CN105584058B - 复合材料制作高铁设备舱底板的工艺 - Google Patents

复合材料制作高铁设备舱底板的工艺 Download PDF

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Publication number
CN105584058B
CN105584058B CN201510947269.5A CN201510947269A CN105584058B CN 105584058 B CN105584058 B CN 105584058B CN 201510947269 A CN201510947269 A CN 201510947269A CN 105584058 B CN105584058 B CN 105584058B
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China
Prior art keywords
bottom plate
fire
retardant prepreg
layers
high ferro
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Application number
CN201510947269.5A
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English (en)
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CN105584058A (zh
Inventor
朱家强
王滨
张四顺
王明
谢长志
罗剑岚
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Shanghai Jin Fei Polytron Technologies Inc
SHANGHAI CEDAR COMPOSITES TECHNOLOGY Co Ltd
Original Assignee
Shanghai Jin Fei Polytron Technologies Inc
SHANGHAI CEDAR COMPOSITES TECHNOLOGY Co Ltd
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Application filed by Shanghai Jin Fei Polytron Technologies Inc, SHANGHAI CEDAR COMPOSITES TECHNOLOGY Co Ltd filed Critical Shanghai Jin Fei Polytron Technologies Inc
Priority to CN201510947269.5A priority Critical patent/CN105584058B/zh
Publication of CN105584058A publication Critical patent/CN105584058A/zh
Priority to US16/063,252 priority patent/US10632724B2/en
Priority to SG11201702926PA priority patent/SG11201702926PA/en
Priority to PCT/CN2016/096336 priority patent/WO2017101492A1/zh
Priority to JP2018532163A priority patent/JP6615357B2/ja
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/10—Trains
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T30/00—Transportation of goods or passengers via railways, e.g. energy recovery or reducing air resistance

Abstract

本发明涉及一种复合材料制作高铁设备舱底板的工艺，复合材料制作高铁设备舱底板的材料包括：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；复合材料制作高铁设备舱底板的工艺包括以下步骤：制作底板主板、底板拉手和两块底板滑块，在安装时，将底板拉手卡在底板主板的一边，两块底板滑块卡在底板主板的另外三边中相对着的两边上。本发明经过铺层设计使得该底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；本发明热压成型工艺使得树脂含量很低，大大减轻底板主板的重量；本发明外型设计美观大方，性能强，较铝合金减重35％～40％。

Description

复合材料制作高铁设备舱底板的工艺
技术领域
本发明涉及一种高铁设备舱底板的工艺，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底板的工艺。
背景技术
高铁设备舱底板是标准动车组设备舱的重要组成部分，在实际运用中，底板承载能力、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底板的工艺。
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底板的工艺，复合材料制作高铁设备舱底板的材料包括：
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/m2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底板的工艺包括以下步骤：
(1)、制作底板主板；
(2)、制作底板拉手；
(3)、制作底板滑块；底板滑块包括两块；
(4)、底板主板、拉手、滑块三者做成底板总成，
在安装时，将底板拉手卡在底板主板的一边，两块底板滑块卡在底板主板的另外三边中相对着的两边上
在本发明的一个具体实施例子中，所述底板主板按照铺层设计从外到内顺序包括如下：
1层198～200g/m2的3K斜纹碳纤维阻燃预浸料；
5～8层300～315g/m2的玻璃纤维阻燃预浸料；
2层235～240g/m2的芳纶阻燃预浸料；
2层100～150g/m2单向碳纤维阻燃预浸料；
1层300g/m2单组分中温固化蓝色环氧片胶；
2层100～150g/m2单向碳纤维阻燃预浸料；
1片厚度16.5mm的芳纶蜂窝；
1层300g/m2单组分中温固化蓝色环氧片胶；
2层100～150g/m2单向碳纤维阻燃预浸料；
5～8层300～315g/m2的玻璃纤维阻燃预浸料；
1层198～200g/m2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，底板拉手铺层工艺包括如下：底板拉手铺层采用20～25层150g/m2单向碳纤维阻燃预浸料，贴合在模具行腔内，采用真空袋压成型，温度为130-150℃，成型时间为4500～4800s。
在本发明的一个具体实施例子中，底板滑块铺层工艺包括如下：底板滑块采用20～25层100～150g/m2单向碳纤维阻燃预浸料包裹PET泡沫，上热压机成型，温度设定130-150℃，成型时间3600～3800s，压力设定为2Mpa～3MPa。
在本发明的一个具体实施例子中，所述芳纶蜂窝密度要求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底板的工艺具有以下优点：
1、经过铺层设计使得该底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、主板和滑块采用模压成型工艺，拉手采用真空袋压工艺，两种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，大大减轻底板主板的重量；
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为本发明的底板总装拆分图。
图2为本发明的底板总装图。
图3-1为本发明中拉手与底板连接的结构示意图。
图3-2为本发明中拉手的截面图。
图4-1为本发明中滑块与底板连接的结构示意图。
图4-2为本发明中滑块的截面图。
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。
本发明为一种复合材料制作高铁设备舱底板的工艺，该复合材料制作高铁设备舱底板的材料包括：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/m2单组分中温固化蓝色环氧片胶。
复合材料制作高铁设备舱底板的工艺包括以下步骤：
(1)、制作底板主板1；
(2)、制作底板拉手2；
(3)、制作底板滑块3；底板滑块3包括两块；
(4)、底板主板1、底板拉手2、底板滑块3四者做成底板总成。
图1为本发明的底板总装拆分图，图2为本发明的底板总装图。如图1-2所示：在安装时，将底板拉手卡在底板主板的一边，两块底板滑块卡在底板主板的另外三边中相对着的两边上。
图3-1为本发明中拉手与底板连接的结构示意图，图3-2为本发明中拉手的截面图，图4-1为本发明中滑块与底板连接的结构示意图，图4-2为本发明中滑块的截面图。
本发明中，底板主板按照铺层设计从外到内顺序包括如下：
1层198～200g/m2的3K斜纹碳纤维阻燃预浸料；
5～8层300～315g/m2的玻璃纤维阻燃预浸料；
2层235～240g/m2的芳纶阻燃预浸料；
2层100～150g/m2单向碳纤维阻燃预浸料；
1层300g/m2单组分中温固化蓝色环氧片胶；
2层100～150g/m2单向碳纤维阻燃预浸料；
1片厚度16.5mm的芳纶蜂窝；
1层300g/m2单组分中温固化蓝色环氧片胶；
2层100～150g/m2单向碳纤维阻燃预浸料；
5～8层300～315g/m2的玻璃纤维阻燃预浸料；
1层198～200g/m2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。
本发明中，底板拉手铺层工艺包括如下：底板拉手铺层采用20～25层150g/m2单向碳纤维阻燃预浸料，贴合在模具行腔内，采用真空袋压成型，温度为130-150℃，成型时间为4500～4800s。
本发明中，底板滑块铺层工艺包括如下：底板滑块采用20～25层100～150g/m2单向碳纤维阻燃预浸料包裹PET泡沫，上热压机成型，温度设定130-150℃，成型时间3600～3800s，压力设定为2Mpa～3MPa。
上述的芳纶蜂窝密度要求48～50kg/m3。
上述的PET泡沫密度要求59～61kg/m3。
下面结合实施例对本发明作进一步说明：
实例一
第一步：底板主板模压成型制作,按照铺层一层200g/m2的3K斜纹碳纤维阻燃预浸料/6层300g/m2的玻璃纤维阻燃预浸料/3层235g/m2的芳纶阻燃预浸料/两层150g/m2单向碳纤维阻燃预浸料/1层300g/m2单组分中温固化蓝色环氧片胶/两层150g/m2单向碳纤维阻燃预浸料/16.5mm芳纶纸蜂窝芯/1层300g/m2单组分中温固化蓝色环氧片胶/两层100～150g/m2单向碳纤维阻燃预浸料/四层300g/m2的玻璃纤维阻燃预浸料/一层200g/m2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。(3K碳纤维中的K为采用的碳纤维原纱的种类，1K是指的碳纤维纱一束是由1000跟单纱组成的，2K就是2000，3K就是3000)
第二步：底板拉手制作，采用全碳纤维结构，真空袋压成型，温度130℃，时间4600s。
第三步：底板滑块采用20层150g/m2单向碳纤维阻燃预浸料包裹PET泡沫，上热压机成型，温度设定130℃，成型时间3600s,压力设定2Mpa。
第四步：CNC雕刻，胶合三部件。
第五步：称重,产品相对实际高铁铝合金底板,减重39％,单位面积载荷超过2500pa.
实例二
第一步：底板主板模压成型制作,按照铺层一层200g/m2的3K斜纹碳纤维阻燃预浸料/7层300g/m2的玻璃纤维阻燃预浸料/2层235g/m2的芳纶阻燃预浸料/两层150g/m2单向碳纤维阻燃预浸料/1层300g/m2单组分中温固化蓝色环氧片胶/两层150g/m2单向碳纤维阻燃预浸料/16.5mm芳纶纸蜂窝芯/1层300g/m2单组分中温固化蓝色环氧片胶/两层100～150g/m2单向碳纤维阻燃预浸料/四层300g/m2的玻璃纤维阻燃预浸料/一层200g/m2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：底板拉手制作，采用全碳纤维结构，真空袋压成型，温度140℃，时间4600s。
第三步：底板滑块采用20层150g/m2单向碳纤维阻燃预浸料包裹PET泡沫，上热压机成型，温度设定140℃，成型时间3600s,压力设定2Mpa。
第四步：CNC雕刻，胶合三部件。
第五步：称重,产品相对实际高铁铝合金底板,减重37％,单位面积载荷超过2500pa.。
实例三
第一步：底板主板模压成型制作,按照铺层一层200g/m2的3K斜纹碳纤维阻燃预浸料/6层300g/m2的玻璃纤维阻燃预浸料/3层235g/m2的芳纶阻燃预浸料/两层150g/m2单向碳纤维阻燃预浸料/1层300g/m2单组分中温固化蓝色环氧片胶/两层150g/m2单向碳纤维阻燃预浸料/16.5mm芳纶纸蜂窝芯/1层300g/m2单组分中温固化蓝色环氧片胶/两层100～150g/m2单向碳纤维阻燃预浸料/四层300g/m2的玻璃纤维阻燃预浸料/一层200g/m2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：底板拉手制作，采用全碳纤维结构，真空袋压成型，温度150℃，时间4600s。
第三步：底板滑块采用20层150g/m2单向碳纤维阻燃预浸料包裹PET泡沫，上热压机成型，温度设定150℃，成型时间3600s,压力设定2Mpa。
第四步：CNC雕刻，胶合三部件。
第五步：称重,产品相对实际高铁铝合金底板,减重39％,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底板的工艺，其特征在于：复合材料制作高铁设备舱底板的材料包括：
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底板的工艺包括以下步骤：
(1)、制作底板主板；
(2)、制作底板拉手；
(3)、制作底板滑块；底板滑块包括两块；
(4)、底板主板、底板拉手、底板滑块四者做成底板总成；
在安装时，将底板拉手卡在底板主板的一边，两块底板滑块卡在底板主板的另外三边中相对着的两边上；
所述底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16.5mm的芳纶蜂窝；
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；
5～8层300～315g/㎡的玻璃纤维阻燃预浸料；
1层198～200g/㎡的3K碳纤维阻燃预浸料；
按照铺层，紧密贴实在模具型腔内，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。
2.根据权利要求1所述的复合材料制作高铁设备舱底板的工艺，其特征在于：底板拉手铺层工艺包括如下：底板拉手铺层采用20～25层150g/㎡单向碳纤维阻燃预浸料，贴合在模具型腔内，采用真空袋压成型，温度为130-150℃，成型时间为4500～4800s。
3.根据权利要求1所述的复合材料制作高铁设备舱底板的工艺，其特征在于：底板滑块铺层工艺包括如下：底板滑块采用20～25层100～150g/㎡单向碳纤维阻燃预浸料包裹PET泡沫，上热压机成型，温度设定130-150℃，成型时间3600～3800s，压力设定为2MPa～3MPa。
4.根据权利要求1所述的复合材料制作高铁设备舱底板的工艺，其特征在于：所述芳纶蜂窝密度要求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底板的工艺，其特征在于：所述PET泡沫密度要求59～61kg/m3。
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