Based on the strategy of killing two birds with one stone, we introduce thermally expandable microspheres into a silicone rubber matrix to fabricate temperature-responsive controllable deformation materials, which exhibit intelligent deformation properties as well as enhanced thermal protection performance, for dynamic thermal protection in the next-generation morphing aircrafts. The formation of hollow structures endows the material with intelligent thermal management ability and makes the thermal conductivity controllable, meeting the requirements of rapid deformation and excellent thermal insulation. The dimensions of the material adaptively expand with increasing temperature, and a constant 50N force can be provided to ensure reliable sealing. Moreover, benefiting from the synergistic effect of the hollow structure and zinc borate in the ceramization process of the silicone rubber, the 10 mm thick material can reduce the temperature from 2000 to 63 °C, and the mass ablation rate is only 4.8 mg/s. To broaden the application of our material, a sensor with a sandwich structure composed of different functional layers is designed. It is pleasantly surprising to observe that the sensor can provide real-time remote warning of fire and overheating sites with a response time as short as 1 s. This synergistic strategy opens a new possibility to fabricate intelligent thermal protection materials.
Keywords: ablation resistance; fire warning; flexible thermal protection; intelligent self-sensing; self-adaptation deformation.