CN110104007B - 一种环保型高速列车平顶板及制备方法 - Google Patents
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Abstract
本发明涉及轨道交通技术领域,其公开了一种环保型高速列车平顶板及制备方法,包括由若干数量的麻纤维复合板拼装连接而成的平顶板组件,所述麻纤维复合板具有叠层结构,所述叠层结构包括中间层、设置在所述中间层两端面的贴面层,所述中间层的两端面带有粘结层;其中,所述中间层为麻纤维板,所述贴面层为防火板,所述粘结层为PP无纺布。本发明进一步提高了平顶板的环保性能和防火性能,并提高了平顶板的强度。
Description
技术领域
本发明涉及轨道交通技术领域,具体涉及一种环保型高速列车平顶板及制备方法。
背景技术
高速轨道交通列车用的平顶板采用纸蜂窝板制作,其存在的问题是:
一是纸蜂窝板在制造过程中要采用大量的胶粘剂,其在后续使用过程中会挥发出有害气体,对人体健康和环境都会造成一定的负面影响。
二是纸蜂窝板的防火性能相对较差。
三是纸蜂窝板的强度相对较低、且使用寿命不长。
发明内容
为了解决上述问题,本发明提出一种环保型高速列车平顶板及制备方法,旨在进一步提高平顶板的环保性能和防火性能,并提高平顶板的强度。具体的技术方案如下:
一种环保型高速列车平顶板,包括由若干数量的麻纤维复合板拼装连接而成的平顶板组件,所述麻纤维复合板具有叠层结构,所述叠层结构包括中间层、设置在所述中间层两端面的贴面层,所述中间层的两端面带有粘结层;其中,所述中间层为麻纤维板,所述贴面层为防火板,所述粘结层为PP无纺布。
上述技术方案中,其平顶板的主体部分采用了麻纤维复合板,由于麻纤维复合板是依靠作为粘结层的PP无纺布连接作为中间层的麻纤维板和作为贴面层的防火板,其结构成分中不含对人体健康和环境有影响的胶粘剂,因此相比传统纸蜂窝板制作的平顶板更加环保。另外,麻纤维板的两面设置有防火板,相对于纸蜂窝板制作的平顶板其防火性能有了较大提高。而且,麻纤维复合板的强度大大高于纸蜂窝板,且使用寿命较长。
本发明中,所述麻纤维复合板上设置有用于麻纤维复合板拼装连接的螺钉连接孔和和安装用沉孔,且所述螺钉连接孔为采用冲压加工制作的冲压孔,所述沉孔为采用数控雕刻机加工的雕刻沉孔。
本发明中,所述麻纤维复合板上设置扬声器安装部,所述扬声器安装部上设置有密孔,所述密孔为采用数控雕刻机加工的雕刻密孔。
本发明中,所述麻纤维复合板上设置有预埋螺母,所述预埋螺母的外圆上带有用于连接所述麻纤维复合板的自攻螺牙。
制作时,在所述麻纤维复合板上预制出预埋螺母安装用的底孔,然后将预埋螺母通过其自攻螺牙镶入底孔内并形成牢固结合。
作为本发明的一种优选方案,所述麻纤维板为由45~55%重量百分比的麻纤维和45~55%重量百分比的丙纶纤维制成的麻纤维板,所述麻纤维板的厚度为8.5~9.5mm,所述防火板的厚度为0.6~0.8mm。
一种环保型高速列车平顶板的制备方法,包括如下方法步骤:
第一步、预制麻纤维毡;
第二步、制作中间层:将麻纤维毡进行多层叠合,再在叠合后的麻纤维毡的两面分别铺上一层PP无纺布,然后进行热压成型制成作为中间层的麻纤维板;
第三步、热压麻纤维复合板:在麻纤维板的两面铺上防火板,然后热压成型制成麻纤维复合板;
第四步、采用数控雕刻机,对麻纤维复合板进行修边加工,并加工出螺钉连接孔、预埋螺母用底孔、安装用沉孔和密孔;
第五步、将加工完成的麻纤维复合板进行装配,制成所述的环保型高速列车平顶板。
本发明中所述预制麻纤维毡包括如下工艺步骤:
步骤1、纤维预处理:采用开包机及粗开松机,对丙纶纤维、麻纤维进行松散处理;
步骤2、计量配比:将所述丙纶纤维、麻纤维进行称重,并按照45~55%重量百分比的麻纤维和45~55%重量百分比的丙纶纤维进行配比;
步骤3、混料除杂:将步骤2中的丙纶纤维、麻纤维混合并除杂处理;
步骤4、梳理:采用高速精梳机,将除杂混合后的纤维进行精梳成网处理;
步骤5、铺网:采用铺网机,将精梳后的混合纤维网以交叉叠层铺网方式铺成多层纤网;所述交叉叠层铺网方式为相邻两层的混合纤维网按照所述混合纤维网中的纤维方向相互交叉的方式进行叠层;其中,所述多层纤网中的每层纤网为15-30g/m2的薄层;
步骤6、针剌成毡:采用具有上下对刺功能的针刺机,对多层纤网进行双面高频上下同步针刺,使得多层纤网结合在一起,形成网状结构的麻纤维毡;
步骤7、真空脱异味处理:将针刺成毡后的麻纤维毡输送到真空脱异味机中,除去异味。
优选的,所述真空脱异味机包括用于放置所述麻纤维毡的密闭容器,所述密闭容器上分别设置有热风循环装置、抽真空装置和压缩空气充气口,且所述有热风循环装置和抽真空装置交替运行以实现麻纤维毡的去异味处理;其中,所述热风循环装置包括加热器和循环风机,且所述加热器和循环风机通过管路串接在所述密闭容器的两端。
真空脱异味机使用时,先通过压缩空气充气口在密闭容器内充入压缩空气,并启动热风循环装置对麻纤维毡进行热风循环加热,加热完成后启动抽真空装置进行抽真空,经过多次的热风循环与抽真空的交替作业,实现麻纤维毡的去异味处理。
上述真空脱异味处理中,采用热风循环与抽真空的交替作业,且热风循环是采用压缩空气的高压热风循环,由此提高了去异味处理的效果,从而进一步提高了高速列车平顶板的环保性能。
优选的,所述第三步的热压麻纤维复合板工序中,设置热压温度为100~105℃,持续保压时间为25~35分钟。
优选的,所述第三步的热压麻纤维复合板工序中,所述热压采用模具热压,并在麻纤维复合板的一面热压出用于提高麻纤维复合板强度的加强筋,所述加强筋为高于麻纤维复合板平面且具有网格状分布的凸筋。
通过在麻纤维复合板的一面(其作为平顶板的背面)模压出网格状分布的凸筋,可以提高平顶板的强度,从而有利于在平顶板的结构设计时适当减少麻纤维复合板的壁厚和重量,进而有利于高速列车的轻量化。
上述通过优化麻纤维板中麻纤维与丙纶纤维的配制比例、麻纤维板的厚度、防火板的厚度参数,以及热压麻纤维复合板的工艺参数,可以提高作为平顶板的麻纤维复合板的质量稳定性。
本发明的有益效果是:
第一,本发明的一种环保型高速列车平顶板及制备方法,其平顶板的主体部分采用了麻纤维复合板,由于麻纤维复合板是依靠作为粘结层的PP无纺布连接作为中间层的麻纤维板和作为贴面层的防火板,其结构成分中不含对人体健康和环境有影响的胶粘剂,因此相比传统纸蜂窝板制作的平顶板更加环保。
第二,本发明的一种环保型高速列车平顶板及制备方法,麻纤维板的两面设置有防火板,相对于纸蜂窝板制作的平顶板其防火性能有了较大提高。
第三,本发明的一种环保型高速列车平顶板及制备方法,其麻纤维复合板的强度大大高于纸蜂窝板,且使用寿命较长。
第四,本发明的一种环保型高速列车平顶板及制备方法,真空脱异味处理中,采用热风循环与抽真空的交替作业,且热风循环是采用压缩空气的高压热风循环,由此提高了去异味处理的效果,从而进一步提高了高速列车平顶板的环保性能。
第五,本发明的一种环保型高速列车平顶板及制备方法,通过优化麻纤维板中麻纤维与丙纶纤维的配制比例、麻纤维板的厚度、防火板的厚度参数,以及热压麻纤维复合板的工艺参数,可以提高作为平顶板的麻纤维复合板的质量稳定性。
第六,本发明的一种环保型高速列车平顶板及制备方法,通过在麻纤维复合板的一面(其作为平顶板的背面)模压出网格状分布的凸筋,可以提高平顶板的强度,从而有利于在平顶板的结构设计时适当减少麻纤维复合板的壁厚和重量,进而有利于高速列车的轻量化。
附图说明
图1是本发明的一种环保型高速列车平顶板的结构示意图;
图2是麻纤维复合板的结构示意图;
图3是真空脱异味机的结构示意图。
图中:1、麻纤维复合板,2、平顶板组件,3、中间层(麻纤维板),4、贴面层(防火板),5、粘结层(PP无纺布),6、螺钉连接孔,7、沉孔,8、密孔。
图中:50、真空脱异味机,51、密闭容器,52、热风循环装置,53、抽真空装置,54、加热器,55、循环风机,56、管路,57、电动截止阀,58、多层支架,59、压缩空气充气口,60、麻纤维毡。
具体实施方式
下面结合附图和实施例,对本发明的具体实施方式作进一步描述。以下实施例仅用于更加清楚地说明本发明的技术方案,而不能以此来限制本发明的保护范围。
实施例1:
如图1至3所示为本发明的一种环保型高速列车平顶板的实施例,包括由若干数量的麻纤维复合板1拼装连接而成的平顶板组件2,所述麻纤维复合板1具有叠层结构,所述叠层结构包括中间层3、设置在所述中间层3两端面的贴面层4,所述中间层3的两端面带有粘结层5;其中,所述中间层为麻纤维板,所述贴面层为防火板,所述粘结层5为PP无纺布。
上述技术方案中,其平顶板的主体部分采用了麻纤维复合板1,由于麻纤维复合板1是依靠作为粘结层的PP无纺布连接作为中间层3的麻纤维板和作为贴面层4的防火板,其结构成分中不含对人体健康和环境有影响的胶粘剂,因此相比传统纸蜂窝板制作的平顶板更加环保。另外,麻纤维板的两面设置有防火板,相对于纸蜂窝板制作的平顶板其防火性能有了较大提高。而且,麻纤维复合板1的强度大大高于纸蜂窝板,且使用寿命较长。
本实施例中,所述麻纤维复合板1上设置有用于麻纤维复合板1拼装连接的螺钉连接孔6和和安装用沉孔7,且所述螺钉连接孔6为采用冲压加工制作的冲压孔,所述沉孔7为采用数控雕刻机加工的雕刻沉孔。
本实施例中,所述麻纤维复合板1上设置扬声器安装部,所述扬声器安装部上设置有密孔7,所述密孔7为采用数控雕刻机加工的雕刻密孔。
本实施例中,所述麻纤维复合板1上设置有预埋螺母,所述预埋螺母的外圆上带有用于连接所述麻纤维复合板的自攻螺牙。
制作时,在所述麻纤维复合板1上预制出预埋螺母安装用的底孔,然后将预埋螺母通过其自攻螺牙镶入底孔内并形成牢固结合。
作为本实施例的一种优选方案,所述麻纤维板为由45~55%重量百分比的麻纤维和45~55%重量百分比的丙纶纤维制成的麻纤维板,所述麻纤维板的厚度为8.5~9.5mm,所述防火板的厚度为0.6~0.8mm。
实施例2:
如图1至3所示为本发明的一种环保型高速列车平顶板的制备方法的实施例,包括如下方法步骤:
第一步、预制麻纤维毡;
第二步、制作中间层:将麻纤维毡进行多层叠合,再在叠合后的麻纤维毡的两面分别铺上一层PP无纺布,然后进行热压成型制成作为中间层3的麻纤维板;
第三步、热压麻纤维复合板:在麻纤维板的两面铺上防火板,然后热压成型制成麻纤维复合板1;
第四步、采用数控雕刻机,对麻纤维复合板1进行修边加工,并加工出螺钉连接孔6、预埋螺母用底孔、安装用沉孔7和密孔8;
第五步、将加工完成的麻纤维复合板1进行装配,制成所述的环保型高速列车平顶板。
本实施例中所述预制麻纤维毡包括如下工艺步骤:
步骤1、纤维预处理:采用开包机及粗开松机,对丙纶纤维、麻纤维进行松散处理;
步骤2、计量配比:将所述丙纶纤维、麻纤维进行称重,并按照45~55%重量百分比的麻纤维和45~55%重量百分比的丙纶纤维进行配比;
步骤3、混料除杂:将步骤2中的丙纶纤维、麻纤维混合并除杂处理;
步骤4、梳理:采用高速精梳机,将除杂混合后的纤维进行精梳成网处理;
步骤5、铺网:采用铺网机,将精梳后的混合纤维网以交叉叠层铺网方式铺成多层纤网;所述交叉叠层铺网方式为相邻两层的混合纤维网按照所述混合纤维网中的纤维方向相互交叉的方式进行叠层;其中,所述多层纤网中的每层纤网为15-30g/m2的薄层;
步骤6、针剌成毡:采用具有上下对刺功能的针刺机,对多层纤网进行双面高频上下同步针刺,使得多层纤网结合在一起,形成网状结构的麻纤维毡;
步骤7、真空脱异味处理:将针刺成毡后的麻纤维毡输送到真空脱异味机中,除去异味。
优选的,所述真空脱异味机50包括用于放置所述麻纤维毡60的密闭容器51,所述密闭容器51上分别设置有热风循环装置52、抽真空装置53和压缩空气充气口59,且所述有热风循环装置52和抽真空装置53交替运行以实现麻纤维毡60的去异味处理;其中,所述热风循环装置52包括加热器54和循环风机55,且所述加热器54和循环风机55通过管路56串接在所述密闭容器51的两端。
真空脱异味机50使用时,先通过压缩空气充气口59在密闭容器51内充入压缩空气,并启动热风循环装置52对麻纤维毡60进行热风循环加热,加热完成后启动抽真空装置53进行抽真空,经过多次的热风循环与抽真空的交替作业,实现麻纤维毡的去异味处理。
上述真空脱异味处理中,采用热风循环与抽真空的交替作业,且热风循环是采用压缩空气的高压热风循环,由此提高了去异味处理的效果,从而进一步提高了高速列车平顶板的环保性能。
优选的,所述第三步的热压麻纤维复合板工序中,设置热压温度为100~105℃,持续保压时间为25~35分钟。
优选的,所述第三步的热压麻纤维复合板工序中,所述热压采用模具热压,并在麻纤维复合板的一面热压出用于提高麻纤维复合板强度的加强筋,所述加强筋为高于麻纤维复合板平面且具有网格状分布的凸筋。
通过在麻纤维复合板的一面(其作为平顶板的背面)模压出网格状分布的凸筋,可以提高平顶板的强度,从而有利于在平顶板的结构设计时适当减少麻纤维复合板的壁厚和重量,进而有利于高速列车的轻量化。
上述通过优化麻纤维板中麻纤维与丙纶纤维的配制比例、麻纤维板的厚度、防火板的厚度参数,以及热压麻纤维复合板的工艺参数,可以提高作为平顶板的麻纤维复合板1的质量稳定性。
实施例3:
对于采用上述实施例1和2所制造的一种环保型高速列车平顶板(取其麻纤维板为样品)进行性能试验,得到结果如下:
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明技术原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (10)
1.一种环保型高速列车平顶板,其特征在于,包括由若干数量的麻纤维复合板拼装连接而成的平顶板组件, 所述麻纤维复合板具有叠层结构,所述叠层结构包括中间层、设置在所述中间层两端面的贴面层,所述中间层的两端面带有粘结层;其中,所述中间层为麻纤维板,所述贴面层为防火板,所述粘结层为PP无纺布;其中,所述麻纤维板是由多层麻纤维毡叠合后采用热压成型制成的麻纤维板,且所述麻纤维毡为采用真空脱异味机进行处理的麻纤维毡;所述真空脱异味机包括用于放置所述麻纤维毡的密闭容器,所述密闭容器上分别设置有热风循环装置、抽真空装置和压缩空气充气口,且所述热风循环装置和抽真空装置交替运行以实现麻纤维毡的去异味处理;其中,所述热风循环装置包括加热器和循环风机,且所述加热器和循环风机通过管路串接在所述密闭容器的两端。
2.根据权利要求1所述的一种环保型高速列车平顶板,其特征在于,所述麻纤维复合板上设置有用于麻纤维复合板拼装连接的螺钉连接孔和和安装用沉孔,且所述螺钉连接孔为采用冲压加工制作的冲压孔,所述沉孔为采用数控雕刻机加工的雕刻沉孔。
3.根据权利要求1所述的一种环保型高速列车平顶板,其特征在于,所述麻纤维复合板上设置扬声器安装部,所述扬声器安装部上设置有密孔,所述密孔为采用数控雕刻机加工的雕刻密孔。
4.根据权利要求1所述的一种环保型高速列车平顶板,其特征在于,所述麻纤维复合板上设置有预埋螺母,所述预埋螺母的外圆上带有用于连接所述麻纤维复合板的自攻螺牙。
5.根据权利要求1所述的一种环保型高速列车平顶板,其特征在于,所述麻纤维板为由45~55%重量百分比的麻纤维和45~55%重量百分比的丙纶纤维制成的麻纤维板,所述麻纤维板的厚度为8.5~9.5mm,所述防火板的厚度为0.6~0.8mm。
6.一种如权利要求1至5中任一项所述的环保型高速列车平顶板的制备方法,其特征在于,包括如下方法步骤:
第一步、预制麻纤维毡;
第二步、制作中间层:将麻纤维毡进行多层叠合,再在叠合后的麻纤维毡的两面分别铺上一层PP无纺布,然后进行热压成型制成作为中间层的麻纤维板;
第三步、热压麻纤维复合板:在麻纤维板的两面铺上防火板,然后热压成型制成麻纤维复合板;
第四步、采用数控雕刻机,对麻纤维复合板进行修边加工,并加工出螺钉连接孔、预埋螺母用底孔、安装用沉孔和密孔;
第五步、将加工完成的麻纤维复合板进行装配,制成所述的环保型高速列车平顶板。
7.根据权利要求6所述的一种环保型高速列车平顶板的制备方法,其特征在于,所述预制麻纤维毡包括如下工艺步骤:
步骤1、纤维预处理:采用开包机及粗开松机,对丙纶纤维、麻纤维进行松散处理;
步骤2、计量配比:将所述丙纶纤维、麻纤维进行称重,并按照45~55%重量百分比的麻纤维和45~55%重量百分比的丙纶纤维进行配比;
步骤3、混料除杂:将步骤2中的丙纶纤维、麻纤维混合并除杂处理;
步骤4、梳理:采用高速精梳机,将除杂混合后的纤维进行精梳成网处理;
步骤5、铺网:采用铺网机,将精梳后的混合纤维网以交叉叠层铺网方式铺成多层纤网;所述交叉叠层铺网方式为相邻两层的混合纤维网按照所述混合纤维网中的纤维方向相互交叉的方式进行叠层;其中,所述多层纤网中的每层纤网为15-30g/m2的薄层;
步骤6、针剌成毡:采用具有上下对刺功能的针刺机,对多层纤网进行双面高频上下同步针刺,使得多层纤网结合在一起,形成网状结构的麻纤维毡;
步骤7、真空脱异味处理:将针刺成毡后的麻纤维毡输送到真空脱异味机中,除去异味。
8.根据权利要求7所述的一种环保型高速列车平顶板的制备方法,其特征在于,所述真空脱异味机包括用于放置所述麻纤维毡的密闭容器,所述密闭容器上分别设置有热风循环装置、抽真空装置和压缩空气充气口,且所述有热风循环装置和抽真空装置交替运行以实现麻纤维毡的去异味处理;其中,所述热风循环装置包括加热器和循环风机,且所述加热器和循环风机通过管路串接在所述密闭容器的两端。
9.根据权利要求6所述的一种环保型高速列车平顶板的制备方法,其特征在于,所述第三步的热压麻纤维复合板工序中,设置热压温度为100~105℃,持续保压时间为25~35分钟。
10.根据权利要求6所述的一种环保型高速列车平顶板的制备方法,其特征在于,所述第三步的热压麻纤维复合板工序中,所述热压采用模具热压,并在麻纤维复合板的一面热压出用于提高麻纤维复合板强度的加强筋,所述加强筋为高于麻纤维复合板平面且具有网格状分布的凸筋。
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