CN108859167A - 一种具有高强度涂层的轻质复合材料列车内饰件 - Google Patents
一种具有高强度涂层的轻质复合材料列车内饰件 Download PDFInfo
- Publication number
- CN108859167A CN108859167A CN201810923668.1A CN201810923668A CN108859167A CN 108859167 A CN108859167 A CN 108859167A CN 201810923668 A CN201810923668 A CN 201810923668A CN 108859167 A CN108859167 A CN 108859167A
- Authority
- CN
- China
- Prior art keywords
- material layer
- inside gadget
- strength coating
- light composite
- train inside
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 52
- 238000000576 coating method Methods 0.000 title claims abstract description 48
- 239000011248 coating agent Substances 0.000 title claims abstract description 47
- 239000000463 material Substances 0.000 claims abstract description 75
- 230000001413 cellular effect Effects 0.000 claims abstract description 20
- 239000002657 fibrous material Substances 0.000 claims abstract description 20
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims abstract description 16
- 238000000465 moulding Methods 0.000 claims description 21
- 239000000758 substrate Substances 0.000 claims description 18
- 239000004814 polyurethane Substances 0.000 claims description 15
- 229920002635 polyurethane Polymers 0.000 claims description 13
- 238000001723 curing Methods 0.000 claims description 11
- 238000000034 method Methods 0.000 claims description 9
- 238000005507 spraying Methods 0.000 claims description 8
- 230000008595 infiltration Effects 0.000 claims description 6
- 238000001764 infiltration Methods 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical group [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
- 239000011521 glass Substances 0.000 claims description 5
- 230000008569 process Effects 0.000 claims description 5
- 229920005830 Polyurethane Foam Polymers 0.000 claims description 4
- 238000006243 chemical reaction Methods 0.000 claims description 4
- 238000005187 foaming Methods 0.000 claims description 4
- 239000011496 polyurethane foam Substances 0.000 claims description 4
- 238000004140 cleaning Methods 0.000 claims description 3
- 239000004744 fabric Substances 0.000 claims description 3
- 238000001746 injection moulding Methods 0.000 claims description 3
- 238000002360 preparation method Methods 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 239000000835 fiber Substances 0.000 claims 1
- 238000002347 injection Methods 0.000 claims 1
- 239000007924 injection Substances 0.000 claims 1
- 238000007711 solidification Methods 0.000 claims 1
- 230000008023 solidification Effects 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 9
- 230000007613 environmental effect Effects 0.000 abstract description 4
- 239000011152 fibreglass Substances 0.000 description 13
- 238000009434 installation Methods 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 230000000116 mitigating effect Effects 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 239000012855 volatile organic compound Substances 0.000 description 2
- 241001391944 Commicarpus scandens Species 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 150000001875 compounds Chemical group 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000003670 easy-to-clean Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 125000002485 formyl group Chemical class [H]C(*)=O 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 208000020442 loss of weight Diseases 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000505 pernicious effect Effects 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000003319 supportive effect Effects 0.000 description 1
Classifications
-
- 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
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
- B29C69/02—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore of moulding techniques only
-
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
-
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
-
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14811—Multilayered articles
-
- 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
- B29C70/34—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 shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/345—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 shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
-
- 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
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
- B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
-
- 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
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
- B61D17/00—Construction details of vehicle bodies
- B61D17/005—Construction details of vehicle bodies with bodies characterised by use of plastics materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/58—Upholstery or cushions, e.g. vehicle upholstery or interior padding
-
- 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
- B32B2605/003—Interior finishings
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Laminated Bodies (AREA)
Abstract
本发明公开了一种具有高强度涂层的轻质复合材料列车内饰件,包括顶板、侧顶板和墙板,所述顶板、侧顶板和墙板均包括复合片材层和高强度涂层,复合片材层包括蜂窝材料层和在蜂窝材料层外由内至外依次包裹覆盖的纤维材料层和聚氨酯材料层。与现有技术相比,本发明的技术方案利用具有高强度涂层的轻质复合板制备列车内饰件,将多种片材合理结合,形成强度高、轻质、安全环保、低成本、高产出的列车内饰件。
Description
技术领域
本申请的技术方案属于轨道列车配件技术领域,具体涉及一种具有高强度涂层的轻质复合材料列车内饰件。
背景技术
轨道交通是指具有固定线路、铺设固定轨道、配备运输车辆及服务设施等的公共交通设施,常见为高铁列车、地铁列车、轻轨列车、云轨列车和传统火车等。在我国以最具代表性的高铁列车为例,近几年的技术、规模均已达到世界一流水平,高铁提速目标逐年更新,所以对于列车的各部件轻量化实施也是如火如荼进行。因为轻量化不仅可以减少车辆高速运行时的冲击载荷、提高乘坐舒适度,同时在降低动力能耗成本、减轻轨道载荷、降低线路建设及维护成本方面也有显著的作用。目前列车内饰中的地板、侧墙、窗框、天花板、侧顶板等非结构件均采用玻璃钢制品,玻璃钢具有轻质、高强、阻燃、易成型、易清洁等优点,使其迅速推广开来,玻璃钢材料对高铁的发展起到了非常重要的作用。
尽管玻璃钢有诸多优点,但在大量应用过程中,人们发现在大尺寸简单型面的侧顶板、侧墙、地板上,玻璃钢有以下几个缺点:(1)挥发性有机物含量高,由于玻璃钢材料在生产过程中会添加含醛、含苯的物质,生产出来的制品会持续挥发有害气体,所以当前应用于列车内饰的主要材料中,玻璃钢材料是挥发性有机化合物(VOC)管控中被重点被关注的对象;(2)依然存在较大降重空间,玻璃钢和钢板的密度比例为1:4.3,因工艺条件要求的约束,其两者材料所对应设计的制品厚度比例约为4.3:1,得到的制品重量比例刚好是接近1:1,也就是说为了轻量化列车零部件而采用了玻璃钢复合材料替代钢材,最后并没有得到一个真实受益的轻量化方案,其降重空间仍较大;(3)性能过剩,以大面积零件的侧顶板和侧墙为例,由于玻璃钢生产工艺的局限性,其厚度一般不能小于3mm,而以顶板、侧顶板和墙板等内饰件相对较低的强度要求来说,本不需要这个厚度,所以多出来的厚度就是多出来的重量。
通过以上分析,玻璃钢不是最好的材料,急需采用更轻、更环保的材料代替玻璃钢制备列车内饰件。
发明内容
本发明的目的是提供一种质量轻、强度高、成本低、安全环保的具有高强度涂层的轻质复合材料列车内饰件。
本发明为达到上述目的,具体通过以下技术方案得以实现的:
一种具有高强度涂层的轻质复合材料列车内饰件,包括顶板、侧顶板和墙板,所述顶板、侧顶板和墙板均包括复合片材层和高强度涂层,复合片材层包括蜂窝材料层和在蜂窝材料层外由内至外依次包裹覆盖的纤维材料层和聚氨酯材料层。
本技术方案所用的复合片材层最内层的蜂窝材料层结构可以增加板材的支撑强度,也可满足列车内饰件对轻质化的要求;在蜂窝材料层的外层包裹的纤维材料层能够提升内部蜂窝材料层的抗冲击能力,不易断裂;通过工艺制作将聚氨酯材料层发泡使纤维材料层和蜂窝材料层粘连,实现板材的整体成型,大大简化了复合板材的制作工艺步骤;在复合片材层最外的高强度涂层可以实现在复合片材层的强度加固,具备高强度抗冲击,同时具有防水和耐腐蚀的效果。
为了实现侧顶板与顶板及两侧墙体的连接、侧顶板与车厢壳体的固定以及纵向相邻两侧顶板端部的连接固定,在侧顶板的一侧边开有定位孔和固定槽,另一侧边开有调整垫片孔和长条状的螺母安装台,两端均开有边条槽。定位孔用于侧顶板安装时定位用;固定槽为安装螺栓过孔,将侧顶板固定于车身骨架上;螺母安装台用于安装螺母拧入,将侧顶板固定于车身骨架上;两端边条槽粘贴边条,用于遮蔽两块侧顶板之间的缝隙;调整垫片孔用于安装垫片以调节侧顶板装配关系。
蜂窝材料层为铝蜂窝层。铝蜂窝层的蜂窝材料窝芯都具备强大支撑作用,能够满足作为支撑主体的强度需求,同时铝蜂窝材料质量轻,实现整体的轻质化。
纤维材料层为玻纤布层。纤维材料层的主要作用是能够将其内部的窝芯包裹限定在一定的空间范围内,同时也实现了减轻内部所受冲击力的效果。蜂窝材料层与纤维材料层通过聚氨酯材料层的渗透、浸润、发泡、固化方式实现层叠固化成型。
聚氨酯材料层为聚氨酯发泡材料层。利用聚氨酯发泡材料层作为聚氨酯材料层的最大优势在于可以在制作工艺上采用发泡工艺进行一次定型,提高了生产效率、降低了制作成本。聚氨酯材料层通过喷涂方式实现覆盖。
高强度涂层为零发泡聚氨酯层,其厚度为0.5~2mm。高强度涂层为不发泡的聚氨酯层,其强度高,表面光滑美观,防护性好,抗冲击性能好,减少表面腐蚀。高强度涂层与聚氨酯材料层为化学反应融合粘连。
该具有高强度涂层的轻质复合材料列车内饰件的制备步骤如下:
(1)将裁切合适的蜂窝材料层铺设于工作台后,在其表面包裹并装订同一尺寸的纤维材料层;
(2)将上步获得的覆盖了纤维材料层的产品置入喷涂机中,在纤维材料层表面均匀喷涂聚氨酯材料层,再送入模压模具的模腔中合模保压固化成型,固化成型过程的温度设置为90~130℃,保压压力为100~300T,保压时间为100~300s;
(3)对上步固化成型完成后开模,获得作为列车内饰件基板坯件的复合片材层,对基板坯件进行整型修边,得到轻质复合材料列车内饰件的基板成品;
(4)对上步完成整型修边的基板成品放入注射模具下模中,将模具下模抽真空后吸附住基板成品,模具的上模、下模合模后上模表面与基板成品留有0.5~2mm空腔,空腔内注入高强度涂层材料,同时上模抽真空引导高强度涂层的聚氨酯充满空腔,后保压,模具温度设置为60~90℃,保压压力为100~200T,保压时间为180~900s;
(5)在上步保压时间完成后开模取件,飞边处理,孔位清理,喷漆,得到具有高硬度涂层的轻质复合材料的列车内饰件。
与现有技术相比,本发明的技术方案利用具有高强度涂层的轻质复合板制备列车内饰件,将多种片材合理结合,形成强度高、轻质、安全环保、低成本、高产出的列车内饰件。
附图说明
图1为本发明的整体结构示意图;
图2为具有高强度涂层的轻质复合材料的结构示意图;
图3为侧顶板的结构示意图。
图中,1、顶板;2、侧顶板;21、定位孔;22、固定槽;23、调整垫片孔;24、螺母安装台;25、边条槽;3、墙板;4、复合片材层;5、高强度涂层;6、蜂窝材料层;7、纤维材料层;8、聚氨酯材料层。
具体实施方式
以下结合附图及实施例对本发明作进一步详细说明。
如图1和图2所示,本发明的一种具有高强度涂层的轻质复合材料列车内饰件,包括顶板1、侧顶板2和墙板3,顶板1固定在列车内墙的天花板位置,侧顶板2固定在顶板2两侧,两侧顶板2的另一侧边分别与两侧的墙板3固定。顶板1、侧顶板2和墙板3均包括复合片材层4和高强度涂层5,高强度涂层5涂覆在复合片材层4的外侧表面,复合片材层4包括蜂窝材料层6和在蜂窝材料层6外由内至外依次包裹覆盖的纤维材料层7和聚氨酯材料层8。
如图3所示,侧顶板2的一侧边开有定位孔21和固定槽22,另一侧边开有调整垫片孔23和长条状的螺母安装台24,两端均开有边条槽25。定位孔21用于侧顶板安装时定位用;固定槽22为安装螺栓过孔,将侧顶板2固定于车身骨架上;螺母安装台24用于安装螺母拧入,将侧顶板2固定于车身骨架上;两端边条槽25粘贴边条,用于遮蔽两块侧顶板2之间的缝隙;调整垫片孔23用于安装垫片以调节侧顶板装配关系。侧顶板2的两侧边分别与顶板1和墙板3搭接后通过螺栓、连接板等方式固定。
顶板1为板片状,多片顶板1连接后构成列车内饰件的天花板部分;在墙板3上开有与列车窗对应的窗口,多片墙板3连接后构成列车内饰件的竖向墙壁部分。利用多层结构的顶板1、侧顶板2和墙板3,将列车内饰件完整包裹,其整体质量降低,降低了列车运行成本,利于列车提速。
复合片材层4为多层复合结构,其中蜂窝材料层6为铝蜂窝层;纤维材料层7为玻纤布层;聚氨酯材料层8为聚氨酯发泡材料层;高强度涂层5为零发泡聚氨酯层,其厚度为0.5~2mm。高强度涂层5的零发泡聚氨酯通过设备料罐负压和水分隔离实现反应过程不发泡,其弯曲、拉伸、冲击强度均远比发泡聚氨酯高。聚氨酯材料层8通过喷涂方式实现覆盖。蜂窝材料层6与纤维材料层7通过聚氨酯材料层8的聚氨酯材料的发泡、渗透、浸润、固化方式实现层叠固化成型。高强度涂层5与聚氨酯材料层8通过高强度涂层5聚氨酯材料的化学反应融合粘连,具体通过聚氨酯的聚合反应实现粘连。对于传统列车内饰件材料如金属或玻璃钢一般为等厚度,在其外形确定后,其产品内表面由于安装需要,可能出现安装位置比较远的情况,由此对应的螺母预埋的结构或其他连接结构需要伸出较长的连接部,增加了局部的材料用量,也相应增加了产品的重量。而本发明中复合材料层根据功能、装配及工艺特点,可制作不等厚产品,复合材料的中间为蜂窝材料,在产品材料整体规格确定后,其厚度对产品的重量影响很小。在性能方面,本发明可以根据零件的实际工况,对强度薄弱区域进行局部加厚,对装配干涉避空处可以减薄,使得产品设计具有较大的自由度。
该具有高强度涂层的轻质复合材料列车内饰件的制备步骤如下:
(1)将裁切合适的蜂窝材料层铺设于工作台后,在其表面包裹并装订同一尺寸的纤维材料层;
(2)将上步获得的覆盖了纤维材料层的产品置入喷涂机中,在纤维材料层表面均匀喷涂聚氨酯材料层,再送入模压模具的模腔中合模保压固化成型,固化成型过程的温度设置为90~130℃,保压压力为100~300T,保压时间为100~300s;
(3)对上步固化成型完成后开模,获得作为列车内饰件基板坯件的复合片材层,对基板坯件进行整型修边,得到轻质复合材料列车内饰件的基板成品;
(4)对上步完成整型修边的基板成品放入注射模具下模中,将模具下模抽真空后吸附住基板成品,模具的上模、下模合模后上模表面与基板成品留有0.5~2mm空腔,空腔内注入高强度涂层材料,同时上模抽真空引导高强度涂层的聚氨酯充满空腔,后保压,模具温度设置为60~90℃,保压压力为100~200T,保压时间为180~900s;
(5)在上步保压时间完成后开模取件,飞边处理,孔位清理,喷漆,得到具有高硬度涂层的轻质复合材料的列车内饰件。
本发明的技术方案利用具有高强度涂层的轻质复合板制备列车内饰件,将多种片材合理结合,形成强度高、轻质、安全环保、低成本、高产出的列车内饰件。
本发明的技术方案的有益效果具体体现在:
1、对于同一侧顶板产品,选用玻璃钢材质方案的重量约9kg,而采用本技术方案的具有高硬度涂层的轻质复合板的重量约为3.8kg,减重比例约60%;
2、本技术方案的具有高硬度涂层的轻质复合板所测得挥发性有机物含量,结果远优于玻璃钢制品,如下表对比:
本发明中的具体实施例仅仅是对本发明的解释,其并不是对本发明的限制,本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改,但只要在本发明的权利要求范围内都受到专利法的保护。
Claims (10)
1.一种具有高强度涂层的轻质复合材料列车内饰件,其特征在于,包括顶板(1)、侧顶板(2)和墙板(3),所述顶板、侧顶板和墙板均包括复合片材层(4)和高强度涂层(5),复合片材层包括蜂窝材料层(6)和在蜂窝材料层外由内至外依次包裹覆盖的纤维材料层(7)和聚氨酯材料层(8)。
2.根据权利要求1所述的具有高强度涂层的轻质复合材料列车内饰件,其特征在于,所述侧顶板的一侧边开有定位孔(21)和固定槽(22),另一侧边开有调整垫片孔(23)和长条状的螺母安装台(24),两端均开有边条槽(25)。
3.根据权利要求1所述的具有高强度涂层的轻质复合材料列车内饰件,其特征在于,蜂窝材料层为铝蜂窝层。
4.根据权利要求1所述的具有高强度涂层的轻质复合材料列车内饰件,其特征在于,纤维材料层为玻纤布层。
5.根据权利要求1所述的具有高强度涂层的轻质复合材料列车内饰件,其特征在于,聚氨酯材料层为聚氨酯发泡材料层。
6.根据权利要求1所述的具有高强度涂层的轻质复合材料列车内饰件,其特征在于,高强度涂层为零发泡聚氨酯层,其厚度为0.5~2mm。
7.根据权利要求1、3或4所述的具有高强度涂层的轻质复合材料列车内饰件,其特征在于,蜂窝材料层与纤维材料层通过聚氨酯材料的渗透、浸润、发泡、固化方式实现层叠固化成型。
8.根据权利要求1或5所述的具有高强度涂层的轻质复合材料列车内饰件,其特征在于,聚氨酯材料层通过喷涂方式实现覆盖。
9.根据权利要求1或6所述的具有高强度涂层的轻质复合材料列车内饰件,其特征在于,高强度涂层与聚氨酯材料层为化学反应融合粘连。
10.根据权利要求1-6任一所述的具有高强度涂层的轻质复合材料列车内饰件,其特征在于,该具有高强度涂层的轻质复合材料列车内饰件的制备步骤如下:
(1)将裁切合适的蜂窝材料层铺设于工作台后,在其表面包裹并装订同一尺寸的纤维材料层;
(2)将上步获得的覆盖了纤维材料层的产品置入喷涂机中,在纤维材料层表面均匀喷涂聚氨酯材料层,再送入模压模具的模腔中合模保压固化成型,固化成型过程的温度设置为90~130℃,保压压力为100~300T,保压时间为100~300s;
(3)对上步固化成型完成后开模,获得作为列车内饰件基板坯件的复合片材层,对基板坯件进行整型修边,得到轻质复合材料列车内饰件的基板成品;
(4)对上步完成整型修边的基板成品放入注射模具下模中,将模具下模抽真空后吸附住基板成品,模具的上模、下模合模后上模表面与基板成品留有0.5~2mm空腔,空腔内注入高强度涂层材料,同时上模抽真空引导高强度涂层的聚氨酯充满空腔,后保压,模具温度设置为60~90℃,保压压力为100~200T,保压时间为180~900s;
(5)在上步保压时间完成后开模取件,飞边处理,孔位清理,喷漆,得到具有高硬度涂层的轻质复合材料的列车内饰件。
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN201810923668.1A CN108859167A (zh) | 2018-08-14 | 2018-08-14 | 一种具有高强度涂层的轻质复合材料列车内饰件 |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN201810923668.1A CN108859167A (zh) | 2018-08-14 | 2018-08-14 | 一种具有高强度涂层的轻质复合材料列车内饰件 |
Publications (1)
Publication Number | Publication Date |
---|---|
CN108859167A true CN108859167A (zh) | 2018-11-23 |
Family
ID=64318713
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN201810923668.1A Pending CN108859167A (zh) | 2018-08-14 | 2018-08-14 | 一种具有高强度涂层的轻质复合材料列车内饰件 |
Country Status (1)
Country | Link |
---|---|
CN (1) | CN108859167A (zh) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN110271229A (zh) * | 2019-05-20 | 2019-09-24 | 北京连成伟业商贸有限责任公司 | 一种基于一体化成型的板件生成方法及板件 |
CN110328871A (zh) * | 2019-08-14 | 2019-10-15 | 南京康特玻璃钢有限公司 | 一种高铁复合材料车身自动化成型方法 |
WO2020207020A1 (zh) * | 2019-04-12 | 2020-10-15 | 苏州科逸住宅设备股份有限公司 | 一种建筑用板材及一种建筑用板材的制作方法 |
CN113103614A (zh) * | 2021-04-08 | 2021-07-13 | 宜兴市渊星玻璃钢风机有限公司 | 一种新型玻璃钢风阀及其制造方法 |
CN113478860A (zh) * | 2021-05-24 | 2021-10-08 | 常州市宏发纵横新材料科技股份有限公司 | 一种复合材料列车车身结构及其成型方法 |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN107199667A (zh) * | 2017-05-22 | 2017-09-26 | 浙江杉盛模塑科技有限公司 | 零发泡聚氨酯复合材料的注射加工方法 |
CN208774104U (zh) * | 2018-08-14 | 2019-04-23 | 浙江杉盛模塑科技有限公司 | 一种具有高强度涂层的轻质复合材料列车内饰件 |
-
2018
- 2018-08-14 CN CN201810923668.1A patent/CN108859167A/zh active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN107199667A (zh) * | 2017-05-22 | 2017-09-26 | 浙江杉盛模塑科技有限公司 | 零发泡聚氨酯复合材料的注射加工方法 |
CN208774104U (zh) * | 2018-08-14 | 2019-04-23 | 浙江杉盛模塑科技有限公司 | 一种具有高强度涂层的轻质复合材料列车内饰件 |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2020207020A1 (zh) * | 2019-04-12 | 2020-10-15 | 苏州科逸住宅设备股份有限公司 | 一种建筑用板材及一种建筑用板材的制作方法 |
CN110271229A (zh) * | 2019-05-20 | 2019-09-24 | 北京连成伟业商贸有限责任公司 | 一种基于一体化成型的板件生成方法及板件 |
CN110328871A (zh) * | 2019-08-14 | 2019-10-15 | 南京康特玻璃钢有限公司 | 一种高铁复合材料车身自动化成型方法 |
CN110328871B (zh) * | 2019-08-14 | 2021-04-06 | 南京康特玻璃钢有限公司 | 一种高铁复合材料车身自动化成型方法 |
CN113103614A (zh) * | 2021-04-08 | 2021-07-13 | 宜兴市渊星玻璃钢风机有限公司 | 一种新型玻璃钢风阀及其制造方法 |
CN113478860A (zh) * | 2021-05-24 | 2021-10-08 | 常州市宏发纵横新材料科技股份有限公司 | 一种复合材料列车车身结构及其成型方法 |
CN113478860B (zh) * | 2021-05-24 | 2022-08-30 | 常州市宏发纵横新材料科技股份有限公司 | 一种复合材料列车车身结构及其成型方法 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CN108859167A (zh) | 一种具有高强度涂层的轻质复合材料列车内饰件 | |
CN108622123A (zh) | 低成本的碳纤维复合材料空铁车体的结构及制造工艺 | |
CN101678865B (zh) | 运输车辆用复合材料整体式车身及其制备方法 | |
CN103635336A (zh) | 具有用于模块化构成的壳体部件的外覆板的外部模块、该模块化构成的壳体部件自身以及用来制造该外部模块的方法 | |
CN110459715A (zh) | 一种复合材料电池盒 | |
CN103707592B (zh) | 一种汽车发动机舱隔热垫及制备方法 | |
CN106863844A (zh) | 一种泡沫夹芯结构复合材料舱门的制造方法 | |
CN209258263U (zh) | 一种轮式车的碳纤维复合材料舱体 | |
CN107825805A (zh) | 一种超混杂层状复合结构及其制备方法 | |
CN205417779U (zh) | 一种复合材料客车车顶 | |
CN208774104U (zh) | 一种具有高强度涂层的轻质复合材料列车内饰件 | |
CN104002879A (zh) | 汽车备胎盖板及其加工工艺、加工设备 | |
CN106476330A (zh) | 一种轨道车辆芳纶蜂窝侧顶板及其制备方法 | |
CN108859168A (zh) | 一种聚氨酯纤维复合材料卡车外饰件 | |
CN209366808U (zh) | 一种碳纤维复合材料浮标贮存箱 | |
CN110518171A (zh) | 一种轻量化铝箱体结构 | |
CN112009217A (zh) | 一种复合材料车门防撞梁及其制备方法 | |
CN108454641B (zh) | 轨道车辆司机室地板及其制造方法 | |
CN104071091B (zh) | 一种多层结构的汽车用增强型车顶隔音垫及其制作方法 | |
CN113696920B (zh) | 轨道交通车辆窗框及其设计方法 | |
CN208774103U (zh) | 一种聚氨酯纤维复合材料卡车外饰件 | |
CN109955697A (zh) | 一种碳纤维车门及其制造方法 | |
CN214776189U (zh) | 一种多元材料新能源客车 | |
CN106985322A (zh) | 一种采用夹芯结构的客车风道的生产工艺 | |
KR102147477B1 (ko) | 접착력 및 내구성이 향상된 다목적 패널 및 이의 제조방법 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PB01 | Publication | ||
PB01 | Publication | ||
SE01 | Entry into force of request for substantive examination | ||
SE01 | Entry into force of request for substantive examination |