CN105500837A - 复合材料制作高铁设备舱裙板的工艺 - Google Patents

复合材料制作高铁设备舱裙板的工艺 Download PDF

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Publication number
CN105500837A
CN105500837A CN201510947266.1A CN201510947266A CN105500837A CN 105500837 A CN105500837 A CN 105500837A CN 201510947266 A CN201510947266 A CN 201510947266A CN 105500837 A CN105500837 A CN 105500837A
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China
Prior art keywords
prepreg
retardant
apron board
fiber
skirtboard
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CN201510947266.1A
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CN105500837B (zh
Inventor
朱家强
王滨
张四顺
王明
谢长志
罗剑岚
刘永凯
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SHANGHAI CEDAR COMPOSITES TECHNOLOGY Co Ltd
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SHANGHAI CEDAR COMPOSITES TECHNOLOGY Co Ltd
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Priority to CN201510947266.1A priority Critical patent/CN105500837B/zh
Publication of CN105500837A publication Critical patent/CN105500837A/zh
Priority to US16/063,250 priority patent/US10828870B2/en
Priority to SG11201702923YA priority patent/SG11201702923YA/en
Priority to PCT/CN2016/096333 priority patent/WO2017101490A1/zh
Priority to JP2018532028A priority patent/JP6615356B2/ja
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    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure

Abstract

本发明涉及一种复合材料制作高铁设备舱裙板的工艺，本发明用的材料包括：芳纶蜂窝、PET泡沫、3K碳纤维阻燃预浸料、单向碳纤维阻燃预浸料、玻璃纤维阻燃预浸料、芳纶阻燃预浸料、300g/m2单组分中温固化蓝色环氧片胶。工艺包括(1)、制作裙板主板；(2)、制作裙板压条；裙板压条包括两种，每一种两条共四条；(3)、裙板主板和裙板压条五者做成裙板总成；裙板主板的四边中相对的两边的裙板压条为同一种，所有的裙板压条均卡在裙板主板上。本发明经过铺层设计使得该裙板在各个角度都能得到很高的强度，增加芳纶设计提供高强冲击性；裙板主板采用模压成型工艺，压条采用袋压工艺，整体强度好；热压成型工艺使得树脂含量很低，裙板主板的重量轻。

Description

复合材料制作高铁设备舱裙板的工艺
技术领域
本发明涉及一种高铁设备舱裙板的工艺，具体涉及一种能制作很高强度且重量轻的复合材料制作高铁设备舱裙板的工艺。
背景技术
高铁设备舱裙板是标准动车组设备舱的重要组成部分，在实际运用中，裙板承载能力、阻燃能力及抗冲击能力等有一定要求，所以在设计铺层、使用材料、设计工艺方面都需考虑；随着科技不断更新，在设计过程中通过轻量化和平顺化有效降低列车在运行过程中的阻力，从而减少持续的能量消耗。通过使用复合材料替代铝合金材料，在确保综合性能指标的前提下，降低整车的自重，提升整列车的轻量化水平。
发明内容
针对上述问题，本发明的主要目的在于提供一种能制作很高强度且重量轻的复合材料制作高铁设备舱裙板的工艺。
本发明是通过下述技术方案来解决上述技术问题的：一种复合材料制作高铁设备舱裙板的工艺，复合材料制作高铁设备舱裙板的材料包括：
芳纶蜂窝、PET泡沫、3K碳纤维阻燃预浸料、单向碳纤维阻燃预浸料、玻璃纤维阻燃预浸料、芳纶阻燃预浸料、300g/㎡单组分中温固化蓝色环氧片胶；
所述复合材料制作高铁设备舱裙板的工艺包括以下步骤：
(1)、裙板主板的制作；
(2)、裙板压条的制作；裙板压条包括两种，每一种两条共四条；
(3)、裙板主板和裙板压条五者做成裙板总成；
裙板主板的四边中相对的两边的裙板压条为同一种，所有的裙板压条均卡在裙板主板上。
在本发明的一个具体实施例子中，裙板主板按照铺层设计从外到内顺序包括如下：
1层198～200g/㎡的3K纹碳纤维阻燃预浸料；
5～8层300～315g/㎡的玻璃纤维阻燃预浸料；
2层235～240g/㎡的芳纶阻燃预浸料；
2层100～150g/㎡单向碳纤维阻燃预浸料；
1层300g/㎡单组分中温固化蓝色环氧片胶；
2层100～150g/㎡单向碳纤维阻燃预浸料；
1片厚度16.4mm芳纶纸蜂窝芯；
1片厚度为100～150g/㎡单向碳纤维阻燃预浸料；
1层300g/㎡单组分中温固化蓝色环氧片胶；
2层100～150g/㎡单向碳纤维阻燃预浸料；
4层300～315g/㎡的玻璃纤维阻燃预浸料；
1层198～200g/㎡的3K斜纹碳纤维阻燃预浸料；
按照铺层，紧密贴实在模具行腔内，在热压机上成型，温度设定为130-150℃，成型时间为3600-3800s，压力设定为4MPa-6Mpa。
在本发明的一个具体实施例子中，裙板压条铺层工艺包括如下：两件裙板压条采用袋压成型，压条由内向外按照铺层顺序包括如下：
1～2层300～315g/㎡的玻璃纤维阻燃预浸料；
4～6层100～150g/㎡单向碳纤维阻燃预浸料；
1层235～240g/㎡的芳纶阻燃预浸料；
2层100～150g/㎡单向碳纤维阻燃预浸料；
1层235～240g/㎡的芳纶阻燃预浸料；
4～6层100～150g/㎡单向碳纤维阻燃预浸料；
1层198～200g/㎡的3K斜纹碳纤维阻燃预浸料；
按照铺层，紧密贴实在模具行腔内，装好风管,在热压机上成型，温度设定130-150℃，成型时间3600-3800s，热压机压力设定4MPa-6Mpa，风管内压1MPa。
在本发明的一个具体实施例子中，所述芳纶纸蜂窝芯密度要求48～50kg/m3。
在本发明的一个具体实施例子中，所述PET泡沫密度要求59～61kg/m3。
本发明的积极进步效果在于：本发明提供的复合材料制作高铁设备舱裙板的工艺具有以下优点：
1、经过铺层设计使得该裙板在各个角度都能得到很高的强度，增加芳纶设计提供高强冲击性；
2、裙板主板采用模压成型工艺，压条采用袋压工艺，提高压条使用强度,不同工艺适用不同产品部件；
3、热压成型工艺使得树脂含量很低，大大减轻裙板主板的重量；
4、外型设计美观大方，性能强，较铝合金减重35％～40％，有较好的应用前景。
附图说明
图1为本发明的裙板总成拆分图。
图2为本发明的裙板总装图。
图3-1为本发明中第一种压条的截面图。
图3-2为本发明中第二种压条的截面图。
图4为本发明的裙板主板的截面图。
具体实施方式
下面结合附图给出本发明较佳实施例，以详细说明本发明的技术方案。
图1为本发明的整体结构示意图，如图1所示，本发明中复合材料制作高铁设备舱裙板的材料包括：芳纶蜂窝、PET泡沫、3K碳纤维阻燃预浸料、单向碳纤维阻燃预浸料、玻璃纤维阻燃预浸料、芳纶阻燃预浸料、300g/㎡单组分中温固化蓝色环氧片胶。
本发明的复合材料制作高铁设备舱裙板的工艺包括以下步骤：
(1)、裙板主板3的制作；
(2)、裙板压条1、2的制作；裙板压条包括两种，每一种两条共四条；
(3)、裙板主板3和裙板压条1、2五者做成裙板总成；
裙板主板的四边中相对的两边的裙板压条为同一种，所有的裙板压条均卡在裙板主板上。
裙板主板按照铺层设计从外到内顺序包括如下：
1层198～200g/㎡的3K纹碳纤维阻燃预浸料；
5～8层300～315g/㎡的玻璃纤维阻燃预浸料；
2层235～240g/㎡的芳纶阻燃预浸料；
2层100～150g/㎡单向碳纤维阻燃预浸料；
1层300g/㎡单组分中温固化蓝色环氧片胶；
2层100～150g/㎡单向碳纤维阻燃预浸料；
1片厚度16.4mm芳纶纸蜂窝芯；
1片厚度为100～150g/㎡单向碳纤维阻燃预浸料；
1层300g/㎡单组分中温固化蓝色环氧片胶；
2层100～150g/㎡单向碳纤维阻燃预浸料；
4层300～315g/㎡的玻璃纤维阻燃预浸料；
1层198～200g/㎡的3K斜纹碳纤维阻燃预浸料；
按照铺层，紧密贴实在模具行腔内，在热压机上成型，温度设定为130-150℃，成型时间为3600-3800s，压力设定为4MPa-6Mpa。
裙板压条铺层工艺包括如下：两件裙板压条采用袋压成型，压条由内向外按照铺层顺序包括如下：
1～2层300～315g/㎡的玻璃纤维阻燃预浸料；
4～6层100～150g/㎡单向碳纤维阻燃预浸料；
1层235～240g/㎡的芳纶阻燃预浸料；
2层100～150g/㎡单向碳纤维阻燃预浸料；
1层235～240g/㎡的芳纶阻燃预浸料；
4～6层100～150g/㎡单向碳纤维阻燃预浸料；
1层198～200g/㎡的3K斜纹碳纤维阻燃预浸料；
按照铺层，紧密贴实在模具行腔内，装好风管,在热压机上成型，温度设定130-150℃，成型时间3600-3800s，热压机压力设定4MPa-6Mpa，风管内压1MPa。
下面结合实施例对本发明作进一步说明：
实例一
第一步：裙板主板模压成型制作，按照铺层一层200g/㎡的3K斜纹碳纤维阻燃预浸料/6层300g/㎡的玻璃纤维阻燃预浸料/3层235g/㎡的芳纶阻燃预浸料/两层150g/㎡单向碳纤维阻燃预浸料/一层300g/㎡单组分中温固化蓝色环氧片胶/两层150g/㎡单向碳纤维阻燃预浸料/一片厚16.4mm芳纶纸蜂窝芯/一层300g/㎡单组分中温固化蓝色环氧片胶/两层100～150g/㎡单向碳纤维阻燃预浸料/四层300g/㎡的玻璃纤维阻燃预浸料/一层200g/㎡的3K斜纹碳纤维阻燃预浸料，将料片贴合在模具中，设定130℃，成型时间3600s，压力设定4MPa。
第二步：裙板两件压条采用袋压成型,压条由内向外按照铺层设计1层300g/㎡的玻璃纤维阻燃预浸料/6层150g/㎡单向碳纤维阻燃预浸料/1层235g/㎡的芳纶阻燃预浸料/2层150g/㎡单向碳纤维阻燃预浸料/1层235g/㎡的芳纶阻燃预浸料/6层150g/㎡单向碳纤维阻燃预浸料/一层200g/㎡的3K斜纹碳纤维阻燃预浸料，按照铺层，紧密贴实在模具行腔内，装好风管，在热压机上成型，温度设定130℃，成型时间3600s，热压机压力设定4MPa，风管内压1MPa。
第三步：CNC雕刻，胶合部件。
第四步：称重：产品相对实际高铁铝合金裙板,减重51％,单位面积载荷超过2500pa。
实例二
第一步：裙板主板模压成型制作,按照铺层一层200g/㎡的3K斜纹碳纤维阻燃预浸料/7层300g/㎡的玻璃纤维阻燃预浸料/2层235g/㎡的芳纶阻燃预浸料/两层150g/㎡单向碳纤维阻燃预浸料/一层300g/㎡单组分中温固化蓝色环氧片胶/两层150g/㎡单向碳纤维阻燃预浸料/一片厚16.4mm芳纶纸蜂窝芯/一层300g/㎡单组分中温固化蓝色环氧片胶/两层100～150g/㎡单向碳纤维阻燃预浸料/四层300g/㎡的玻璃纤维阻燃预浸料/一层200g/㎡的3K斜纹碳纤维阻燃预浸料，将料片贴合在模具中，设定140℃，成型时间3600s，压力设定4MPa。
第二步：裙板两件压条采用袋压成型，压条由内向外按照铺层设计2层300g/㎡的玻璃纤维阻燃预浸料/4层150g/㎡单向碳纤维阻燃预浸料/1层235g/㎡的芳纶阻燃预浸料/2层150g/㎡单向碳纤维阻燃预浸料/1层235g/㎡的芳纶阻燃预浸料/6层150g/㎡单向碳纤维阻燃预浸料/一层200g/㎡的3K斜纹碳纤维阻燃预浸料，按照铺层，紧密贴实在模具行腔内，装好风管，在热压机上成型，温度设定140℃，成型时间3600s，热压机压力设定5Mpa，风管内压1MPa。
第三步：CNC雕刻，胶合部件。
第四步：称重：产品相对实际高铁铝合金裙板,减重52％,单位面积载荷超过2500pa。
实例三
第一步：裙板主板模压成型制作，按照铺层一层200g/㎡的3K斜纹碳纤维阻燃预浸料/6层300g/㎡的玻璃纤维阻燃预浸料/3层235g/㎡的芳纶阻燃预浸料/两层150g/㎡单向碳纤维阻燃预浸料/一层300g/㎡单组分中温固化蓝色环氧片胶/两层150g/㎡单向碳纤维阻燃预浸料/一片厚16.4mm芳纶纸蜂窝芯/一层300g/㎡单组分中温固化蓝色环氧片胶/两层100～150g/㎡单向碳纤维阻燃预浸料/四层300g/㎡的玻璃纤维阻燃预浸料/一层200g/㎡的3K斜纹碳纤维阻燃预浸料，将料片贴合在模具中，设定150℃，成型时间3600s，压力设定4MPa。
第二步：裙板两件压条采用袋压成型,压条由内向外按照铺层设计1层300g/㎡的玻璃纤维阻燃预浸料/4层150g/㎡单向碳纤维阻燃预浸料/1层235g/㎡的芳纶阻燃预浸料/2层150g/㎡单向碳纤维阻燃预浸料/1层235g/㎡的芳纶阻燃预浸料/8层150g/㎡单向碳纤维阻燃预浸料/一层200g/㎡的3K斜纹碳纤维阻燃预浸料，按照铺层，紧密贴实在模具行腔内，装好风管,在热压机上成型，温度设定150℃，成型时间3600s，热压机压力设定6MPa，风管内压1MPa。
第三步：CNC雕刻，胶合部件。
第四步：称重：产品相对实际高铁铝合金裙板，减重51％，单位面积载荷超过2500pa。
以上显示和描述了本发明的基本原理和主要特征和本发明的优点。本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内，本发明要求保护范围由所附的权利要求书及其等效物界定。

Claims (5)

1.一种复合材料制作高铁设备舱裙板的工艺，其特征在于：复合材料制作高铁设备舱裙板的材料包括：
芳纶蜂窝、PET泡沫、3K碳纤维阻燃预浸料、单向碳纤维阻燃预浸料、玻璃纤维阻燃预浸料、芳纶阻燃预浸料、300g/㎡单组分中温固化蓝色环氧片胶；
所述复合材料制作高铁设备舱裙板的工艺包括以下步骤：
(1)、裙板主板的制作；
(2)、裙板压条的制作；裙板压条包括两种，每一种两条共四条；
(3)、裙板主板和裙板压条五者做成裙板总成；
裙板主板的四边中相对的两边的裙板压条为同一种，所有的裙板压条均卡在裙板主板上。
2.根据权利要求1所述的复合材料制作高铁设备舱裙板的工艺，其特征在于：裙板主板按照铺层设计从外到内顺序包括如下：
1层198～200g/㎡的3K纹碳纤维阻燃预浸料；
5～8层300～315g/㎡的玻璃纤维阻燃预浸料；
2层235～240g/㎡的芳纶阻燃预浸料；
2层100～150g/㎡单向碳纤维阻燃预浸料；
1层300g/㎡单组分中温固化蓝色环氧片胶；
2层100～150g/㎡单向碳纤维阻燃预浸料；
1片厚度16.4mm芳纶纸蜂窝芯；
1片厚度为100～150g/㎡单向碳纤维阻燃预浸料；
1层300g/㎡单组分中温固化蓝色环氧片胶；
2层100～150g/㎡单向碳纤维阻燃预浸料；
4层300～315g/㎡的玻璃纤维阻燃预浸料；
1层198～200g/㎡的3K斜纹碳纤维阻燃预浸料；
按照铺层，紧密贴实在模具行腔内，在热压机上成型，温度设定为130-150℃，成型时间为3600-3800s，压力设定为4MPa-6Mpa。
3.根据权利要求1所述的复合材料制作高铁设备舱裙板的工艺，其特征在于：裙板压条铺层工艺包括如下：两件裙板压条采用袋压成型，压条由内向外按照铺层顺序包括如下：
1～2层300～315g/㎡的玻璃纤维阻燃预浸料；
4～6层100～150g/㎡单向碳纤维阻燃预浸料；
1层235～240g/㎡的芳纶阻燃预浸料；
2层100～150g/㎡单向碳纤维阻燃预浸料；
1层235～240g/㎡的芳纶阻燃预浸料；
4～6层100～150g/㎡单向碳纤维阻燃预浸料；
1层198～200g/㎡的3K斜纹碳纤维阻燃预浸料；
按照铺层，紧密贴实在模具行腔内，装好风管,在热压机上成型，温度设定130-150℃，成型时间3600-3800s，热压机压力设定4MPa-6Mpa，风管内压1MPa。
4.根据权利要求1所述的复合材料制作高铁设备舱裙板的工艺，其特征在于：所述芳纶纸蜂窝芯密度要求48～50kg/m3。
5.根据权利要求1所述的复合材料制作高铁设备舱裙板的工艺，其特征在于：所述PET泡沫密度要求59～61kg/m3。
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