High-temperature composite with anisotropic graphite binder
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Solution Overview
Problem
High-temperature insulation materials face challenges in balancing thermal radiation and conduction insulation while maintaining mechanical stability, as dense materials effectively block radiation but increase conduction, and less dense materials suppress conduction but not convection, leading to inefficiencies in heat management and potential local overheating.
Innovation Solution
The use of layered composite materials with a high-temperature-resistant, low-density material for conduction insulation and a dense reflective material for radiation and convection insulation, where the connection between layers is enhanced by a carbonizable binder containing flat anisotropic graphite particles to minimize heat conduction and stress buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If dense reflective materials are used to prevent heat radiation and convection, then radiation insulation is improved, but thermal conductivity increases leading to increased heat conduction
Solution Approach 1:
The insulation system is divided into multiple discrete layers with alternating functions: dense reflective layers (graphite foil) for radiation/convection protection and low-density insulating layers (carbon fiber felt, porous graphite) for conduction protection. This segmentation allows each layer to specialize in one function without compromising the other.
Solution Approach 2:
The patent employs composite material structures combining graphite foil layers with carbon fiber-reinforced carbon matrices, and incorporates porous graphite materials. These composites integrate the high reflectivity and mechanical strength of dense materials with the low thermal conductivity of porous structures, achieving both radiation and conduction insulation simultaneously.
2Loss of energy
If low-density materials are used to suppress heat conduction, then conduction insulation is improved, but convection protection is reduced
Solution Approach 1:
The insulation system is divided into multiple discrete layers with alternating functions: dense reflective layers (graphite foil) for radiation/convection protection and low-density insulating layers (carbon fiber felt, porous graphite) for conduction protection. This segmentation allows each layer to specialize in one function without compromising the other.
Solution Approach 2:
The patent employs composite material structures combining graphite foil layers with carbon fiber-reinforced carbon matrices, and incorporates porous graphite materials. These composites integrate the high reflectivity and mechanical strength of dense materials with the low thermal conductivity of porous structures, achieving both radiation and conduction insulation simultaneously.
3Loss of energy
If layered composite materials are used to achieve both radiation and conduction insulation, then thermal insulation performance is improved, but mechanical stability may be compromised
Solution Approach 1:
The patent employs composite material structures combining graphite foil layers with carbon fiber-reinforced carbon matrices, and incorporates porous graphite materials. These composites integrate the high reflectivity and mechanical strength of dense materials with the low thermal conductivity of porous structures, achieving both radiation and conduction insulation simultaneously.
Solution Approach 2:
The patent utilizes the anisotropic thermal conductivity parameter of graphite materials, where thermal conductivity is highly directional (high in-plane, low through-thickness). By orienting graphite foil layers and using carbon fiber reinforcement, the composite achieves favorable mechanical properties while maintaining thermal insulation performance.
4Stability of the object's composition
If carbonizable binder is used to connect layers, then layer cohesion is improved, but heat conduction between layers increases
Solution Approach 1:
The patent incorporates porous graphite materials as bonding layers between insulation layers. The porous structure provides mechanical adhesion while the air pockets within the porous structure minimize thermal conduction pathways, reducing interfacial heat transfer compared to dense binder materials.
Solution Approach 2:
The patent uses a carbonizable binder that decomposes during carbonization to form a carbon-rich bonding layer. This binder serves its primary function during manufacturing (providing cohesion) and then transforms into a low-conductivity carbon structure that maintains bonding while minimizing heat transfer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively reduces heat loss through both radiation and conduction, prevents local overheating, and enhances mechanical stability by using flat anisotropic graphite particles in the binder to align with the thermal conductivity characteristics of graphite, ensuring reliable cohesion without significant heat transfer across interfaces.
Implementation Method 1
the thermal conductivity in the flat anisotropic particles of graphite is at least a factor of 10 higher along the layer planes of the graphite than perpendicular to the layer planes of the graphite
Implementation Method 2
a second, dense reflective material (e.g. graphite foil) for insulation against thermal radiation and convection
Implementation Method 3
thermal insulations are preferably formed from layered composite materials, which include at least one high-temperature-resistant material of relatively low thermal conductivity
Data Source
Figure 1
AI summary
High-temperature-resistant composite, comprises a carbonized binder containing planar anisotropic graphite particles and at least two layers, each formed of a material such as high-temperature-resistant carbon-based materials and high-temperature-resistant graphite-based materials, joined to one another by the carbonized binder. Independent claims are included for: (1) a process for joining two items such as layers and components and formed from the materials comprising applying the carbonizable binder having planar anisotropic graphite particles to a surface of a first item to be joined to a second item resulting in a binder-coated surface, applying the second item onto the binder-coated surface of the first item, curing the carbonizable binder, and performing at least one of carbonization and graphitization of the carbonizable binder; and (2) a composite component comprising an apparatus such as heat shields, thermal insulations, furnace internals, and high-temperature resistant parts, where the apparatus formed of the high-temperature-resistant composite.