Lightweight and thermally insulating carbon-bonded carbon fiber/graphite composite with enhanced in-plane heat-leading functionality for efficient thermal protection materials

Non-ablative thermal protection materials are subjected to localized high-density heat flux, facing extreme temperatures and uneven temperature distribution. Heat dredging is expected to enhance thermal protection efficiency and alleviate its resistance to temperature pressure. In this study, the function of in-plane (IP) heat leading is innovatively incorporated to increase the thermal-protection efficiency of carbon-bonded carbon fiber (CBCF) composites. The modified composite is prepared by a one-step integrated filter press process in which continuous flexible graphite paper (FGP) is used as the heat-leading layer. The typical micromorphology, mechanical response, thermal-insulation and heat-leading performance are determined. The CBCF/FGP composites with a 0.1 mm thick heat-leading layer exhibits a density of 0.22 g/cm³. The compressive strength increased by 160 % in the IP direction while remaining consistent in the through-the-thickness direction relative to that of the pure CBCFs. The thermal conductivity in the insulation and heat-leading directions at room temperature are 0.061 W/mK and 21.14 W/mK, respectively, indicating significant anisotropy with an approximately 350-fold difference. The incorporation of FGP effectively enhances the IP heat-leading capabilities of CBCF composites, potentially improving their thermal-insulation efficiency when combined with different matrix materials.