CN110641088A - 一种轨道车辆轻量化复合板材 - Google Patents

一种轨道车辆轻量化复合板材 Download PDF

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CN110641088A
CN110641088A CN201910930484.2A CN201910930484A CN110641088A CN 110641088 A CN110641088 A CN 110641088A CN 201910930484 A CN201910930484 A CN 201910930484A CN 110641088 A CN110641088 A CN 110641088A
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skin layer
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戈建鸣
蔡银平
黄振振
付姝珺
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KTK Group Co Ltd
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Abstract

本发明涉及涉及轨道交通技术领域，尤其是一种轨道车辆轻量化复合板材，上预浸料蒙皮层与下预浸料蒙皮层之间设有芯材层，上、下预浸料蒙皮层与芯材层之间通过预浸料树脂粘结层粘结，上、下预浸料蒙皮层与芯材层之间为热压罐成型或热压成型或真空袋压成型，芯材层为泡沫芯或芳纶蜂窝芯或铝蜂窝芯，轻量化、可设计性强、树脂含量精确可控、制品厚度及纤维体积分数可控、制品质量稳定、制品质量一致性与可靠性高等，此外还具有成型工艺简单、生产效率高、性能远远高于传统玻璃钢与金属材料等优点，质量轻、强度高、环保，可在满足材料性能要求的前提下实现轻量化，具有极大的应用潜力与市场价值。

Description

一种轨道车辆轻量化复合板材
技术领域
本发明涉及轨道交通技术领域，尤其是一种轨道车辆轻量化复合板材。
背景技术
目前，传统的应用在轨道车辆上的内装产品为铝合金或玻璃钢结构，其中铝合金部件在生产过程包括型材下料、型材机加工、清洗、焊接、打磨、后处理等工序，总工序繁多，质量控制成本高。而且铝合金结构内装件由于刚度较差，通常需要在产品背部加框架进行补强，结构形式为铝合金+背部铝合金型材框架补强，铝的密度较大，大约2.7g/cm3，背部需要加框架补强，制备的内装产品较重，重量更是大大增加，不符合轻量化，且隔热性能差、隔声性能差。
而玻璃钢结构同样背部需要加大量补强框架，结构形式为玻璃钢+背部铝合金框架补强，纤维方向难以控制，可设计性差、树脂含量不易控制、制品厚度及纤维体积分数不易控制，产品一致性与稳定性差，玻璃钢结构内装产品刚度差，原料中含有多种挥发物，如含有甲醛、苯乙烯等易挥发性有机化合物，环保性差，玻璃钢产品重量较重，尺寸稳定性差，传统材料均不符合轻量化及环保要求。
发明内容
本发明要解决的技术问题是：提供一种轨道车辆轻量化复合板材，轻量化，精确控制树脂含量和制品厚度，提高产品可靠性、稳定性，确保产品的质量一致性。
本发明解决其技术问题所采用的技术方案是：一种轨道车辆轻量化复合板材，包括上预浸料蒙皮层、芯材层以及下预浸料蒙皮层，所述的上预浸料蒙皮层与下预浸料蒙皮层之间设有芯材层，上、下预浸料蒙皮层与芯材层之间通过预浸料树脂粘结层粘结，上、下预浸料蒙皮层与芯材层之间为热压罐成型或热压成型或真空袋压成型，芯材层为泡沫芯或芳纶蜂窝芯或铝蜂窝芯。
进一步的，上预浸料蒙皮层上表面上依次设有隔离布、隔离膜以及透气毡。
进一步的，上、下预浸料蒙皮层由玻璃纤维、碳纤维、芳纶纤维、天然纤维中的一种或多种组成。
进一步的，上、下预浸料蒙皮层为酚醛树脂或环氧树脂或双马来酰亚胺树脂，预浸料树脂层中树脂含量35％～55％。
本发明的有益效果是：本发明轻量化、可设计性强、树脂含量精确可控、制品厚度及纤维体积分数可控、制品质量稳定、制品质量一致性与可靠性高等，此外还具有成型工艺简单、生产效率高、性能远远高于传统玻璃钢与金属材料等优点，质量轻、强度高、环保，可在满足材料性能要求的前提下实现轻量化，具有极大的应用潜力与市场价值。
附图说明
图1是本发明的结构示意图；
图2是本发明应用在实施例1上的结构示意图；
图3是本发明应用在实施例2上的结构示意图；
图4是本发明应用在实施例3上的结构示意图；
图5是本发明应用在实施例4上的结构示意图；
图6是本发明应用在实施例5上的结构示意图；
图7是本发明应用在实施例6上的结构示意图。
图中：1.上预浸料蒙皮层，2.芯材层，3.预浸料树脂粘结层，5.下预浸料蒙皮层。
具体实施方式
现在结合附图和优选实施例对本发明作进一步详细的说明。这些附图均为简化的示意图，仅以示意方式说明本发明的基本结构，因此其仅显示与本发明有关的构成。
如图1～7所示的一种轨道车辆轻量化复合板材，包括上预浸料蒙皮层1、芯材层2以及下预浸料蒙皮层5，上预浸料蒙皮层1与下预浸料蒙皮层5之间设有芯材层2，上、下预浸料蒙皮层1、5与芯材层2之间通过预浸料树脂粘结层3粘结，上、下预浸料蒙皮层1、5与芯材层2之间为热压罐成型或热压成型或真空袋压成型，芯材层2为泡沫芯或芳纶蜂窝芯或铝蜂窝芯。
芯材层2与上、下预浸料蒙皮层1、5之间均设有胶膜层。
上预浸料蒙皮层1的上表面上依次设有隔离布、隔离膜、透气毡中任一种或两种。
上预浸料蒙皮层1上表面上依次设有隔离布、隔离膜以及透气毡。
上、下预浸料蒙皮层1、5由玻璃纤维、碳纤维、芳纶纤维、天然纤维中的一种或多种组成。
上、下预浸料蒙皮层1、5为酚醛树脂或环氧树脂或双马来酰亚胺树脂，预浸料树脂层3中树脂含量35％～55％。
实施例1：如图2所示的轻量化复合材料墙板
1.上、下预浸料蒙皮层1、5选材：预浸料纤维为玻璃纤维，预浸料树脂粘结层3为环氧树脂，树脂含量45％。
2.芯材层2选材：泡沫芯。
3.成型步骤：在模具表面涂脱模剂，然后依次铺放下预浸料蒙皮层5、胶膜、芯材、胶膜、上预浸料蒙皮层1、隔离布、隔离膜、透气毡，然后打真空袋对坯料进行封装，抽真空，并把产品放入热压罐，热压罐内抽真空，同时加热完成固化。加热温度60～180℃，成型时间2～120min。
实施例2：如图3所示的轻量化复合材料窗下墙板
1.上、下预浸料蒙皮层1、5选材：预浸料纤维为碳纤维，预浸料树脂粘结层3为环氧树脂，树脂含量40％。
2.芯材层2选材：泡沫芯。
3.成型步骤：在模具表面涂脱模剂，然后依次铺放下预浸料蒙皮层5、胶膜芯材、胶膜、上预浸料蒙皮层1、隔离布、透气毡，然后打真空袋对坯料进行封装，抽真空，并把产品放入热压罐，热压罐内抽真空，同时加热完成固化。加热温度60～180℃，成型时间2～120min。
实施例3：如图4所示的轻量化复合材料门立柱罩板
1.上、下预浸料蒙皮层1、5选材：预浸料纤维为玻璃纤维，预浸料树脂粘结层3为酚醛树脂，树脂含量50％。
2.芯材层2选材：泡沫芯。
3.成型步骤：在模具表面涂脱模剂，然后依次下铺放预浸料蒙皮层5、胶膜、芯材、胶膜、上预浸料蒙皮层1、隔离膜、透气毡，然后打真空袋对坯料进行封装，抽真空，并把产品放入烘箱，同时加热完成固化。加热温度60～180℃，成型时间2～120min。
实施例4：如图5所示的轻量化复合材料间壁
1.上、下预浸料蒙皮层1、5选材：预浸料纤维为玻璃纤维和芳纶纤维，预浸料树脂粘结层3为双马来酰亚胺树脂，树脂含量55％。
2.芯材层2选材：芳纶蜂窝芯。
3.成型步骤：在模具表面涂脱模剂，然后依次铺放下预浸料蒙皮层5、芯材、上预浸料蒙皮层1、隔离布、隔离膜、透气毡。然后打真空袋对坯料进行封装，抽真空，把坯料移入烘箱，加热完成固化。加热温度60～180℃，成型时间2～120min。
实施例5：如图6所示的轻量化复合材料地板
1.上、下预浸料蒙皮层1、5选材：预浸料纤维为玻璃纤维，预浸料树脂粘结层3为环氧树脂，树脂含量45％。
2.芯材层2选材：铝蜂窝芯。
3.成型步骤：在模具表面涂脱模剂，然后依次铺放下预浸料蒙皮层5、芯材、上预浸料蒙皮层1、隔离膜、透气毡。然后打真空袋对坯料进行封装，抽真空，把坯料移入烘箱，加热完成固化。加热温度60～180℃，成型时间2～120min。
实施例6：如图7所示的轻量化复合材料中顶板
1.上、下预浸料蒙皮层1、5选材：预浸料纤维为玻璃纤维，预浸料树脂粘结层3为环氧树脂，树脂含量45％。
2.芯材层2选材：芳纶蜂窝芯。
3.成型步骤：在模具表面涂脱模剂，然后依次铺放下预浸料蒙皮层5、胶膜、芯材、胶膜、上预浸料蒙皮层1。然后启动热压机，加热、加压完成固化。压机压力2～7MPa,加热温度60～180℃，成型时间2～120min。
以上说明书中描述的只是本发明的具体实施方式，各种举例说明不对本发明的实质内容构成限制，所属技术领域的普通技术人员在阅读了说明书后可以对以前所述的具体实施方式做修改或变形，而不背离发明的实质和范围。

Claims (4)

1.一种轨道车辆轻量化复合板材，其特征在于：包括上预浸料蒙皮层(1)、芯材层(2)以及下预浸料蒙皮层(5)，所述的上预浸料蒙皮层(1)与下预浸料蒙皮层(5)之间设有芯材层(2)，上、下预浸料蒙皮层(1、5)与芯材层(2)之间通过预浸料树脂粘结层(3)粘结，上、下预浸料蒙皮层(1、5)与芯材层(2)之间为热压罐成型或热压成型或真空袋压成型，芯材层(2)为泡沫芯或芳纶蜂窝芯或铝蜂窝芯。
2.如权利要求1所述的一种轨道车辆轻量化复合板材，其特征在于：所述的芯材层(2)与上、下预浸料蒙皮层(1、5)之间均设有胶膜层。
3.如权利要求1所述的一种轨道车辆轻量化复合板材，其特征在于：所述的上、下预浸料蒙皮层(1、5)由玻璃纤维、碳纤维、芳纶纤维、天然纤维中的一种或多种组成。
4.如权利要求1所述的一种轨道车辆轻量化复合板材，其特征在于：所述的上、下预浸料蒙皮层(1、5)为酚醛树脂或环氧树脂或双马来酰亚胺树脂，预浸料树脂层(3)中树脂含量35％～55％。
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