Three-phase composite, and preparation method and use thereof

Patent metadata

Field	Value
Publication number	US-2026054456-A1
Application number	US-202418944712-A
Country	US
Kind code	A1
Filing date	Nov 12, 2024
Priority date	Aug 21, 2024
Publication date	Feb 26, 2026
Grant date	—

Abstract

A three-phase composite, and a preparation method and use thereof are provided. The three-phase composite includes a hollow glass microsphere composite foam and a plurality of carbon fiber tubes filled in the hollow glass microsphere composite foam; where the carbon fiber tubes are arranged in a two-dimensional closest packing manner, two adjacent carbon fiber tubes have a center-to-center spacing of 29.9 mm to 34 mm, and each of the carbon fiber tubes has a wall thickness of 0.45 mm to 1 mm; and two ends of each of the carbon fiber tubes each are sealed by an end cap.

First claim

What is claimed is:

1 . A three-phase composite, comprising a hollow glass microsphere composite foam and a plurality of carbon fiber tubes filled in the hollow glass microsphere composite foam;
wherein the carbon fiber tubes are arranged in a two-dimensional closest packing manner, two adjacent carbon fiber tubes have a center-to-center spacing of 29.9 mm to 34 mm, and each of the carbon fiber tubes has a wall thickness of 0.45 mm to 1 mm; and two ends of each of the carbon fiber tubes each are sealed by an end cap.

2 . The three-phase composite of claim 1 , wherein a standard piece of the three-phase composite has a cross-section shape selected from the group consisting of a circle, a hexagon, and a square, and the standard piece of the three-phase composite has a height of 150 mm to 500 mm.

3 . The three-phase composite of claim 1 , wherein each of the carbon fiber tubes has an inner diameter of 26 mm to 30 mm.

4 . The three-phase composite of claim 1 , wherein each of the carbon fiber tubes is prepared by a process comprising the steps of:
subjecting a thin-layer carbon fiber prepreg and a thick-layer carbon fiber prepreg to orthogonal lamination in a carbon fiber direction to obtain a laminated carbon fiber prepreg, and rolling the laminated carbon fiber prepreg to obtain a tube blank; wherein a thickness ratio of the thin-layer carbon fiber prepreg to the thick-layer carbon fiber prepreg is in a range of 1:2; and winding a biaxially oriented polypropylene (BOPP) film on a surface of the tube blank, and then conducting curing and demolding in sequence to obtain a carbon fiber tube.

5 . The three-phase composite of claim 4 , wherein the curing comprises low-temperature curing and high-temperature curing in sequence, the low-temperature curing is conducted at a temperature of 75° C. to 85° C. for 25 min to 35 min, and the high-temperature curing is conducted at a temperature of 120° C. to 140° C. for 110 min to 130 min.

6 . The three-phase composite of claim 1 , wherein the end cap is prepared by a material selected from the group consisting of a carbon fiber, a titanium alloy, and an aluminum alloy, and the end cap has a shape selected from the group consisting of a sheet and a hemispherical shell.

7 . The three-phase composite of claim 1 , wherein the hollow glass microsphere composite foam has a density of 0.4-0.5 g/cm 3 .

8 . A method for preparing the three-phase composite of claim 1 , comprising a method 1 or a method 2; wherein
the method 1 comprises the following steps: preparing a mold according to a shape of the three-phase composite; and arranging the plurality of carbon fiber tubes in the mold and pouring a mixture of a glass microsphere and an epoxy resin into the mold, and then conducting curing and molding to obtain the three-phase composite; and the method 2 comprises the following steps: processing a cured hollow glass microsphere composite foam to obtain the hollow glass microsphere composite foam with pores; and embedding the plurality of carbon fiber tubes in the pores, and then conducting sealing and adhesion to obtain the three-phase composite.

9 . The method of claim 8 , wherein an adhesive for the sealing and adhesion comprises an epoxy resin.

10 . A method of using the three-phase composite of claim 1 , comprising using the three-phase composite as a buoyancy material.

11 . The three-phase composite of claim 4 , wherein a standard piece of the three-phase composite has a cross-section shape selected from the group consisting of a circle, a hexagon, and a square, and the standard piece of the three-phase composite has a height of 150 mm to 500 mm.

12 . The three-phase composite of claim 4 , wherein each of the carbon fiber tubes has an inner diameter of 26 mm to 30 mm.

13 . The method of claim 8 , wherein a standard piece of the three-phase composite has a cross-section shape selected from the group consisting of a circle, a hexagon, and a square, and the standard piece of the three-phase composite has a height of 150 mm to 500 mm.

14 . The method of claim 8 , wherein each of the carbon fiber tubes has an inner diameter of 26 mm to 30 mm.

15 . The method of claim 8 , wherein each of the carbon fiber tubes is prepared by a process comprising the steps of:
subjecting a thin-layer carbon fiber prepreg and a thick-layer carbon fiber prepreg to orthogonal lamination in a carbon fiber direction to obtain a laminated carbon fiber prepreg, and rolling the laminated carbon fiber prepreg to obtain a tube blank; wherein a thickness ratio of the thin-layer carbon fiber prepreg to the thick-layer carbon fiber prepreg is in a range of 1:2; and winding a biaxially oriented polypropylene (BOPP) film on a surface of the tube blank, and then conducting curing and demolding in sequence to obtain a carbon fiber tube.

16 . The method of claim 8 , wherein the curing comprises low-temperature curing and high-temperature curing in sequence, the low-temperature curing is conducted at a temperature of 75° C. to 85° C. for 25 min to 35 min, and the high-temperature curing is conducted at a temperature of 120° C. to 140° C. for 110 min to 130 min.

17 . The method of claim 8 , wherein the end cap is prepared by a material selected from the group consisting of a carbon fiber, a titanium alloy, and an aluminum alloy, and the end cap has a shape selected from the group consisting of a sheet and a hemispherical shell.

18 . The method of claim 8 , wherein the hollow glass microsphere composite foam has a density of 0.4-0.5 g/cm 3 .

19 . The method of claim 10 , wherein a standard piece of the three-phase composite has a cross-section shape selected from the group consisting of a circle, a hexagon, and a square, and the standard piece of the three-phase composite has a height of 150 mm to 500 mm.

20 . The method of claim 10 , wherein each of the carbon fiber tubes has an inner diameter of 26 mm to 30 mm.

Assignees

• Univ Harbin Eng

Inventors

• Wu Linzhi
• Yu Guocai
• Jin Yang
• Zhao Zheng
• Liu Mingyu
• Cong Fanglin
• Wang Chengyang
• Lin Zhuang

Classifications

• B29C70/025

  with particular filler · CPC title

• B29C70/66

  the filler comprising hollow constituents, e.g. syntactic foam · CPC title

• B29C44/00

  Shaping by internal pressure generated in the material, e.g. swelling or foaming {; Producing porous or cellular expanded plastics articles} · CPC title

• B29K2509/08

  Glass · CPC title

• B29K2507/04

  Carbon · CPC title