CN110356058A - 一种耐冲击高速列车设备舱复合底板及其制备方法和应用 - Google Patents

一种耐冲击高速列车设备舱复合底板及其制备方法和应用 Download PDF

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CN110356058A
CN110356058A CN201910554441.9A CN201910554441A CN110356058A CN 110356058 A CN110356058 A CN 110356058A CN 201910554441 A CN201910554441 A CN 201910554441A CN 110356058 A CN110356058 A CN 110356058A
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layer
carbon fiber
prepreg
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bottom board
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张丽娇
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CRRC Industry Institute Co Ltd
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Abstract

本发明属于轨道交通应用领域，具体涉及一种耐冲击防火高速列车设备舱复合底板及其制备方法和应用。所述复合板由内至外包括：第一层：碳纤维单向布预浸料；第二层：PET泡沫或NOMEX纸蜂窝；第三层：碳纤维单向布预浸料；第四层：混杂纤维预浸料；所述混杂纤维是由超高分子量聚乙烯与碳纤维混编而成；第五层：碳纤维平纹织物预浸料；第六层：聚氨酯防火涂层。本发明所述耐冲击高速列车设备舱复合底板不仅比现有复合底板轻，而且抗冲击性能显著提升，特别是耐尖锐物的低能量冲击稳定性得到大幅提高，同时还具有良好的防火性能。

Description

一种耐冲击高速列车设备舱复合底板及其制备方法和应用
技术领域
本发明属于轨道交通应用领域，具体涉及一种耐冲击高速列车设备舱复合底板及其制备方法和应用。
背景技术
高铁设备舱底板是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、设计工艺方面需要综合考虑。
现有的高速列车设备舱复合底板主要是采用碳纤维+玻璃纤维+芳纶复合材料，利用真空袋辅助成型工艺制得的，其具有重量轻的特点。但在列车高速运行中，有轧轨道上的石子对列车底部冲击破坏性非常大，而常规的碳纤维复合底板难以抵抗这种高速低能量冲击力，需要经常更换；此外，此类复合地板的防火性能也不达标。
发明内容
本发明的目的是为了克服现有高铁设备舱底板存在的耐冲击性差、防火性能差的问题，提供了一种耐冲击防火高速列车设备舱复合底板。本发明所述耐冲击高速列车设备舱复合底板不仅比现有复合底板轻，而且抗冲击性能显著提升，特别是耐尖锐物的低能量冲击稳定性得到大幅提高，同时还具有良好的防火性能。
本发明所述的复合板，由内至外包括：
第一层：碳纤维单向布预浸料；
第二层：PET泡沫或NOMEX纸蜂窝；
第三层：碳纤维单向布预浸料；
第四层：混杂纤维预浸料；所述混杂纤维是由超高分子量聚乙烯与碳纤维混编而成；
第五层：碳纤维平纹织物预浸料；
第六层：聚氨酯防火涂层。
本发明采用超高分子量聚乙烯与碳纤维混编而成的混杂纤维替换现有设备舱底板中常用的芳纶和玻璃纤维，同时对各层材质作适配性调整，使各层材质之间产生较强的界面结合力及良好的抗低速冲击能量性能的协同作用，从而在减轻重量的同时，进一步增强复合板的耐冲击性及耐尖锐物的低能量冲击稳定性。采用的混编织物预浸料与碳纤维预浸料具有较好的界面结合性能，降低分层概率，提高界面结合力，综合利用复合材料的多种性能优势。表面的聚氨酯防护涂层，有效隔离氧气与内部树脂基体，起到了防护隔离作用，同时具有较好的防污隔热作用。
在本发明的一些实施例中，所述复合板包括：第一层包括3～6层碳纤维单向布预浸料，第二层包括厚度为5-7mm PET泡沫或NOMEX纸蜂窝，第三层包括2～5层碳纤维单向布预浸料，第四层包括2～3层混杂纤维预浸料，第五层包括1层预浸料碳纤维平纹织物。本发明发现，在各层材质选择基础上，通过对各层层数的优化调整，各层之间形成较强的界面结合力及良好的抗低速冲击能量性能的协同作用、通过采用fibersim软件的计算，第一层和第三层均采用0°、±45°或90°的铺层方式，具有较好的层间剪切强度。第四层混杂纤维预浸料为碳纤维与超高分子量聚乙烯的混编预浸料，与第三层和第五层能够很好的结合，从而进一步提高复合板的耐冲击性能及耐尖锐物的低能量冲击稳定性。
在本发明的一些实施例中，所述第二层分别与所述第一层、第三层的单向布铺层角度为0°、±45°或90°。按此铺设方式铺层，更有利于提高复合板的耐冲击性和耐尖锐物的低能量冲击稳定性。
为了进一步提高复合板的防火性能，所述碳纤维单向布或碳纤维平纹织物中的碳纤维选自防火等级达到EN45545标准SL3级别的复合碳纤维材料。
在本发明的一些实施例中，所述第六层聚氨酯防火涂层的厚度以2～3mm为宜。所述第六层聚氨酯防火涂层是采用刮涂或喷涂方式在第五层表面形成的。
本发明所述的复合板可采用本领域常规加工方式，如模压工艺制得。
本发明还提供了上述复合板在高铁设备舱底板、高铁设备舱端板等耐中低速能量冲击及刚性要求较高的薄板中的应用。
本发明还提供了一种高铁设备舱底板，包含上述复合板。
本发明的有益效果如下：
本发明在现有高铁设备舱底板复合层结构中引入超高分子量聚乙烯与碳纤维混编而成的混杂纤维，同时对其他各层材质作适配性调整，使各层材质之间产生协同作用，从而在减轻重量(可降低15％)的同时，增强复合板的耐冲击性(可提高40％)及耐尖锐物的低能量冲击稳定性。
附图说明
图1为实施例1所述复合板的结构示意图。
图中：1、第一层碳纤维单向布预浸料；2、第二层PET泡沫或NOMEX纸蜂窝；3、第三层碳纤维单向布预浸料；4、第四层混杂纤维预浸料；5、第五层碳纤维平纹织物预浸料；6、第六层聚氨酯防火涂层。
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
本实施例提供一种复合板，如图1所示，由内至外包括：
第一层：4层碳纤维单向布预浸料，铺层方式为[45/90/-45/0]；
第二层：NOMEX纸蜂窝；厚度为6mm；
第三层：5层碳纤维单向布预浸料，铺层方式为[90/-45/0/45/90]；
第四层：3层混杂纤维预浸料；所述混杂纤维是由超高分子量聚乙烯与碳纤维混编而成；
第五层：1层碳纤维平纹织物预浸料(根据表面花纹要求可多种选择)；
第六层：刮涂2～3mm厚聚氨酯防火涂层一层。
其中，所述第一层、第三层单向预浸布铺层方式为0°/90°。
所述碳纤维单向布、碳纤维平纹织物中的碳纤维选自防火等级达到EN45545标准SL3级别的复合碳纤维材料。
实施例2
本实施例提供一种复合板，与实施例1的区别在于，第二层为PET泡沫。
第一层：6层碳纤维单向布预浸料，铺层方式为[45/-45/0/-45/45/90]；
第二层：PET纸蜂窝；厚度为5mm；
第三层：4层碳纤维单向布预浸料，铺层方式为[45/90/-45/0]；
第四层：2层混杂纤维预浸料；所述混杂纤维是由超高分子量聚乙烯与碳纤维混编而成，编织方式为斜纹织物；
第五层：1层碳纤维平纹织物预浸料(根据表面花纹要求可多种选择)；
第六层：刮涂2～3mm厚聚氨酯防火涂层一层。
其中，所述第一层、第三层单向布铺层方式为0°/±45°。
效果验证
对实施例1和2所得复合板进行性能测试。
测试方法：质量0.5kg的混凝土球，以250km/h和300Km/h的速度、90°角度冲击底板，测试抗冲击性，防火性能采用标准EN45545的SL3标准检定。
对比例：目前本领域最常用的高铁设备舱底板使用的复合板，见发明专利201510947269，其结构为玻纤+碳纤+芳纶，具体为：外侧采用1层3K斜纹碳纤维预浸布+5层玻璃纤维布+2层芳纶纤维布+1层3K单向碳纤维布+芳纶纸蜂窝+1层3K斜纹碳纤维布+3层玻璃纤维布+1层3K单向碳纤维布。
经测试，实施例1的底板单位面积载荷≥2500Pa，单位质量较对比例降低15％；
实施例2的底板单位面积载荷≥2500Pa，单位质量较对比例降低17％；
对比例1的底板单位面积载荷≥2500Pa，单位质量较铝合金降低39％。
由此可见，本发明所述的复合底板在不低于原强度下质量降低15％左右，抗低能量冲击性能显著提高。主要采用了超高分子量的聚乙烯与碳纤的混编布，既提高了抗冲击强度又降低了质量。防火性能由原来的DIN5510-2级别S3/SR2/ST2提升为EN45545的SL3级别。通过表面刮涂的防火涂层形成阻隔，提高了耐火性能，特殊的聚氨酯防火层可以适当降低因采用阻燃树脂而降低的强度，优化设计，提高材料性能，从而实现进一步减重。
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 (7)

1.一种复合板，其特征在于，由内至外包括：
第一层：碳纤维单向布预浸料；
第二层：PET泡沫或NOMEX纸蜂窝；
第三层：碳纤维单向布预浸料；
第四层：混杂纤维预浸料；所述混杂纤维是由超高分子量聚乙烯与碳纤维混编而成；
第五层：碳纤维平纹织物预浸料；
第六层：聚氨酯防火涂层。
2.根据权利要求1所述的复合板，其特征在于，所述复合板包括：
第一层包括3～6层碳纤维单向布预浸料；
第二层包括厚度为5-7mm PET泡沫或NOMEX纸蜂窝；
第三层包括2～5层碳纤维单向布预浸料；
第四层包括2～3层混杂纤维预浸料；
第五层包括1层预浸料碳纤维平纹织物；
第六层包括聚氨酯防火涂层。
3.根据权利要求1或2所述的复合板，其特征在于，所述第一层和第三层的碳纤维单向布的铺层方式为0°、±45°或90°。
4.根据权利要求1所述的复合板，其特征在于，所述碳纤维单向布和所述碳纤维平纹织物中的碳纤维选自防火等级达到EN45545标准SL3级别的复合碳纤维材料。
5.根据权利要求1所述的复合板，其特征在于，所述第六层聚氨酯防火涂层的厚度为2～3mm。
6.权利要求1-5任一所述复合板在高铁设备舱底板、高铁设备舱端板中的应用。
7.一种高铁设备舱底板，其特征在于，包括权利要求1-5任一所述复合板。
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