CN109094581A - 一种高速列车用设备舱裙板及其制备方法 - Google Patents

一种高速列车用设备舱裙板及其制备方法 Download PDF

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CN109094581A
CN109094581A CN201810989636.1A CN201810989636A CN109094581A CN 109094581 A CN109094581 A CN 109094581A CN 201810989636 A CN201810989636 A CN 201810989636A CN 109094581 A CN109094581 A CN 109094581A
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skirtboard
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CN109094581B (zh
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张丽娇
章潇慧
陈朝中
洪恩哲
李要君
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CRRC Industry Institute Co Ltd
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及一种高速列车用设备舱裙板及其制备方法。所述高速列车用设备舱裙板由外蒙皮、片胶、中间夹层、片胶、内蒙皮组成；其中，所述外蒙皮是由聚乙烯纤维/碳纤维混编预浸布铺层得到的；所述聚乙烯纤维为超高分子量聚乙烯纤维。本发明所述设备舱裙板的制备方法采用热压成型工艺，通过钢制模具铺层后进行热压得到，该工艺成本低易操作，工艺重复性好，制品尺寸稳定性高，模具可多次重复使用，适宜批量生产。所得混合纤维增强复合材料设备舱裙板具有质轻，防腐蚀，防冲击、阻燃的综合功能，较原铝合金材质减重55％以上，各方面性能指标均满足设备舱裙板的要求。

Description

一种高速列车用设备舱裙板及其制备方法
技术领域
本发明涉及一种高速列车用设备舱裙板及其制备方法，属于轨道交通新材料应用技术领域。
背景技术
高性能纤维增强复合材料与传统轻量化材料相比，具有密度小、强度高、模量高等优点，适合用作轨道交通的轻量化、环保材料。
现有技术已公开一种复合材料制得的高速列车用设备舱裙板的工艺，其通过对铺层设计、使用材料、设计工艺等方面进行改进，得到高强度且重量轻的复合材料设备舱裙板。其中，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。虽然该裙板的重量及单位荷载性能有所改善，但为了获得更好的使用效果，还有待于对高速列车用设备舱裙板的性能作进一步提升，有鉴于此，特提出本申请。
发明内容
针对上述问题，本发明提出一种新型高速列车用设备舱裙板及其制备方法。通过对裙板铺层材料的筛选及铺层设计，得到相对强度更高、重量更轻、性能更优、耐腐蚀性更好的高速列车用设备舱裙板。
本发明所采用的技术方案如下。
一种高速列车用设备舱裙板，由外蒙皮、片胶、中间夹层、片胶、内蒙皮组成；其中，所述外蒙皮是由聚乙烯纤维/碳纤维混编预浸布铺层得到的；优选地，所述聚乙烯纤维为超高分子量聚乙烯纤维，其分子量范围为300万～500万。
进一步地，所述聚乙烯纤维与碳纤维混编预浸布的层数为5～8层。
进一步地，所述聚乙烯纤维/碳纤维混编预浸布中，碳纤维与聚乙烯纤维以体积比1:1混编；编织方法优选斜纹编织；织物面密度为180-200gsm，优选190gsm；其含胶量为42±3％。所述碳纤维和聚乙烯纤维混编预浸布的树脂为环氧树脂。
进一步地，所述外蒙皮的厚度为4-7mm。
进一步地，所述中间夹层由芳纶纸蜂窝芯制得；优选厚度为17～18mm。
进一步地，所述内蒙皮由碳纤维预浸布铺层得到的；优选地，所述碳纤维预浸布层数为5～8层。
进一步地，所述碳纤维预浸布选自3K斜纹碳纤维预浸布和/或3K单向碳纤维预浸布。
进一步优选地，所述内蒙皮由3～5层3K斜纹碳纤维预浸布和2～4层3K单向碳纤维预浸布铺层得到；更进一步优选地，所述3K单向碳纤维预浸布0°、90°两方向铺层。
进一步地，所述碳纤维预浸布的树脂为环氧树脂。
作为本发明优选实施方式之一，所述高速列车用设备舱裙板由外至内各层顺序为：
(1)聚乙烯纤维/碳纤维混编布6层；
(2)片胶1层；
(3)芳纶纸蜂窝17～18mm厚度1层；
(4)片胶1层；
(5)3K斜纹碳纤维预浸布5层；
(6)3K单向碳纤维预浸布0°、90°两方向2层。
本发明还提供一种高速列车用设备舱裙板的制备方法，包括：将各预浸布按要求在预定型装置内铺层，用热压成型工艺制备得到。
其中，在本发明所述热压成型工艺中，本领域技术人员可根据实际需求选择所掌握的适用于所述工艺的各类模具。如设备舱底板及侧板等的模具，或其它设备部件的模具。所述预定型装置采用普通钢制模具。
本发明所述热压成型工艺的操作条件为：
(1)热压机温度设置为120℃±5℃；
(2)机台压力设置与模具温度相关：
当模具温度为60℃，机台压力设为2MPa；
当模具温度为70-80℃，机台压力设为3MPa；
当模具温度为90℃-125℃，机台压力设为4MPa，底板主板成型时间控制为1.5h。
作为本发明优选实施方式之一，所述高速列车用设备舱裙板的制备方法，包括：
步骤一：设计并制作钢制模具，分为阴阳双模；
步骤二：将模具内部涂硅油或贴聚四氟乙烯脱模布；
步骤三：将3K单向碳纤维预浸料0°、90°两方向2层、3K斜纹碳纤维预浸布5层，中温固化蓝色片胶1层、芳纶纸蜂窝17～18mm厚度1层、中温固化蓝色片胶1层、聚乙烯纤维/碳纤维混编预浸布6层；
步骤四：覆盖阳模并压紧；
步骤五：热压成型的热压机温度设置为120℃±5℃，机台压力设置与温度相关：当模具温度为60℃，机台压力设为2MPa；当模具温度为70-80℃，机台压力设为3MPa；当模具温度为90℃-125℃，机台压力设为4MPa，底板主板成型时间控制为1.5h；
步骤六：冷却，脱模，进行机加工完成裙板制作。
与现有技术相比，本发明的有益效果如下：
本发明采用超高分子量聚乙烯纤维与碳纤维的混合编织预浸料来制作裙板的外蒙皮，具有表面耐冲击性能好，强度高，耐老化性能好，重量轻的优势，且成型工艺简单易操作，完美解决提高冲击强度与韧性的问题。
与原有的碳纤-玻纤-芳纶纤维混合纤维制裙板相比，本发明所得高速列车用设备舱裙板质量更轻，工艺操作性更便捷。经验证，本发明所得高速列车用设备舱裙板的重量较原铝制裙板至少降低了55％，较碳纤-玻纤-芳纶纤维混合纤维制裙板减低至85％以下，单位面积载荷超过3000Pa，具有质轻高强耐冲击的特点。
附图说明
图1为本发明所述高速列车用设备舱裙板的结构示意图；图中：1、外蒙皮层；2、夹芯层；3、内蒙皮层。
图2为本发明所述高速列车用设备舱裙板的加工工艺图；图中：5、阳模；6、裙板制件；7、阴模；8、热压机。
图3为本发明所述高速列车用设备舱裙板的工艺流程图。
具体实施方式
以下实施例用于说明本发明，但不用来限制本发明的范围。
实施例1一种高速列车用设备舱裙板
本实施例提供一种高速列车用设备舱裙板，由外至内各层顺序为：
(1)聚乙烯纤维/碳纤维混编布6层；
(2)片胶1层；
(3)芳纶纸蜂窝17～18mm厚度1层；
(4)片胶1层；
(5)3K斜纹碳纤维预浸布5层；
(6)3K单向碳纤维预浸布0°、90°两方向2层。
实施例2一种高速列车用设备舱裙板的制备
本实施例提供一种高速列车用设备舱裙板的制备方法，包括：
步骤一：设计并制作钢制模具，分为阴阳双模；
步骤二：将模具内部涂硅油或贴聚四氟乙烯脱模布；
步骤三：将3K单向碳纤维预浸料0°、90°两方向2层、3K斜纹碳纤维预浸布5层，中温固化蓝色片胶1层、芳纶纸蜂窝17～18mm厚度1层、中温固化蓝色片胶1层、聚乙烯纤维/碳纤维混编预浸布6层；
步骤四：覆盖阳模并压紧；
步骤五：热压成型的热压机温度设置为120℃±5℃，机台压力设置与温度相关：当模具温度为60℃，机台压力设为2MPa；当模具温度为70-80℃，机台压力设为3MPa；当模具温度为90℃-125℃，机台压力设为4MPa，底板主板成型时间控制为1.5h；
步骤六：冷却，脱模，进行机加工完成裙板制作。
效果验证
按照本领域设备舱裙板常规检测方法对实施例2所得设备舱裙板、现有碳纤-玻纤-芳纶纤维混合纤维制裙板、铝制裙板进行测试，结果如下：
本发明所得高速列车用设备舱裙板质量更轻，较原铝制裙板至少降低了55％，较碳纤-玻纤-芳纶纤维混合纤维制裙板减低至85％以下，单位面积载荷超过3000Pa，具有质轻高强耐冲击的特点。
虽然，上文中已经用一般性说明及具体实施方案对本发明作了详尽的描述，但在本发明基础上，可以对之作一些修改或改进，这对本领域技术人员而言是显而易见的。因此，在不偏离本发明精神的基础上所做的这些修改或改进，均属于本发明要求保护的范围。

Claims (10)

1.一种高速列车用设备舱裙板，其特征在于，由外蒙皮、片胶、中间夹层、片胶、内蒙皮组成；其中，所述外蒙皮是由聚乙烯纤维/碳纤维混编预浸布铺层得到的；
优选地，所述聚乙烯纤维为超高分子量聚乙烯纤维，进一步优选其分子量范围为300万～500万。
2.根据权利要求1所述的高速列车用设备舱裙板，其特征在于，所述聚乙烯纤维与碳纤维混编预浸布的层数为5～8层。
3.根据权利要求1或2所述的高速列车用设备舱裙板，其特征在于，所述聚乙烯纤维/碳纤维混编预浸布中，碳纤维与聚乙烯纤维以体积比1:1混编；编织方法优选斜纹编织；织物面密度为180-200gsm；其含胶量为42±3％。
4.根据权利要求1-3任一所述的高速列车用设备舱裙板，其特征在于，所述中间夹层由芳纶纸蜂窝芯制得；优选厚度为17～18mm。
5.根据权利要求1-4任一所述的高速列车用设备舱裙板，其特征在于，所述内蒙皮由碳纤维预浸布铺层得到的；优选地，所述碳纤维预浸布层数为5～8层。
6.根据权利要求5所述的高速列车用设备舱裙板，其特征在于，所述碳纤维预浸布选自3K斜纹碳纤维预浸布和/或3K单向碳纤维预浸布。
7.根据权利要求1-6任一所述的高速列车用设备舱裙板，其特征在于，所述内蒙皮由3～5层3K斜纹碳纤维预浸布和2～4层3K单向碳纤维预浸布铺层得到；
优选地，所述3K单向碳纤维预浸布0°、90°两方向铺层。
8.根据权利要求1-7任一所述的高速列车用设备舱裙板，其特征在于，由外至内各层顺序为：
(1)聚乙烯纤维/碳纤维混编布6层；
(2)片胶1层；
(3)芳纶纸蜂窝17～18mm厚度1层；
(4)片胶1层；
(5)3K斜纹碳纤维预浸布5层；
(6)3K单向碳纤维预浸布0°、90°两方向2层。
9.一种高速列车用设备舱裙板的制备方法，其特征在于，包括：将各预浸布按要求在预定型装置内铺层，用热压成型工艺制备得到；
其中，所述热压成型工艺的操作条件为：
(1)热压机温度设置为120℃±5℃；
(2)机台压力设置与模具温度相关：
当模具温度为60℃，机台压力设为2MPa；
当模具温度为70-80℃，机台压力设为3MPa；
当模具温度为90℃-125℃，机台压力设为4MPa。
10.根据权利要求9所述的高速列车用设备舱裙板的制备方法，其特征在于，包括：
步骤一：设计并制作钢制模具，分为阴阳双模；
步骤二：将模具内部涂硅油或贴聚四氟乙烯脱模布；
步骤三：将3K单向碳纤维预浸料0°、90°两方向2层、3K斜纹碳纤维预浸布5层，中温固化蓝色片胶1层、芳纶纸蜂窝17～18mm厚度1层、中温固化蓝色片胶1层、聚乙烯纤维/碳纤维混编预浸布6层；
步骤四：覆盖阳模并压紧；
步骤五：热压成型的热压机温度设置为120℃±5℃；
机台压力设置与温度相关：当模具温度为60℃，机台压力设为2MPa；当模具温度为70-80℃，机台压力设为3MPa；当模具温度为90℃-125℃，机台压力设为4MPa，底板主板成型时间控制为1.5h；
步骤六：冷却，脱模，进行机加工完成裙板制作。
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