the overall structure of a composite insulation board with high elastic modulus provided by this utility model;

[0016] Figure 2 A schematic diagram of the internal structure of the corrugated core layer of a composite insulation board with high elastic modulus provided by this utility model;

[0017] Figure 3 This is a partial structural diagram of point A of a composite insulation board with high elastic modulus provided by this utility model.

[0018] Legend: 1. Upper dense panel; 2. Lower dense panel; 3. Corrugated core layer; 301. Reinforcing skeleton; 302. Peak; 303. Trough; 304. Bionic reinforcement node. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0020] To facilitate understanding of this utility model, a more comprehensive description of this utility model will be provided below with reference to relevant embodiments, and several embodiments of this utility model will be given. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of this utility model more thorough and complete.

[0021] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0023] Example 1

[0024] like Figure 1-3 As shown, this utility model provides a technical solution: a composite insulation board with high elastic modulus, comprising as follows Figure 1 As shown, the high elastic modulus composite insulation board of this embodiment includes an upper dense panel 1, a lower dense panel 2, and a corrugated core layer 3. The corrugated core layer 3 is located between the upper dense panel 1 and the lower dense panel 2. The corrugated core layer 3 has a three-dimensional continuous undulating structure. An integrated reinforcing skeleton 301 is incorporated inside the corrugated core layer 3. The reinforcing skeleton 301 has a multi-level fiber mesh structure. The main fiber bundles of the reinforcing skeleton 301 are woven along the curved surface of the corrugated core layer 3. Bionic reinforcing nodes 304 are embedded at the apex of the crests 302 and troughs 303 of the corrugated core layer 3. The interior of the bionic reinforcing nodes 304 has a porous mesh structure. The upper dense panel 1 and the lower dense panel 2 are bonded to the corrugated core layer 3 with resin composite material. The corrugated core layer 3 provides isotropic stiffness through asymmetric corrugations, reducing anisotropy to below 15%. The bionic reinforcing nodes 304 achieve a rigid-flexible transition, efficiently converting out-of-plane loads into in-plane stresses.

[0025] Example 2

[0026] like Figure 1-3As shown, the reinforcing skeleton 301 includes main fiber bundles woven at ±45° angles along the main stress direction of the corrugated core layer 3, and secondary fiber networks formed by leading out and weaving from the intersection nodes of the main fiber bundles. Nanofiber bridges connect the nodes of the secondary fiber network. Through the synergistic effect of the main, secondary, and microfiber networks, a multi-scale stress transmission and dispersion path is constructed. This significantly improves the overall modulus and strength while effectively suppressing crack initiation and propagation, thus increasing the material's damage tolerance. The main fiber bundles of the reinforcing skeleton 301 are high-modulus carbon fiber bundles, the secondary fiber network is an aramid fiber network, and the nanofiber bridges are nanocellulose whiskers. The carbon fibers provide ultra-high modulus. Aramid fibers provide excellent toughness and impact resistance, while nanocellulose whiskers greatly increase the interfacial bonding area and mechanical interlocking effect between the fiber and resin, forming a composite reinforcement system that combines rigidity and flexibility with interface strengthening. The biomimetic reinforcement node 304 is a 3D printed metal or high-modulus ceramic component with micro-texture on its outer surface. Multiple extension arms of the biomimetic reinforcement node 304 are interwoven and anchored with the main fiber bundles and resin matrix of the surrounding reinforcement skeleton 301. The biomimetic node provides rigid support at the stress concentration points of the corrugated structure to prevent local buckling. Its porous structure facilitates resin filling to form strong mechanical interlocking. Its high modulus characteristics effectively improve the local stiffness of the core layer and optimize the load distribution.

[0027] Microcapsules are uniformly dispersed within the resin composite material bonded to the upper dense panel 1, lower dense panel 2, and corrugated core layer 3. The microcapsule shells are made of brittle polymers, and the interiors are filled with a repair agent. A gradient interface transition layer is provided between the main fiber bundles and the resin matrix of the reinforcing skeleton 301. From the inside out, the gradient interface transition layer includes a micro-etched layer on the fiber surface, a rigid polymer segment layer grafted thereon, a flexible polymer segment layer, and an outer functional group layer. This gradient interface transition layer achieves a smooth transition of modulus between the fiber and the resin, and provides a dual bonding mechanism of chemical bonding and mechanical interlocking, significantly improving performance. The interfacial bonding strength and durability are improved. The corrugated wavelength, wave height and corrugated angle of the corrugated core layer 3 vary periodically or gradiently along the length of the board. The design of the corrugated parameters can adjust the stiffness and isotropicity of the board in different directions, so as to achieve the designability of performance. In the expected high stress concentration area of ​​the composite insulation board, the corrugated density of the corrugated core layer 3 and the distribution density of the main fiber bundle of the reinforcing skeleton 301 are greater than those in other areas. This design realizes intelligent material distribution and local reinforcement, and improves the load-bearing capacity and fatigue life of key areas in a targeted manner without significantly increasing the weight.

[0028] The working process of this utility model is as follows: When using a composite insulation board with a high elastic modulus, firstly, when it is installed as a supporting insulation component and bears the load, the three-dimensional corrugated core layer 3 efficiently converts the out-of-plane load into in-plane stress. The main fiber bundle network of the reinforcing skeleton 301 serves as the main load-bearing path to transfer most of the load. The biomimetic reinforcing nodes 304 provide rigid support and disperse stress at stress concentration points. When the material develops microcracks due to accidental impact, the crack tip expands and encounters the microcapsules, causing them to rupture. The released repair agent polymerizes under the action of a catalyst, achieving crack healing. The gradient interface layer ensures that even under alternating stress, the fibers and resin are not easily debonded. The entire system works in concert, thus maintaining high stiffness, high strength, and excellent insulation and sealing reliability over a long period of time under harsh working conditions.

[0029] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A composite insulating board with high elastic modulus, comprising an upper dense panel (1), a lower dense panel (2), and a corrugated core layer (3), wherein the corrugated core layer (3) is located between the upper dense panel (1) and the lower dense panel (2), characterized in that: The corrugated core layer (3) is a three-dimensional continuous undulating structure. The corrugated core layer (3) is internally integrated with a reinforcing skeleton (301). The reinforcing skeleton (301) is a multi-level fiber mesh structure. The main fiber bundles of the reinforcing skeleton (301) are woven along the curved surface of the corrugated core layer (3). Bionic reinforcing nodes (304) are embedded at the apex of the crests (302) and troughs (303) of the corrugated core layer (3). The bionic reinforcing nodes (304) are internally porous mesh structures. The upper dense panel (1) and the lower dense panel (2) are bonded to the corrugated core layer (3) as a whole by resin composite bonding.

2. The composite insulation board with high elastic modulus according to claim 1, characterized in that: The reinforcing skeleton (301) includes a main fiber bundle woven at ±45° along the main stress direction of the corrugated core layer (3) surface, and a secondary fiber network formed by leading out from the intersection of the main fiber bundles and weaving them together. The nodes of the secondary fiber network are connected to nanofiber bridges.

3. A composite insulation board with high elastic modulus according to claim 2, characterized in that: The main fiber bundle of the reinforcing skeleton (301) is a high-modulus carbon fiber bundle, the secondary fiber network is an aramid fiber network, and the nanofiber bridge is a nanocellulose whisker.

4. A composite insulation board with high elastic modulus according to claim 2, characterized in that: The biomimetic reinforcement node (304) is a three-dimensional printed metal or high-modulus ceramic component with micro-texture on its outer surface. The multiple extension arms of the biomimetic reinforcement node (304) are interwoven and anchored with the main fiber bundles and resin matrix of the surrounding reinforcement skeleton (301).

5. A composite insulation board with high elastic modulus according to claim 1, characterized in that: Microcapsules are uniformly dispersed in the resin composite material in which the upper dense panel (1), the lower dense panel (2), and the corrugated core layer (3) are bonded. The outer shell of the microcapsules is a brittle polymer, and the inside is filled with a repair agent. A gradient interface transition layer is provided between the main fiber bundle resin matrix of the reinforcing skeleton (301).

6. A composite insulation board with high elastic modulus according to claim 1, characterized in that: The corrugated core layer (3) has a periodic or gradient variation in its corrugated wavelength, wave height, and corrugated angle along the length of the plate.

7. A composite insulation board with high elastic modulus according to claim 1, characterized in that: In the expected high stress concentration area of ​​the composite insulation board, the corrugation density of the corrugated core layer (3) and the distribution density of the main fiber bundles of the reinforcing skeleton (301) are greater than in other areas.

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