CN107719394B - Fiber-reinforced foam sandwich structure composite material locomotive cockpit and preparation method thereof - Google Patents
Fiber-reinforced foam sandwich structure composite material locomotive cockpit and preparation method thereof Download PDFInfo
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- CN107719394B CN107719394B CN201610654719.6A CN201610654719A CN107719394B CN 107719394 B CN107719394 B CN 107719394B CN 201610654719 A CN201610654719 A CN 201610654719A CN 107719394 B CN107719394 B CN 107719394B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
- B61D17/00—Construction details of vehicle bodies
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/36—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
Abstract
The utility model provides a fibre reinforcement foam sandwich structure combined material locomotive cockpit, includes preceding top and bottom plate, and preceding top and bottom plate all include covering, covering and foam core down, and upper covering, covering and reinforcement layer all adopt fibre reinforcement combined material down, and the resin in upper covering, covering and the reinforcement layer down is fire-retardant epoxy, and the reinforcing fabric in upper covering, covering and the reinforcement layer down is the multilayer that stacks together, and the thickness of upper covering and covering down is 4mm ~ 8 mm. The invention also discloses a preparation method of the fiber reinforced foam sandwich structure composite material locomotive cockpit, which comprises the steps of preparing the front top of the locomotive cockpit, preparing a baseplate of the locomotive cockpit, bonding and reinforcing the front top and the baseplate, post-curing the cabin body of the locomotive cockpit and the like. The method for preparing the locomotive cockpit has the advantages that the weight reduction effect is obvious, the energy can be effectively saved, the cockpit body is prepared by using the vacuum auxiliary forming process, the cost is low, the integral forming is easy, and the complicated part assembling process is simplified.
Description
Technical Field
The invention relates to high-speed rail transit equipment, in particular to a fiber-reinforced foam sandwich structure composite material locomotive cockpit and a preparation method thereof.
Background
In the field of high-speed rail transit, composite materials are becoming more and more important materials, and are used as internal equipment and decorative materials, and are also more and more widely applied to bearing structures. Most of the composite material products are formed parts, and the manufactured products do not need to be machined, so that the production efficiency is high, and the manufacturing cost is low. The composite material is widely applied to rail transit vehicles, and plays an important role in reducing carriage weight, reducing noise and vibration, improving safety and comfort, reducing maintenance and the like.
At present, the cabin body structure of the locomotive cockpit is made of metal, and the structure has the following defects: the weight is too heavy, the steel is easily corroded by the influence of the environment, and deformation is easily caused by the influence of welding in the forming process. The structure of the locomotive cockpit body made of the composite material is not reported.
Composite materials have gradually become the main material of railway vehicles, and play more and more important roles along with the development of passenger and freight trains in the directions of high speed, heavy loading, comfort and safety, and the process of replacing the original metal structure with the composite materials in different structural areas of the railway vehicles is a continuous exploration process.
Chinese patent 201510579742.9 discloses a carbon fiber composite car body, which only mentions that carbon fiber composite is used for the car body, and how the carbon fiber is specifically distributed in the carbon fiber composite and what technical performance requirements can be met is not mentioned, and the requirement of the cockpit at the two ends of the locomotive on fire prevention, heat insulation, sound insulation and high speed impact resistance is higher than that of the carriage in the middle of the locomotive, therefore, a scheme specially aiming at the locomotive cockpit is needed to solve the problem, and the weight of the car body and the cost are reduced, and simultaneously, various performance requirements of the locomotive cockpit can be met.
Disclosure of Invention
The invention aims to provide a fiber reinforced foam sandwich structure composite material locomotive cockpit and a preparation method thereof, and aims to solve the problems in the background art.
In order to achieve the aim, the invention provides a fiber reinforced foam sandwich structure composite material locomotive cockpit, which comprises a front top 1 and a bottom plate 2, wherein the bottom plate is adhered to the bottom of the front top through a reinforcing layer 3, the front top and the bottom plate which are adhered into a whole form a cockpit cabin body, the front top and the bottom plate respectively comprise an upper skin 4, a lower skin 5 and a foam core material 6, the upper skin, the lower skin and the reinforcing layer are all made of fiber reinforced composite materials, resin in the upper skin, the lower skin and the reinforcing layer is flame-retardant epoxy resin, reinforcing fabrics in the upper skin, the lower skin and the reinforcing layer are all multiple layers which are laid together, the reinforcing fabrics in the front top and the bottom plate are all made of one or more of carbon fiber fabrics, glass fiber fabrics and carbon fiber-glass fiber mixed woven fabrics, and the thicknesses of the upper skin and the lower skin in the front top and the bottom plate are all between 3mm and 8 mm.
Furthermore, the number of the laid layers of the reinforced fabric in the upper skin and the lower skin is equal to 8-12, the reinforced fabric in the reinforcing layer is a multi-axis carbon fiber fabric with the number of the laid layers being not less than 6, and the surface density of the reinforced fabric in the upper skin, the lower skin and the reinforcing layer is 350-650 g/sq.
Further, the reinforcing fabrics in the upper skin, the lower skin and the reinforcing layer are all formed by alternately laying two multiaxial fabrics with the area density of 400g per square meter and the direction of (0 degrees and 90 degrees) and the area density of 600g per square meter and the direction of (+45 degrees and-45 degrees), and the layers of the fabrics in the upper skin are sequentially laid in (0 degrees and 90 degrees)/(+ 45 degrees and-45 degrees/(0 degrees and 90 degrees)// (+45 degrees and-45 degrees)/(0 degrees and 90 degrees) and/(+ 45 degrees and-45 degrees/(0 degrees and 90 degrees and-45 degrees) respectively; the plies of the fabric of each layer in the lower skin are successively (+45 °, -45 °, (+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(+ 90 °)).
The foam core material is any one of PET foam, phenolic foam, PMI foam and PVC foam.
Further, preceding top bottom edge is equipped with the joint limit 11 of personally submitting the L shape with bottom plate edge complex transversal, and L shape joint limit is the bonding department of preceding top and bottom plate, and whole bottom plate encircles in the casing on preceding top, and the reinforcement layer pastes and glues in the cockpit before the gap department of top and bottom plate joint and cover the gap, and the skin pastes under reinforcement layer upper portion and the preceding top, and the lower part of reinforcement layer pastes with the skin on the bottom plate.
Further, the reinforcing fabric on the outermost layer of the upper skin of the front top is arranged or replaced by twill carbon fiber fabric.
The front top and the bottom plate are respectively of a structure integrally formed through a die, the front top is provided with a window hole and a lamp hole which penetrate through the upper skin, the foam core material and the lower skin along the thickness direction, and fins which are convenient for installing the window frame and the lamp frame are arranged in the window hole and the lamp hole.
The mold for manufacturing the front top and the bottom plate is coated with transparent gel coat before the upper skin or the lower skin is laid, and the thickness of the transparent gel coat after curing is not more than 0.6 mm.
Preferably, the thickness of the transparent gel coat after curing is 0.25 mm-0.6 mm.
And a metal embedded part 7 used for being fixedly connected with an external device is arranged on the bottom plate, one end of the metal embedded part is embedded between the bottom plate lower skin and the foam core material, and the other end of the metal embedded part penetrates through the bottom plate lower skin and extends out of the bottom plate. According to the fiber reinforced foam sandwich structure composite material locomotive cockpit, the invention also provides a preparation method of the fiber reinforced foam sandwich structure composite material locomotive cockpit, which comprises the following steps:
1) preparation of front roof of locomotive cockpit
1-a, preparing a front top die; cleaning the surface of the mold, wiping a release agent on the surface of the mold, and airing for later use;
1-b, brushing gel coat; uniformly brushing the prepared transparent gel coat on a mold, wherein the thickness of the cured gel coat is less than or equal to 0.6 mm;
1-c, laying and glue preparation; after the gel coat is cured, laying raw materials according to the sequence of the upper skin/the foam core material/the lower skin, and preparing flame-retardant epoxy resin glue;
1-d, molding; adopting VARI (vacuum assisted forming) process to inject glue for integral forming;
1-e, curing and demolding; and after the front top skin of the cab is gelled, the front top die is disassembled, and the front top of the locomotive cab is taken out.
2) Preparation of locomotive cockpit bottom plate
Preparing a bottom plate mold; cleaning the surface of the mold, wiping a release agent on the surface of the mold, and airing for later use;
2-b, brushing gel coat; uniformly brushing the prepared transparent gel coat on a mold, wherein the thickness of the cured gel coat is less than or equal to 0.6 mm;
2-c, spreading and glue preparation; after the gel coat is cured, laying raw materials according to the sequence of the lower skin/the foam core material/the upper skin, and preparing flame-retardant epoxy resin glue;
2-d, molding; adopting VARI (vacuum assisted forming) process to inject glue for integral forming;
2-e, curing and demolding; and after the skin of the cockpit bottom plate is gelled, disassembling the bottom plate mould and taking out the locomotive cockpit bottom plate.
3) Bonding and reinforcing of front top and bottom plate
3-a. bonding of front roof to floor
The front top and the bottom plate of the cockpit are placed in the front top die and the bottom plate die respectively, then putty is brushed on the joint of the front top and the bottom plate (namely the edge of the bottom plate and the L-shaped clamping edge of the front top) respectively, on one hand, the front top and the bottom plate of the cockpit are subjected to preliminary bonding, on the other hand, gaps between the front top and the bottom plate are filled, then the bottom plate die and the front top die are fixed together, and the putty extruded from the joint of the front top and the bottom plate is cleaned up.
3-b. reinforcement of front roof and floor
After the putty is cured, more than 6 layers of reinforcing fabrics are hand-pasted in the reinforcing area and are formed by vacuum bag pressing.
4) Post-curing of locomotive cockpit body
After the reinforcing layers of the front top and the bottom plate are gelled, the whole cabin body and the mold are placed into an oven, heating is started, the temperature is kept constant at 80 ℃ for 5 hours, heating is stopped, when the temperature of the mold is reduced to 50 ℃, the mold can be detached, and the cabin body of the locomotive cockpit is taken out.
In the preparation method of the locomotive cockpit, the technological processes of the step 1 and the step 2 can be respectively carried out simultaneously.
The viscosity of the flame retardant epoxy resin used in the steps 1 and 2 is 100-300 mPa $
The putty in the step 3 can be prepared by adding the filler into the flame-retardant epoxy resin which is the same as that in the step 1 and the step 2.
Has the advantages that: the invention provides a fiber reinforced foam core material structure composite material locomotive cockpit and a preparation method thereof, wherein a locomotive cockpit body adopts a fiber reinforced foam core material structure, and compared with a locomotive cockpit body with a metal structure, the fiber reinforced foam core material structure composite material locomotive cockpit has a remarkable weight reduction effect (the weight reduction reaches 60 percent), can effectively save energy, has extremely important significance for the application of the fiber reinforced composite material on the locomotive cockpit, and has great development space and wide market application prospect; the composite material is used for preparing the locomotive cockpit body, and has important significance for improving the application level of the composite material on railway vehicles and promoting the continuous development of railway industry.
The method for preparing the locomotive cockpit uses the vacuum assisted molding (VARI) process to prepare the cockpit body, has low cost, is easy to integrally mold, and simplifies the complex assembly process of parts.
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a perspective view of a locomotive cockpit structure according to a preferred embodiment of the present invention;
FIG. 2 is a bottom view of a locomotive cockpit of a preferred embodiment of the present invention;
FIG. 3 is a top front bottom view of the preferred embodiment of the present invention;
FIG. 4 is an enlarged view of the invention at section I of FIG. 3;
FIG. 5 is a cross-sectional view of the base plate of the preferred embodiment of the present invention;
FIG. 6 is a front top cross-sectional view of the preferred embodiment of the present invention;
FIG. 7 is a schematic view of a window and light hole of a preferred embodiment of the present invention;
fig. 8 is a cross-sectional view B-B of fig. 7 of the present invention.
In the figure: 1-front top, 11-clamping edge, 12-window hole, 13-lamp hole, 14-flash, 2-bottom plate, 3-reinforcing layer, 4-upper skin, 5-lower skin, 6-foam core material and 7-metal embedded part.
Detailed Description
Embodiments of the invention will be described in detail below with reference to the accompanying drawings, but the invention can be implemented in many different ways, which are defined and covered by the claims.
Referring to fig. 1-6, a fiber reinforced foam sandwich structure composite material locomotive cockpit comprises a front roof 1 and a bottom plate 2, the bottom plate 2 is adhered to the bottom of the front roof 1 through a reinforcing layer 3, the front roof 1 and the bottom plate 2 which are adhered into a whole form a cockpit cabin body, the front roof and the bottom plate respectively comprise an upper skin 4, a lower skin 5 and a foam core material 6, the upper skin, the lower skin and the reinforcing layer all adopt fiber reinforced composite materials, the resins in the upper skin, the lower skin and the reinforcing layer are all flame retardant epoxy resins, the reinforcing fabrics in the upper skin, the lower skin and the reinforcing layer are all 10 layers which are laid together, the reinforcing fabric in the front roof adopts one or more of multiaxial carbon fiber fabrics, multiaxial glass fiber fabrics and carbon fiber-glass fiber hybrid fabrics, the reinforcing fabric in the bottom plate adopts one or more of carbon fiber fabrics, glass fiber fabrics and carbon fiber-glass fiber hybrid fabrics, and the thicknesses of the upper skin and the lower skin in the front top and the bottom plate are both between 3mm and 8 mm.
The technical effects of the present invention are illustrated below by examples 1 to 3 and comparative examples 1 and 2:
in embodiments 1 to 3, the bottom edge of the front roof 1 is provided with a clamping edge 11 having an L-shaped cross section, which is matched with the edge of the bottom plate, the L-shaped clamping edge is located at a bonding position between the front roof and the bottom plate, the entire bottom plate 2 is enclosed in the casing of the front roof 1, the reinforcing layer 3 is attached to a gap between the front roof and the bottom plate in the cockpit and covers the gap, the upper portion of the reinforcing layer is attached to the skin under the front roof, and the lower portion of the reinforcing layer is attached to the skin on the bottom plate, and in embodiments 1 to 3, the reinforcing layer is of a bent structure, and a bending angle of the reinforcing layer is equal to an included angle between the front roof and the bottom plate at the reinforcing position.
Examples 1 to 3, in the case where multiaxial fabrics were used for both the upper skin and the lower skin of the front roof, the plies of the fabrics of the respective layers in the upper skin were (0 °, 90 °)/(+45 °, -45 °)/(+ 0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(+45 °, -45 °); the plies of the fabric of each layer in the lower skin are successively (+45 °, -45 °, (+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(+ 90 °)).
In examples 1 to 3, the outermost fabric (i.e., the first fabric) in the front top cover was replaced with a twill carbon fiber fabric. In examples 1-3, the area density of each layer of fabric in the front top and bottom sheets is from about 350 to about 650 grams per square meter.
In examples 1 to 3, the reinforcing layer is 6 layers of multiaxial carbon fiber fabrics, the reinforcing fabric in the reinforcing layer is formed by alternately laying two multiaxial fabrics having an area density of 400 g/square meter, a direction of (0 °, 90 °), and an area density of 600 g/square meter, and a direction of (+45 °, -45 °), in which the fabric layers in the reinforcing layer are sequentially laid (0 °, 90 °)/(+45 °, -45 °)/(+ 0 °, 90 °)/(+45 °, -45 °), in which, referring to fig. 1, the reinforcing layer is adhered to a gap between the front top and the bottom plate in the cockpit and covers all gaps, referring to fig. 4, the upper portion of the reinforcing layer is adhered to the skin under the front top, the lower portion of the reinforcing layer is adhered to the skin on the bottom plate, and the total width of the reinforcing layer is 200 to 300mm, after bending, the upper part and the lower part respectively occupy half of the width and are respectively stuck with the front top and the bottom plate.
Referring to fig. 7 and 8, the front top is provided with a window hole 12 and a lamp hole 13 penetrating through the upper skin, the foam core material and the lower skin along the thickness direction, and a flange 14 facilitating installation of the window frame and the lamp frame is arranged in the window hole and the lamp hole.
Example 1:
the thickness of the upper skin and the lower skin is 3 mm.
The preparation method of the fiber reinforced foam sandwich structure composite material locomotive cockpit in the embodiment 1 comprises the following steps:
1) preparation of front top of locomotive cockpit body
Cleaning the surface of a front top die, wiping the surface of the front top die of the cab for 3 times with a release agent, drying, uniformly brushing a prepared transparent gel coat on the front top die, controlling the thickness of the gel coat to be about 0.4mm, paving a layer of twill carbon fiber fabric after gel curing of the gel coat, sequentially paving 9 layers of multi-axial carbon fiber fabric/PET foam/10 layers of multi-axial carbon fiber fabric, preparing flame-retardant epoxy resin, injecting glue by a VARI process, curing at room temperature for 24 hours, disassembling the front top die, and taking out the front top of the locomotive cab.
2) Preparation of bottom plate of locomotive cockpit body
Cleaning the surface of a bottom plate mold, wiping a release agent on the surface of the bottom plate mold for 3 times, drying, uniformly brushing the prepared transparent gel coat on the bottom plate mold, controlling the thickness of the gel coat to be about 0.4mm, sequentially laying 10 layers of carbon fiber fabric/metal embedded part/PET foam/10 layers of carbon fiber fabric after gel coating, preparing flame-retardant epoxy resin, injecting glue through a VARI process, curing at room temperature for 24 hours, disassembling the bottom plate mold, and taking out the bottom plate of the locomotive cockpit.
3) Bonding and reinforcing of front top and bottom plate of cockpit body
Firstly, respectively placing the front top and the bottom plate of the cockpit into a front top die and a bottom plate die, then respectively brushing putty at the joint of the front top and the bottom plate, then fixing the bottom plate die and the front top die together, cleaning the putty extruded at the joint of the front top and the bottom plate, after the putty is cured, manually pasting 6 layers of multiaxial carbon fiber fabrics, and forming by a vacuum bag pressing process.
4) Post-curing of locomotive cockpit body
After the reinforcing layers of the front top and the bottom plate are gelled, putting the whole cabin body and the joint body of the two molds into an oven, starting heating and raising the temperature, keeping the temperature of 80 ℃ constant for 5 hours, stopping heating, starting mold removal when the temperature of the molds is reduced to 50 ℃, and taking out the cabin body of the locomotive cockpit.
Example 2:
the thickness of the upper skin and the lower skin is 6 mm.
The preparation method of the fiber reinforced foam sandwich structure composite material locomotive cockpit in the embodiment 2 comprises the following steps:
1) preparation of front top of locomotive cockpit body
Cleaning the surface of a front top die, wiping a release agent on the surface of the front top die for 3 times, drying, uniformly brushing a prepared transparent gel coat on the die, controlling the thickness of the gel coat to be about 0.4mm, paving a layer of twill carbon fiber fabric after gel of the gel coat is cured, sequentially paving 9 layers of multiaxial glass fiber fabric/phenolic foam/10 layers of multiaxial glass fiber fabric, preparing flame-retardant epoxy resin, injecting glue through a VARI process, curing at room temperature for 24 hours, disassembling the die, and taking out the front top of a locomotive cockpit.
2) Preparation of bottom plate of locomotive cockpit body
Cleaning the surface of a bottom plate mold, wiping a release agent on the surface of the bottom plate mold for 3 times, drying, uniformly brushing the prepared transparent gel coat on the mold, controlling the thickness of the gel coat to be about 0.3mm, sequentially laying 10 layers of glass fiber fabric/metal embedded part/phenolic foam/10 layers of glass fiber fabric after gel of the gel coat is cured, preparing flame-retardant epoxy resin, injecting glue through a VARI process, curing at room temperature for 24 hours, disassembling the bottom plate mold, and taking out the bottom plate of the locomotive cockpit.
3) Bonding and reinforcing of front top and bottom plate of cockpit body
Firstly, respectively placing the front top and the bottom plate of the cockpit into a front top die and a bottom plate die, then respectively brushing putty at the joint of the front top and the bottom plate, then fixing the bottom plate die and the front top die together, cleaning the putty extruded at the joint of the front top and the bottom plate, after the putty is cured, manually pasting 6 layers of multiaxial glass fiber fabrics, and forming by using a vacuum bag pressing process.
4) Post-curing of locomotive cockpit body
After the reinforcing layers of the front top and the bottom plate are gelled, putting the whole cabin body and the joint body of the two molds into an oven, starting heating and raising the temperature, keeping the temperature of 80 ℃ constant for 5 hours, stopping heating, starting mold removal when the temperature of the molds is reduced to 50 ℃, and taking out the cabin body of the locomotive cockpit.
Example 3:
the thickness of the upper skin and the lower skin is 8 mm.
Example 3 of the preparation method of the fiber reinforced foam sandwich structure composite locomotive cockpit:
1) preparation of front top of locomotive cockpit body
Cleaning the surface of a front top die, wiping a release agent on the surface of the front top die for 3 times, drying, uniformly brushing a prepared transparent gel coat on the front top die, controlling the thickness of the gel coat to be about 0.5mm, paving a layer of twill carbon fiber fabric after gel curing of the gel coat, sequentially paving 9 layers of carbon fiber-glass fiber mixed fabric/PMI foam/10 layers of carbon fiber-glass fiber mixed fabric, preparing flame-retardant epoxy resin, injecting glue through a VARI process, curing at room temperature for 24 hours, disassembling the front top die, and taking out the front top of a locomotive cockpit.
2) Preparation of bottom plate of locomotive cockpit body
Cleaning the surface of a bottom plate mold, wiping a release agent on the surface of the bottom plate mold for 3 times, drying, uniformly brushing the prepared transparent gel coat on the bottom plate mold, controlling the thickness of the gel coat to be about 0.4mm, sequentially laying 10 layers of carbon fiber-glass fiber mixed fabric/metal embedded part/PMI foam/10 layers of carbon fiber-glass fiber mixed fabric after gel curing of the gel coat, preparing flame-retardant epoxy resin, injecting glue through a VARI process, curing for 24 hours at room temperature, disassembling the mold, and taking out the bottom plate of the locomotive cockpit.
3) Bonding and reinforcing of front top and bottom plate of cockpit body
Firstly, respectively placing the front top and the bottom plate of the cockpit into a front top die and a bottom plate die, then respectively brushing putty at the joint of the front top and the bottom plate, then fixing the bottom plate die and the front top die together, and cleaning up the putty extruded from the joint of the front top and the bottom plate. After the putty is cured, 6 layers of carbon fiber fabrics are pasted by hands and formed by a vacuum bag pressing process.
4) Post-curing of locomotive cockpit body
After the reinforcing layers of the front top and the bottom plate are gelled, putting the whole cabin body and the combination of the two molds into an oven, starting heating, keeping the temperature of 80 ℃ constant for 5 hours, stopping heating, starting demolding when the temperature of the molds is reduced to 50 ℃, and taking out the cabin body of the locomotive cockpit.
The viscosity of the flame-retardant epoxy resin used in examples 1 to 3 was 300mPa · s.
Comparative example 1
The thickness of the upper skin and the lower skin in comparative example 1 was 2.5mm, and the other conditions and parameters were the same as those in example 1.
Comparative example 2
The thickness of the upper skin and the lower skin in comparative example 2 was 8.5 mm; the other conditions and parameters were the same as in example 2.
The examples 1 to 3, the comparative examples 1 and 2 were subjected to a weight test, a sound insulation test, a high-speed impact test on the cabin using an aluminum block having a weight of 1kg and a speed of 320km/h, and a lighting test, respectively, to obtain the effects of the examples and comparative examples as shown in Table I
Watch 1
| Weight reduction | Sound insulation volume | High speed impact resistance | Thickness of upper and lower skins | |
| Example 1 | 63％ | 38dB | Is not penetrated through | 3mm |
| Example 2 | 60.5％ | 42dB | Is not penetrated through | 6mm |
| Example 3 | 58％ | 45dB | Is not penetrated through | 8mm |
| Comparative example 1 | 64％ | 36dB | Penetration | 2.5mm |
| Comparative example 2 | 57％ | 46dB | Is not penetrated through | 8.5mm |
The sizes of the locomotive composite material cockpit in the examples 1 to 3 and the comparative examples 1 and 2 of the invention are as follows: the length of the test piece is 3960mm, the width of the test piece is 3098mm, the height of the test piece is 2510mm, the overall weight of the test piece manufactured in the embodiments 1 to 3 after the test piece is assembled is 2500-2600 kg, and the weight of the test piece is reduced by 60 percent compared with the weight of the existing metal cockpit, and after the test detection of the fiber reinforced foam sandwich structure composite locomotive cockpit, the flame retardant grade meets the DIN5510-2:2009 fire protection grade S3 grade requirement, the heat insulation performance and the sound insulation performance meet the TB/T3107 plus 2011 Unit type combination vehicle window standard requirement of railway passenger train, and the high-speed impact resistance meets the UIC CODE 651 plus 2002 Standard requirement of railway vehicle cab. The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A composite locomotive cockpit with a fiber reinforced foam sandwich structure is characterized by comprising a front top (1) and a bottom plate (2), wherein the bottom plate is bonded at the bottom of the front top through a reinforcing layer (3), the front top and the bottom plate which are bonded into a whole form a cockpit cabin body, the front top and the bottom plate both comprise an upper skin (4), a lower skin (5) and a foam core material (6), the upper skin, the lower skin and the reinforcing layer are all made of fiber reinforced composite materials, the resin in the upper skin, the resin in the lower skin and the resin in the reinforcing layer are all flame-retardant epoxy resin, the reinforcing fabrics in the upper skin, the lower skin and the reinforcing layer are all multiple layers which are paved together, the reinforcing fabrics in the front top and the bottom plate are all made of one or more of carbon fiber fabrics, glass fiber fabrics and carbon fiber-glass fiber mixed fabrics, and the thicknesses of the upper skin and the lower skin in the front top and the bottom plate are all between 3mm and 8 mm.
2. The locomotive cockpit of a fiber reinforced foam sandwich structure composite material according to claim 1, wherein the number of the stacked layers of the reinforcing fabric in the upper skin and the lower skin is equal to 8-12, the reinforcing fabric in the reinforcing layer is a multi-axial carbon fiber fabric with the number of the stacked layers being not less than 6, and the surface density of the reinforcing fabric in the upper skin, the lower skin and the reinforcing layer is between 350 g/square meter and 650 g/square meter.
3. The locomotive cockpit of a fiber reinforced foam sandwich structure composite material according to claim 2, wherein the reinforcing fabrics in the upper skin, the lower skin and the reinforcing layer are formed by alternately laying two multiaxial fabrics with an area density of 400g per square meter, a direction of (0 °, 90 °), and an area density of 600g per square meter, and a direction of (+45 °, -45 °), and the layers of the fabrics in the upper skin are sequentially laid in a sequence of (0 °, 90 °)/(+45 °, -45 °)/(+ 0 °, 90 °)/(+45 °), (0 °, 90 °)/(+45 °), -45 °)/(+45 °; the plies of the fabric of each layer in the lower skin are successively (+45 °, -45 °, (+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(0 °, 90 °)/(+45 °, -45 °)/(+ 90 °)).
4. The composite locomotive cab with the fiber reinforced foam sandwich structure according to any one of claims 1 to 3, wherein the foam core material is any one of PET foam, phenolic foam, PMI foam and PVC foam.
5. The locomotive cab with the fiber reinforced foam sandwich structure as claimed in any one of claims 1 to 3, wherein a clamping edge (11) with an L-shaped cross section is arranged at the bottom edge of the front roof and matched with the edge of the bottom plate, the L-shaped clamping edge is a bonding part of the front roof and the bottom plate, the whole bottom plate is enclosed in a shell of the front roof, the reinforcing layer is bonded at a gap between the front roof and the bottom plate in the locomotive cab and covers the gap, the upper part of the reinforcing layer is bonded with the lower skin of the front roof, and the lower part of the reinforcing layer is bonded with the upper skin of the bottom plate.
6. The locomotive cab with the fiber reinforced foam sandwich structure composite material as claimed in any one of claims 1 to 3, wherein the reinforcing fabric of the outermost layer of the upper skin of the front roof is a twill carbon fiber fabric.
7. The locomotive cab with the fiber reinforced foam sandwich structure as claimed in any one of claims 1 to 3, wherein the front roof and the bottom plate are integrally formed by a mold, and the front roof is provided with a window hole (12) and a lamp hole (13) penetrating through the upper skin, the foam core material and the lower skin along the thickness direction, and the window hole and the lamp hole are internally provided with fins (14) facilitating installation of the window frame and the lamp frame.
8. The method for preparing the locomotive cockpit provided with the fiber reinforced foam sandwich structure composite material according to any one of claims 1 to 7, comprising the following steps of:
1) preparation of front roof of locomotive cockpit
1-a, preparing a front top die; cleaning the surface of the mold, wiping a release agent on the surface of the mold, and airing for later use;
1-b, brushing gel coat; uniformly brushing the prepared transparent gel coat on a mold, wherein the thickness of the cured gel coat is less than or equal to 0.6 mm;
1-c, laying and glue preparation; after the gel coat is cured, laying raw materials according to the sequence of the upper skin/the foam core material/the lower skin, and preparing flame-retardant epoxy resin glue;
1-d, molding; adopting a VARI process to inject glue for integral molding;
1-e, curing and demolding; and after the front top skin of the cab is gelled, the front top die is disassembled, and the front top of the locomotive cab is taken out.
2) Preparation of locomotive cockpit bottom plate
Preparing a bottom plate mold; cleaning the surface of the mold, wiping a release agent on the surface of the mold, and airing for later use;
2-b, brushing gel coat; uniformly brushing the prepared transparent gel coat on a mold, wherein the thickness of the cured gel coat is less than or equal to 0.6 mm;
2-c, spreading and glue preparation; after the gel coat is cured, laying raw materials according to the sequence of the lower skin/the metal embedded part/the foam/the upper skin, and preparing the flame-retardant epoxy resin adhesive;
2-d, molding; adopting VARI (vacuum assisted forming) process to inject glue for integral forming;
2-e, curing and demolding; and coating gel on the cockpit bottom plate, disassembling the bottom plate mould, and taking out the locomotive cockpit bottom plate.
3) Bonding and reinforcing of front top and bottom plate
3-a. bonding of front roof to floor
The front top and the bottom plate of the cockpit are placed in the front top die and the bottom plate die respectively, then putty is brushed on the joint of the front top and the bottom plate (namely the edge of the bottom plate and the L-shaped clamping edge of the front top) respectively, the front top and the bottom plate of the cockpit are preliminarily bonded, on the other hand, a gap between the front top and the bottom plate is filled, then the bottom plate die and the front top die are fixed together, and the putty extruded from the joint of the front top and the bottom plate is cleaned up.
3-b. reinforcement of front roof and floor
After the putty is cured, more than 6 layers of reinforcing fabrics are hand-pasted in the reinforcing area and are formed by vacuum bag pressing.
4) Post-curing of locomotive cockpit body
After the reinforcing layers of the front top and the bottom plate are gelled, the whole cabin body and the mold are placed into an oven, heating is started, the temperature is kept constant at 80 ℃ for 5 hours, heating is stopped, the mold is removed when the temperature of the mold is lower than 50 ℃, and the cabin body of the locomotive cockpit is taken out.
9. The method for preparing the fiber reinforced foam sandwich structure composite locomotive cockpit according to claim 8, wherein the processes of step 1 and step 2 are performed simultaneously.
10. The method for preparing the fiber-reinforced foam sandwich structure composite material locomotive cockpit according to claim 8, wherein the viscosity of the flame-retardant epoxy resin used in steps 1 and 2 is 100-300 mPa ≤, and the putty used in step 3 is prepared by blending the same flame-retardant epoxy resin and filler as in steps 1 and 2.
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| CN108454639A (en) * | 2018-04-12 | 2018-08-28 | 江苏华复轨道交通科技有限公司 | A kind of motor car equipment cabin holder and preparation method thereof using pultrude process production |
| CN109677042B (en) * | 2019-01-22 | 2021-04-30 | 衡阳泰豪通信车辆有限公司 | High-strength light multi-layer carbon fiber special-shaped cabin wall plate |
| CN109664843A (en) * | 2019-02-02 | 2019-04-23 | 北京北方长龙新材料技术有限公司 | A kind of modularized integrated vehicle cab |
| CN110001182B (en) * | 2019-04-04 | 2021-03-26 | 北京卫星制造厂有限公司 | Preparation method of heat-proof and load-bearing integrated outsole structure of return airship |
| CN110001181B (en) * | 2019-04-04 | 2021-03-26 | 北京卫星制造厂有限公司 | Preparation method of heat-proof and load-bearing integrated hood structure of return airship |
| CN111086286A (en) * | 2019-12-24 | 2020-05-01 | 中国航空工业集团公司西安飞机设计研究所 | Light high-temperature-resistant lightning-proof composite board and forming method |
| CN111605221A (en) * | 2020-06-02 | 2020-09-01 | 常州市新创智能科技有限公司 | Preparation method of composite material of flame-retardant fast curing resin by HMP process |
| CN112571823B (en) * | 2020-11-30 | 2022-07-22 | 江苏新扬新材料股份有限公司 | Composite material framework, forming die and forming method thereof |
| CN112590242B (en) * | 2020-12-01 | 2023-02-10 | 株洲电力机车广缘科技有限责任公司 | Forming method of bullet train head cover with carbon fiber sandwich structure |
| CN113696927B (en) * | 2021-09-26 | 2023-05-23 | 中车唐山机车车辆有限公司 | Rail vehicle |
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| CN103072284B (en) * | 2012-12-06 | 2015-12-02 | 中国船舶重工集团公司第七二五研究所 | A kind of sandwich structure composite material and manufacture method thereof containing strengthening muscle |
| CN104401011B (en) * | 2014-10-30 | 2017-11-07 | 中国人民解放军国防科学技术大学 | Sandwich structure composite material and preparation method thereof |
| CN105690799B (en) * | 2016-03-23 | 2018-06-01 | 航天材料及工艺研究所 | The preparation method of carbon fiber enhancement resin base composite material rail vehicle headstock hood |
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