CN116001402A - Sound insulation board for interior trim of railway passenger car, preparation method and application thereof - Google Patents
Sound insulation board for interior trim of railway passenger car, preparation method and application thereof Download PDFInfo
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
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Abstract
The invention provides a sound insulation board for interior decoration of a railway passenger car, and a preparation method and application thereof. The sound insulation board for the interior trim sequentially comprises a sound insulation board surface board layer, a corrugated sandwich board layer and a sound insulation board lining board layer, wherein the corrugated sandwich board layer sequentially comprises a corrugated sandwich board upper board layer, a middle corrugated core layer and a corrugated sandwich board lower board layer. The sound insulation board surface plate layer comprises short carbon fibers and flame retardant materials, and the corrugated sandwich plate layer and the sound insulation board substrate layer respectively comprise basalt fibers and flame retardant materials. The sound insulation board for the interior trim is prepared by adopting a heat treatment method, has simple process, short molding period and high production efficiency, can be applied to a railway passenger car, has a sound insulation effect of more than 30 dB, meets the requirement of light weight of the railway passenger car, can realize weight reduction of more than 20%, and can improve the strength, impact resistance and flame retardance of a door plate structure.
Description
Technical Field
The invention relates to the field of railway carriages, in particular to a sound insulation board for interior decoration of a railway carriage, a preparation method and application thereof.
Background
In recent years, the requirements of environmental protection and environmental protection on the track traffic are higher and higher, the production of light-weight passenger vehicles is imperative, and the light-weight aim is achieved mainly by adopting new high-performance materials, new processes and new structures at present. The light-weight high-performance new material has the most obvious effect on the weight reduction of the vehicle, so that the bus interior system adopts the light-weight material and the corresponding preparation process, and the method is one of the most rapid and effective methods for realizing the light weight of the vehicle. In addition, the passenger car body also needs to meet the requirements of safety and comfort, which requires a certain sound insulation effect of a new high-performance material or structure. Therefore, the novel sound insulation board for the railway carriage is developed, the weight of the car body structure is reduced on the premise of not affecting the noise performance, and the novel sound insulation board is of great benefit to the sound insulation reduction of the railway carriage.
In the prior art, the interior panel structure of the common rail passenger car mostly adopts the structures of a surface layer frame and a middle filling material, and the high-speed rail passenger car adopts a simpler lightweight composite door panel which comprises two layers of panels, a core material is filled in the middle of the two layers of panels, and the core material mostly adopts aluminum honeycomb, paper honeycomb or foaming materials. However, the technical problem that the weight of the existing door plate is heavy is mainly solved, the decorative function can be achieved to a certain extent, and the requirement of the railway passenger car on the sound insulation performance of the interior decoration plate cannot be met completely.
The carbon fiber and basalt fiber are light in weight and high in strength, and have excellent performances of corrosion resistance, high temperature resistance, fire resistance and the like. Among them, carbon fibers have high specific strength and specific modulus, and most remarkable weight reduction effect, but are expensive and have conductivity, so that they are not suitable for use in a large amount in some cases. In contrast, basalt fiber has the characteristics of low price, noise damping, sound absorption, fire prevention and the like, and is particularly suitable for manufacturing vehicle interior trim materials. According to theory, the composite material is prepared by combining two materials of carbon fiber and basalt fiber with a high polymer, and the obtained composite material not only has excellent specific strength, specific rigidity, corrosion resistance and fire resistance, but also can be matched with a specific structure for use, and further improves the sound insulation and noise reduction functions. However, at present, there is no report on how to combine two materials, namely carbon fiber and basalt fiber, and how to combine them together with high efficiency and reliability, so that the preparation of the sound insulation board meeting the requirements of the railway passenger car is a problem to be solved at present.
Disclosure of Invention
In view of the above, the invention aims to provide a sound insulation board for interior decoration of a railway carriage, a preparation method and application thereof. The sound insulation board comprises a carbon fiber composite material panel, a basalt composite material lining board and a basalt composite material sandwich corrugated board serving as a core part, can effectively achieve the effects of light weight, high strength, impact resistance, sound insulation, noise reduction and the like, and has better comprehensive performance.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect, the invention provides a sound insulation board for interior decoration of a railway passenger car, which sequentially comprises a sound insulation board layer, a corrugated sandwich board layer and a sound insulation board lining layer, wherein the corrugated sandwich board layer sequentially comprises a corrugated sandwich board upper board layer, a middle corrugated core layer and a corrugated sandwich board lower board layer.
Preferably, the acoustical panel cover sheet layer comprises short carbon fibers and a flame retardant material.
Preferably, the corrugated sandwich panel layer comprises basalt fibers and a flame retardant material.
Preferably, the baffle substrate layer comprises basalt fibers and a flame retardant material.
Preferably, the mass ratio of the short carbon fibers to the flame retardant material in the sound insulation board surface layer is (10-15): (85-90).
Preferably, the mass ratio of basalt fiber to flame retardant material in the corrugated sandwich plate layer is (30-50): (50-70).
Preferably, the mass ratio of basalt fiber to flame retardant material in the sound insulation board substrate layer is (30-50): (50-70).
Preferably, the thickness of the sound insulation board surface layer is 1-2 mm.
Preferably, the thickness of the corrugated sandwich plate layer is 10-16 mm.
Preferably, the thickness of the baffle substrate layer is 6-8 mm.
Preferably, the thickness of the upper deck layer of the corrugated sandwich plate is 2-4 mm.
Preferably, the thickness of the intermediate corrugated core layer is 6-8 mm.
Preferably, the thickness of the lower deck layer of the corrugated sandwich board is 2-4 mm.
Preferably, the length of the short carbon fiber is 8-10 mm.
Preferably, the corrugations of the intermediate corrugated core layer comprise diamond-shaped corrugations or trapezoidal corrugations.
Preferably, the flame retardant material comprises a nylon PA66 material.
In a second aspect, the invention provides a method for preparing the sound insulation board for the interior decoration of the railway carriage, which comprises the following steps:
(1) Mixing the oxidized short carbon fiber with a flame retardant material to obtain a first composite material, mixing basalt fiber with the flame retardant material to obtain a second composite material,
(2) Respectively carrying out first hot pressing treatment on the first composite material and the second composite material to respectively obtain a first composite material prepreg and a second composite material prepreg;
(3) Respectively placing the first composite material prepreg and the second composite material prepreg into a flat mold according to a first layering sequence, and performing second hot pressing treatment to respectively obtain a sound insulation board surface layer and a sound insulation board substrate layer;
(4) Respectively placing the second composite material prepreg into a flat mold and a corrugated mold according to a second layering sequence, respectively performing third hot pressing treatment, respectively obtaining a corrugated sandwich panel layer and a middle corrugated core layer, placing the corrugated sandwich panel layer and the middle corrugated core layer into the flat mold according to structures of an upper panel layer, a middle corrugated core layer and a lower panel layer of the corrugated sandwich panel, and performing fourth hot pressing treatment, thereby obtaining a corrugated sandwich panel layer;
(5) And placing the sound insulation board layer, the corrugated sandwich board layer and the sound insulation board lining layer into a flat plate mold according to a third layering sequence, and performing fifth hot pressing treatment to obtain the sound insulation board for the interior trim of the railway passenger car.
Preferably, the temperature of the first hot pressing treatment is 180-220 ℃, the pressure is 2-3 MPa, and the time is 5-10 min.
Preferably, the temperature of the second hot pressing treatment is 200-300 ℃, the pressure is 2-3 MPa, and the time is 8-20 min.
Preferably, the temperature of the third hot pressing treatment is 200-300 ℃, the pressure is 1-2 MPa, and the time is 8-20 min.
Preferably, the temperature of the fourth hot pressing treatment is 200-300 ℃, the pressure is 0.1-0.3 MPa, and the time is 15-30 min.
The temperature of the fifth hot pressing treatment is 200-300 ℃, the pressure is 2-3 MPa, and the time is 15-30 min.
Preferably, the first, second and third ply orders are 0 °/90 ° ply orders, respectively.
Preferably, the oxidized short carbon fiber is obtained by treating the carbon fiber for 1-4 hours at 400-500 ℃, naturally cooling and then carrying out short cutting treatment.
Preferably, after the fifth hot pressing treatment is completed, the method further comprises the step of treating the obtained product at 150-180 ℃ for 1-3 hours.
In a third aspect, the present invention provides a railway carriage, which includes the acoustic panel for interior decoration according to the above technical solution;
and the sound insulation board layer of the sound insulation board for the interior trim is connected with the side wall of the railway carriage body through adhesive resin.
Compared with the prior art, the invention has the beneficial effects that:
(1) The invention provides a sound insulation board for interior decoration of a railway passenger car, which is characterized in that a carbon fiber composite material panel and a basalt composite material lining board are added in the interior decoration board structure of the railway passenger car, and a basalt composite material sandwich corrugated board is added in the core part, so that the advantages of carbon fiber materials and basalt materials can be effectively exerted, the cost is reduced, the effects of light weight, high strength, impact resistance, sound insulation, noise reduction and the like can be effectively achieved, the sound insulation board has better comprehensive performance, the sound insulation board structure is flexible to manufacture, can be conveniently installed and paved on the side wall of a car body, and has good economic and social benefits;
(2) The invention adopts the heat treatment method to prepare the sound insulation board for the interior trim of the railway passenger car, has the characteristics of short molding cycle, high production efficiency and high degree of freedom of structural design, can be secondarily molded and recycled, can improve the strength and impact resistance of the door plate structure, can play a role in flame retardance to a certain extent while sound insulation and noise reduction are carried out, can omit the use of flame retardant materials of fireproof fibers and Volatile Organic Compounds (VOC) materials, further improves the comfort of passengers, and eliminates the residual stress in the sound insulation board, particularly on the interface, in one step, improves the interlayer bonding performance and finally improves the integral performance of the sound insulation board.
Drawings
FIG. 1 is a schematic view of a structure of an interior acoustic panel for a railway car;
wherein 1 is a sound insulation board layer; 2 is a corrugated sandwich plate layer; 3 is a sound insulation board lining layer; 4 is an adhesive resin layer; 5 is the surface of the side wall of the vehicle body; and 6 is a side wall of the vehicle body.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in conjunction with the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Aiming at the problem that the interior panel of the railway carriage is poor in sound insulation performance in the prior art, the invention provides a sound insulation board for the interior of the railway carriage, which sequentially comprises a sound insulation board layer, a corrugated sandwich board layer and a sound insulation board lining layer. The thickness of the sound insulation board surface plate layer is 1-2 mm, the thickness of the corrugated sandwich plate layer is 10-16 mm, and the thickness of the sound insulation board substrate plate layer is 6-8 mm. In the invention, the corrugated sandwich panel layer sequentially comprises an upper corrugated sandwich panel layer, a middle corrugated core layer and a lower corrugated sandwich panel layer. The thickness of the upper deck layer of the corrugated sandwich board is 2-4 mm, the thickness of the middle corrugated core layer is 6-8 mm, and the thickness of the lower deck layer of the corrugated sandwich board is 2-4 mm. The corrugation of the middle corrugated core layer can be selected according to the requirement, such as diamond corrugation or trapezoid corrugation.
In the present invention, the soundproof panel layer includes short carbon fibers having ultra-high mechanical strength, low density and good thermal stability, and the source of the short carbon fibers is not particularly limited and is generally commercially available, and in some embodiments of the present invention, T300K type carbon fibers may be specifically selected to prepare the short carbon fibers, and the length of the short carbon fibers is preferably 8 to 12mm from the viewpoint of cost efficiency and performance. The source of the flame retardant material is not particularly limited, as long as it has flame retardancy, and in some embodiments of the present invention, may be specifically selected from nylon PA66 materials. In the present invention, the corrugated sandwich panel layer includes basalt fibers and a flame retardant material, and the acoustic panel substrate layer includes basalt fibers and a flame retardant material. The source of basalt fiber is not particularly limited, and the basalt fiber can be a common commercial product, and the flame retardant material is described in the related content and is not described in detail herein.
In order to ensure the sound insulation effect of the final sound insulation board for the interior trim, the use amount of the short carbon fiber, the basalt fiber and the flame retardant material needs to be controlled, and if the use amount of the flame retardant material is excessive, the comprehensive performance of the composite material is reduced. Thus, in some embodiments of the invention, the mass ratio of short carbon fibers to flame retardant material in the acoustical panel substrate layer is (10-15): (85-90), the mass ratio of basalt fibers to flame retardant material in the corrugated sandwich panel layer is (30-50): (50-70), and the mass ratio of basalt fibers to flame retardant material in the acoustical panel substrate layer is (30-50): (50-70).
According to the sound insulation board for the interior trim, the carbon fiber composite material panel and the basalt composite material lining board are added in the interior trim board structure of the railway passenger car, and the basalt composite material sandwich corrugated board is added in the core part, so that the advantages of carbon fiber materials and basalt materials can be effectively played, the cost is reduced, the effects of light weight, high strength, impact resistance, sound insulation, noise reduction and the like can be effectively achieved, and the sound insulation board has better comprehensive performance. The sound insulation board structure for the interior trim is flexible to manufacture, can be applied to rail coaches, is installed and paved on the side wall of the coach body, and has good economic and social benefits.
The invention also provides a preparation method of the sound insulation board for the interior trim, which comprises the following steps:
(1) Mixing the oxidized short carbon fiber with a flame retardant material to obtain a first composite material, mixing basalt fiber with the flame retardant material to obtain a second composite material,
(2) Respectively carrying out first hot pressing treatment on the first composite material and the second composite material to respectively obtain a first composite material prepreg and a second composite material prepreg;
(3) Respectively placing the first composite material prepreg and the second composite material prepreg into a flat mold according to a first layering sequence, and performing second hot pressing treatment to respectively obtain a sound insulation board surface layer and a sound insulation board substrate layer;
(4) Respectively placing the second composite material prepreg into a flat mold and a corrugated mold according to a second layering sequence, respectively performing third hot pressing treatment, respectively obtaining a corrugated sandwich panel layer and a middle corrugated core layer, placing the corrugated sandwich panel layer and the middle corrugated core layer into the flat mold according to structures of an upper panel layer, a middle corrugated core layer and a lower panel layer of the corrugated sandwich panel, and performing fourth hot pressing treatment, thereby obtaining a corrugated sandwich panel layer;
(5) And placing the sound insulation board layer, the corrugated sandwich board layer and the sound insulation board lining layer into a flat plate mold according to a third layering sequence, and performing fifth hot pressing treatment to obtain the sound insulation board for the interior trim of the railway passenger car.
According to the invention, firstly, the oxidized short carbon fiber is mixed with the flame retardant material to obtain a first composite material, and the basalt fiber is mixed with the flame retardant material to obtain a second composite material. The oxidized short carbon fiber is obtained by treating the carbon fiber for 1-4 hours at 400-500 ℃, naturally cooling and then carrying out short cutting treatment. In some embodiments of the present invention, the oxidized short carbon fiber is preferably dried at 90-120 ℃ for 4-8 hours, and then mixed with the flame retardant material dried at 70-100 ℃ for 3-8 hours to obtain the first composite material with the mass fraction of the short carbon fiber of 10-15%. The source of the flame retardant material is not particularly limited, as long as it has flame retardancy, and in some embodiments of the present invention, may be specifically selected from nylon PA66 materials. It should be noted that after the carbon fiber is subjected to high-temperature oxidation treatment, the strength and impact toughness of the first composite material can be improved by 10-20%, so that the comprehensive performance of a final product, namely the sound insulation board, is improved. In some embodiments of the present invention, basalt fiber is preferably dried at 90-120 ℃ for 4-8 hours, and then mixed with flame retardant material dried at 70-100 ℃ for 3-8 hours to obtain a second composite material with 30-50% of basalt fiber mass fraction.
And then, respectively carrying out first hot pressing treatment on the first composite material and the second composite material to respectively obtain a first composite material prepreg and a second composite material prepreg. In some embodiments of the present invention, it is preferred that the first composite material and the second composite material are dried at 140 to 170 ℃ for 3 to 8 hours and then subjected to a first heat pressing treatment. The drying is preferably carried out in a vacuum oven. In the invention, the first hot pressing treatment is performed in a flat vulcanizing machine, wherein the temperature of the hot pressing treatment is 180-220 ℃, the pressure is 2-3 MPa, and the time is 5-10 min.
And then, respectively placing the first composite material prepreg and the second composite material prepreg into a flat mold according to the first layering sequence, and performing second hot pressing treatment to respectively obtain the sound insulation board surface layer and the sound insulation board substrate layer. In some embodiments of the present invention, the first composite prepreg and the second composite prepreg are placed in a flat mold in a layering order of 0 °/90 °, respectively, and then a second heat press treatment (at a temperature of 200 to 300 ℃, a pressure of 2 to 3MPa, and a time of 8 to 20 minutes) is performed on a flat vulcanizing machine to obtain a soundproof panel layer. The layering sequence of 0/90 ° is a technical means well known to those skilled in the art, and will not be described herein, and the number of symmetry times can be adjusted conventionally according to the thicknesses of the sound insulation board layer and the sound insulation board substrate layer.
And then respectively placing the second composite material prepreg into a flat plate mold and a corrugated mold according to a second layering sequence, respectively carrying out third hot pressing treatment, respectively obtaining a corrugated sandwich panel layer and a middle corrugated core layer, and placing the corrugated sandwich panel layer and the middle corrugated core layer into the flat plate mold according to the structures of an upper panel layer, a middle corrugated core layer and a lower panel layer of the corrugated sandwich panel, and carrying out fourth hot pressing treatment, thereby obtaining the corrugated sandwich panel layer. In some embodiments of the present invention, the second composite prepreg is placed in a flat mold and a corrugated mold in a layering sequence of 0 °/90 °, and a third hot press treatment is performed on a flat vulcanizing machine at a temperature of 200 to 300 ℃ and a pressure of 1 to 2MPa for 8 to 20 minutes, respectively, to obtain a corrugated sandwich panel layer and an intermediate corrugated core layer, respectively. The intermediate corrugated core layer may be a multi-level hierarchical structure. In some embodiments of the present invention, the corrugated sandwich panel layer and the intermediate corrugated core layer are preferably dried at 70-90 ℃ for 8-15 min after being washed with acetone for 15-30 min, then placed in a flat mold according to the structure of the corrugated sandwich panel upper panel layer, the intermediate corrugated core layer and the corrugated sandwich panel lower panel layer, and subjected to a fourth heat pressing treatment on a flat vulcanizing machine at 200-300 ℃ and a pressure of 0.1-0.3 MPa for 15-30 min, and the corrugated sandwich panel layer is obtained after the fourth heat pressing treatment is completed.
And then placing the sound insulation board surface layer, the corrugated sandwich board layer and the sound insulation board lining layer into a flat plate mold according to a third layering sequence, and performing fifth hot pressing treatment to obtain the sound insulation board for the interior trim of the railway passenger car. In some embodiments of the present invention, the soundproof panel sheet layer, the corrugated sandwich sheet layer and the soundproof panel lining sheet layer are placed in a flat mold in a layering order of 0 °/90 °, and subjected to a fifth heat pressing treatment on a flat vulcanizing machine at a temperature of 200 to 300 ℃ and a pressure of 2 to 3MPa for 15 to 30 minutes, to obtain the soundproof panel for interior decoration of the railway carriage. In some embodiments of the present invention, after the fifth hot pressing treatment is completed, the obtained product is preferably treated at 150 to 180 ℃ for 1 to 3 hours, and then is naturally cooled to room temperature in the air, thereby obtaining the soundproof board. The interlayer shear strength of the sound insulation board can be improved by 18.5%, and the fracture strength of the sound insulation board is further improved.
The invention adopts the heat treatment method to prepare the sound insulation board for the interior trim of the railway passenger car, has the characteristics of short molding cycle, high production efficiency and high degree of freedom of structural design, can be secondarily molded and recycled, can improve the strength and impact resistance of the door plate structure, can play a role in flame retardance to a certain extent while sound insulation and noise reduction are carried out, can omit the use of flame retardant materials of fireproof fibers and Volatile Organic Compounds (VOC) materials, further improves the comfort of passengers, and eliminates the residual stress in the sound insulation board, particularly on the interface, in one step, improves the interlayer bonding performance and finally improves the integral performance of the sound insulation board.
The invention also provides a railway carriage, which comprises the sound insulation board for the interior decoration, which is related to the technical scheme. And the sound insulation board layer of the sound insulation board for the interior trim is connected with the side wall of the railway carriage body through adhesive resin. In some embodiments of the present invention, the interior acoustic panel is glued according to the installation and paving requirements to prepare a glued acoustic panel of a desired size, which is then mounted to the side wall of the vehicle body by means of a glue resin. The bonding resin can be selected from environment-friendly polyurethane adhesives.
Through researches, the railway passenger car provided with the sound insulation plate has the sound insulation effect reaching more than 30 dB, meets the requirement of light weight of the railway passenger car, and can realize weight reduction by more than 20%.
In order to further illustrate the present invention, the following examples are provided. The experimental materials used in the following examples of the present invention are not particularly limited and may be commercially available or prepared according to conventional preparation methods well known to those skilled in the art. Wherein basalt fiber is purchased from Zhejiang stone gold basalt fiber Co., ltd, model BFCS-15-12.
Example 1
The embodiment provides a sound insulation board for interior decoration of a railway passenger car, the structural schematic diagram of which is shown in figure 1, wherein 1 is a sound insulation board layer with the thickness of 1mm;2 is a corrugated sandwich plate layer with the thickness of 10mm; the thickness of the upper deck layer of the corrugated sandwich board is 2mm; the thickness of the middle corrugated core layer is 6mm; the thickness of the lower deck layer of the corrugated sandwich board is 2mm;3 is a sound insulation board lining layer with the thickness of 6mm;4 is an adhesive resin layer; 5 is the surface of the side wall of the vehicle body; and 6 is a side wall of the vehicle body.
The preparation method comprises the following steps:
(1) Preparation of short carbon fiber SCF: placing the T300 48K type CF (carbon fiber) in a high-temperature environment box, treating for 2 hours at a high temperature of 450 ℃, naturally cooling, and preparing the short carbon fiber with the length of 8mm into a high-temperature oxidized carbon fiber SCF;
(2) Preparation of SCF/PA66 (flame retardant) and BF/PA66 (flame retardant) masterbatch: and (3) drying the high-temperature oxidized carbon fiber in the step (1) at 100 ℃ for 5 hours, mixing with PA66 powder after drying at 80 ℃ for 6 hours, and uniformly stirring to obtain a mixture with the mass fraction of the short carbon fiber of 10%. Extruding and granulating the mixture on a double-screw extruder to obtain a SCF/PA66 (flame retardant) composite material master batch, wherein the preparation method of the BF/PA66 (flame retardant) master batch is the same as that of the master batch, and the BF/PA66 (flame retardant) master batch with the basalt fiber mass fraction of 40% is obtained;
(3) Preparation of the acoustic panel prepreg: drying the SCF/PA66 (flame retardant) composite master batch and the BF/PA66 (flame retardant) master batch in the step (2) in a vacuum drying oven at 150 ℃ for 5 hours respectively, and hot-pressing the master batch and the BF/PA66 (flame retardant) in a flat vulcanizing machine for 10 minutes under the working condition of 2.5MPa and 200 ℃ respectively to prepare a sound-insulating panel prepreg SCF/PA66 (flame retardant) and a sound-insulating panel prepreg BF/PA66 (flame retardant);
(4) Preparation of a sound insulation board panel and a sound insulation board lining board: respectively placing the SCF/PA66 (flame retardant) prepreg in the step (3) into a flat plate mold according to the layering sequence of 0 ℃/90 ℃, and respectively carrying out hot pressing on the flat plate mold for 10min under the working condition of 2.5MPa and 240 ℃ on a flat plate vulcanizing machine to prepare a sound insulation plate panel; placing the BF/PA66 (flame retardant) prepreg in the step 3 into a flat plate mold according to the layering sequence of 0 degree/90 degrees, and hot-pressing for 10min on a flat plate vulcanizing machine under the working condition of 2.5MPa and 240 ℃ to prepare a sound insulation plate lining plate;
(5) Preparing a corrugated sandwich plate: respectively placing BF/PA66 (flame retardant) prepreg in the step (3) into a flat plate mold and a corrugated mold according to the layering sequence of 0 degree/90 degrees, and respectively hot-pressing for 10min on a flat plate vulcanizing machine under the working condition of the pressure of 1.5MPa and the temperature of 220 ℃ to prepare a panel and a corrugated sandwich layer of the corrugated sandwich plate; then cleaning the prepared panel and corrugated core layer with acetone for 20min, drying in a drying oven at 80 ℃ for 10min, sequentially placing the panel and the corrugated core layer in a flat plate mold according to the structures of an upper panel, a middle corrugated core layer and a lower panel, and hot-pressing on a flat plate vulcanizing machine at 250 ℃ and 0.1MPa until the panel and the corrugated core layer are cooled to room temperature to obtain a corrugated sandwich panel;
(6) Preparation of the sound insulation plate: after the sound-insulating board panels, the corrugated sandwich boards and the sound-insulating board lining boards in the steps (4) and (5) are processed in a cleaning and drying mode in the steps, sequentially and alternately layering the sound-insulating board panels, the corrugated sandwich boards and the sound-insulating board lining boards in turn are placed in a mould coated with a release agent, then the mould is placed in a preheated flat vulcanizing machine, the temperature is raised to 240 ℃, the pressure is increased to 2.5MPa, the pressure is maintained for 20 minutes, the sound-insulating board is naturally cooled to 100 ℃, and demoulding is completed, so that the sound-insulating board is obtained;
(7) Heat treatment of the acoustic panel: and (3) annealing the sound insulation board in the step (6) in a heat treatment furnace at 150 ℃ for 1h, naturally cooling the sound insulation board to room temperature in air after annealing, and further improving the breaking strength of the sound insulation board by improving the interlayer shearing strength by 18.5%.
(8) And (3) mounting of the sound insulation plate: and (3) cementing the soundproof board subjected to the heat treatment in the step (7) according to the installation and paving requirements to prepare a cementing soundproof board with a required size, and installing the cementing soundproof board on the surface of the side wall of the vehicle body through cementing resin.
Example 2
The embodiment provides another sound insulation board for the interior decoration of the railway passenger car, the structural schematic diagram of which is shown in fig. 1, wherein 1 is a sound insulation board layer with the thickness of 2mm;2 is a corrugated sandwich plate layer with the thickness of 16mm; the thickness of the upper deck layer of the corrugated sandwich board is 4mm; the thickness of the middle corrugated core layer is 8mm; the thickness of the lower deck layer of the corrugated sandwich board is 4mm;3 is a sound insulation board lining layer with the thickness of 8mm;4 is an adhesive resin layer; 5 is the surface of the side wall of the vehicle body; 6 is the side wall of the vehicle body;
the preparation method comprises the following steps:
(1) Preparation of short carbon fiber SCF: placing the T300 48K type CF (carbon fiber) in a high-temperature environment box, treating for 2 hours at a high temperature of 450 ℃, naturally cooling, and preparing the short carbon fiber with the length of 12mm into a high-temperature oxidized carbon fiber SCF;
(2) Preparation of SCF/PA66 (flame retardant) and BF/PA66 (flame retardant) masterbatch: and (3) drying the high-temperature oxidized carbon fiber in the step (1) at 100 ℃ for 5 hours, mixing with PA66 powder after drying at 80 ℃ for 6 hours, and uniformly stirring to obtain a mixture with the mass fraction of the short carbon fiber of 10%. Extruding and granulating the mixture on a double-screw extruder to obtain a SCF/PA66 (flame retardant) composite material master batch, wherein the preparation method of the BF/PA66 (flame retardant) master batch is the same as that of the master batch, and the BF/PA66 (flame retardant) master batch with the basalt fiber mass fraction of 40% is obtained;
(3) Preparation of the acoustic panel prepreg: respectively placing the SCF/PA66 (flame retardant) composite material master batch and the BF/PA66 (flame retardant) master batch in the step (2) in a vacuum drying oven at 150 ℃ for drying for 5 hours, and respectively carrying out hot pressing on the master batch and the BF/PA66 (flame retardant) in a flat vulcanizing machine under the working condition of 2MPa and 220 ℃ for 8 minutes to respectively prepare a prepreg SCF/PA66 (flame retardant) of the sound-proof panel and a prepreg BF/PA66 (flame retardant) of the sound-proof panel;
(4) Preparation of a sound insulation board panel and a sound insulation board lining board: respectively placing the SCF/PA66 (flame retardant) prepreg in the step (3) into a flat plate mold according to the layering sequence of 0 ℃/90 ℃, and respectively carrying out hot pressing on the flat plate mold for 10min under the working condition of 2.5MPa and 240 ℃ on a flat plate vulcanizing machine to prepare a sound insulation plate panel; placing the BF/PA66 (flame retardant) prepreg in the step 3 into a flat plate mold according to the layering sequence of 0 degree/90 degrees, and hot-pressing for 10min on a flat plate vulcanizing machine under the working condition of 2.5MPa and 240 ℃ to prepare a sound insulation plate lining plate;
(5) Preparing a corrugated sandwich plate: respectively placing BF/PA66 (flame retardant) prepreg in the step (3) into a flat plate mold and a corrugated mold according to the layering sequence of 0 degree/90 degrees, and respectively hot-pressing for 10min on a flat plate vulcanizing machine under the working condition of the pressure of 1.5MPa and the temperature of 220 ℃ to prepare a panel and a corrugated sandwich layer of the corrugated sandwich plate; then cleaning the prepared panel and corrugated core layer with acetone for 20min, drying in a drying oven at 80 ℃ for 10min, sequentially placing the panel and the corrugated core layer in a flat plate mold according to the structures of an upper panel, a middle corrugated core layer and a lower panel, and hot-pressing on a flat plate vulcanizing machine at 250 ℃ and 0.1MPa until the panel and the corrugated core layer are cooled to room temperature to obtain a corrugated sandwich panel;
(6) Preparation of the sound insulation plate: after the sound-insulating board panels, the corrugated sandwich boards and the sound-insulating board lining boards in the steps (4) and (5) are processed in a cleaning and drying mode in the steps, sequentially and alternately layering the sound-insulating board panels, the corrugated sandwich boards and the sound-insulating board lining boards in turn are placed in a mould coated with a release agent, then the mould is placed in a preheated flat vulcanizing machine, the temperature is raised to 240 ℃, the pressure is increased to 2.5MPa, the pressure is maintained for 20 minutes, the sound-insulating board is naturally cooled to 100 ℃, and demoulding is completed, so that the sound-insulating board is obtained;
(7) Heat treatment of the acoustic panel: and (3) annealing the sound insulation board in the step (6) in a heat treatment furnace at 150 ℃ for 1h, naturally cooling the sound insulation board to room temperature in air after annealing, and further improving the breaking strength of the sound insulation board by improving the interlayer shearing strength by 18.5%.
(8) And (3) mounting of the sound insulation plate: and (3) cementing the soundproof board subjected to the heat treatment in the step (7) according to the installation and paving requirements to prepare a cementing soundproof board with a required size, and installing the cementing soundproof board on the surface of the side wall of the vehicle body through cementing resin.
The existing interior trim part sound insulation plates of the railway passenger car mostly adopt aluminum honeycomb plates, and the method has large equipment investment and a large production flow. The sound insulation board for the interior trim of the railway passenger car, which is produced by the invention, has the characteristics of simple process, short molding period, high production efficiency and high degree of freedom of structural design, can be secondarily molded and recycled, can effectively achieve the effects of light weight, high strength, impact resistance, sound insulation, noise reduction and the like while reducing the cost, has better comprehensive performance, and can also achieve the flame-retardant function to a certain extent while sound insulation and noise reduction.
The interior trim sound insulation boards obtained in the embodiments 1 and 2 are subjected to comprehensive mechanical tests by adopting general test standards (GB/T12816-2006, GB/T12816-2006 and GB/T21563-2018) of a railway passenger car, and each performance index is superior to that of the traditional interior trim. Wherein, the sound insulation effect can reach more than 30 dB on average, the weight can be reduced by more than 20% on average, the strength can be improved by more than 20% on average, and the impact resistance can be improved by more than 15% on average.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (10)
1. The sound insulation board for the interior trim of the railway passenger car is characterized by sequentially comprising a sound insulation board surface board layer, a corrugated sandwich board layer and a sound insulation board lining layer;
the corrugated sandwich panel layer sequentially comprises an upper corrugated sandwich panel layer, a middle corrugated core layer and a lower corrugated sandwich panel layer;
the sound insulation board surface plate layer comprises short carbon fibers and a flame retardant material;
the corrugated sandwich panel layer comprises basalt fibers and a flame retardant material;
the baffle substrate layer includes basalt fibers and a flame retardant material.
2. The soundproof panel for interior trim of a railway carriage according to claim 1, wherein the mass ratio of the short carbon fiber to the flame retardant material in the soundproof panel layer is (10-15): (85-90);
the mass ratio of basalt fiber to flame retardant material in the corrugated sandwich plate layer is (30-50) (50-70);
the mass ratio of basalt fiber to flame retardant material in the sound insulation board lining layer is (30-50) (50-70).
3. The soundproof panel for interior trim of a railway carriage according to claim 1, wherein the thickness of the soundproof panel layer is 1 to 2mm;
the thickness of the corrugated sandwich plate layer is 10-16 mm;
the thickness of the sound insulation board lining layer is 6-8 mm.
4. A sound insulation board for interior trim of a railway car according to claim 3, wherein the thickness of the upper deck layer of the corrugated sandwich board is 2-4 mm;
the thickness of the middle corrugated core layer is 6-8 mm;
the thickness of the lower deck layer of the corrugated sandwich board is 2-4 mm.
5. The soundproof panel for interior trim of a railway carriage according to claim 1, wherein the length of the short carbon fiber is 8 to 12mm;
the corrugations of the middle corrugated core layer comprise diamond corrugations or trapezoid corrugations;
the flame retardant material comprises a nylon PA66 material.
6. The method for producing an acoustic panel for interior trim of a railway car according to any one of claims 1 to 5, comprising the steps of:
(1) Mixing the oxidized short carbon fiber with a flame retardant material to obtain a first composite material, mixing basalt fiber with the flame retardant material to obtain a second composite material,
(2) Respectively carrying out first hot pressing treatment on the first composite material and the second composite material to respectively obtain a first composite material prepreg and a second composite material prepreg;
(3) Respectively placing the first composite material prepreg and the second composite material prepreg into a flat mold according to a first layering sequence, and performing second hot pressing treatment to respectively obtain a sound insulation board surface layer and a sound insulation board substrate layer;
(4) Respectively placing the second composite material prepreg into a flat mold and a corrugated mold according to a second layering sequence, respectively performing third hot pressing treatment, respectively obtaining a corrugated sandwich panel layer and a middle corrugated core layer, placing the corrugated sandwich panel layer and the middle corrugated core layer into the flat mold according to structures of an upper panel layer, a middle corrugated core layer and a lower panel layer of the corrugated sandwich panel, and performing fourth hot pressing treatment, thereby obtaining a corrugated sandwich panel layer;
(5) And placing the sound insulation board layer, the corrugated sandwich board layer and the sound insulation board lining layer into a flat plate mold according to a third layering sequence, and performing fifth hot pressing treatment to obtain the sound insulation board for the interior trim of the railway passenger car.
7. The method according to claim 6, wherein the first autoclave is performed at a temperature of 180 to 220 ℃, a pressure of 2 to 3MPa, and a time of 5 to 10 minutes;
the temperature of the second hot pressing treatment is 200-300 ℃, the pressure is 2-3 MPa, and the time is 8-20 min;
the temperature of the third hot pressing treatment is 200-300 ℃, the pressure is 1-2 MPa, and the time is 8-20 min;
the temperature of the fourth hot pressing treatment is 200-300 ℃, the pressure is 0.1-0.3 MPa, and the time is 15-30 min;
the temperature of the fifth hot pressing treatment is 200-300 ℃, the pressure is 2-3 MPa, and the time is 15-30 min.
8. The method of claim 6, wherein the first layering sequence, the second layering sequence, and the third layering sequence are each 0 °/90 ° alternating layering sequences.
9. The preparation method according to claim 6, wherein the oxidized short carbon fiber is obtained by treating carbon fiber at 400-500 ℃ for 1-4 hours, naturally cooling and then performing short cutting treatment;
after the fifth hot pressing treatment is finished, the method further comprises the step of treating the obtained product at 150-180 ℃ for 1-3 hours.
10. A railway carriage, characterized by comprising the soundproof panel for interior trim of a railway carriage according to any one of claims 1 to 5 or the soundproof panel for interior trim of a railway carriage produced by the production method according to any one of claims 6 to 9;
and the sound insulation board layer of the sound insulation board for the interior trim is connected with the side wall of the railway carriage body through adhesive resin.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310001727.0A CN116001402A (en) | 2023-01-03 | 2023-01-03 | Sound insulation board for interior trim of railway passenger car, preparation method and application thereof |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202310001727.0A CN116001402A (en) | 2023-01-03 | 2023-01-03 | Sound insulation board for interior trim of railway passenger car, preparation method and application thereof |
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| DE10255039A1 (en) * | 2002-11-26 | 2004-06-09 | Ibs Brocke Gmbh & Co. Kg | Flat pressed composite product for vehicle interior lining panels comprises a lightweight core with internal chambers between outer layers of natural fiber and thermoplastic |
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| CN215097564U (en) * | 2021-04-23 | 2021-12-10 | 中车青岛四方机车车辆股份有限公司 | Sound insulation structure and rail vehicle body |
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| DE10255039A1 (en) * | 2002-11-26 | 2004-06-09 | Ibs Brocke Gmbh & Co. Kg | Flat pressed composite product for vehicle interior lining panels comprises a lightweight core with internal chambers between outer layers of natural fiber and thermoplastic |
| CN2761418Y (en) * | 2004-12-30 | 2006-03-01 | 北京龙源一手新型建材科技有限公司 | Composite corrugated board |
| KR20160074296A (en) * | 2014-12-18 | 2016-06-28 | 한국세라믹기술원 | Method for manufacturing hybrid ceramic fiber reinforced composite material and hybrid ceramic fiber reinforced composite material manufactured thereby |
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