EP3580109B1 - Roof segments for the roof of a carriage body - Google Patents

Roof segments for the roof of a carriage body Download PDF

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Publication number
EP3580109B1
EP3580109B1 EP18704529.9A EP18704529A EP3580109B1 EP 3580109 B1 EP3580109 B1 EP 3580109B1 EP 18704529 A EP18704529 A EP 18704529A EP 3580109 B1 EP3580109 B1 EP 3580109B1
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EP
European Patent Office
Prior art keywords
roof
wall
roof segment
segment
segments
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP18704529.9A
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German (de)
French (fr)
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EP3580109A1 (en
Inventor
Shaoqing Liu
Zhicheng GUO
Zhengyu Song
Dongyuan Liu
Jiajie He
Qinshu Tu
Werner Hufenbach
Andreas Ulbricht
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CRRC Qingdao Sifang Co Ltd
CG Rail GmbH
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CRRC Qingdao Sifang Co Ltd
CG Rail GmbH
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Publication of EP3580109A1 publication Critical patent/EP3580109A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies
    • B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
    • B61D17/12—Roofs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies
    • B61D17/005—Construction details of vehicle bodies with bodies characterised by use of plastics materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies
    • B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
    • B61D17/043—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures connections between superstructure sub-units
    • B61D17/045—The sub-units being construction modules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies
    • B61D17/24—Construction details of vehicle bodies with body structures of wood
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D27/00—Heating, cooling, ventilating, or air-conditioning
    • B61D27/0018—Air-conditioning means, i.e. combining at least two of the following ways of treating or supplying air, namely heating, cooling or ventilating

Definitions

  • the invention relates to the roof segments of a car body, with several roof segments forming the roof of the car body and for a rail vehicle for passenger transport, in particular for use in short-distance operations, such as on underground and suburban trains, in which the rail vehicles or the train units formed from them in have to be accelerated and braked at short intervals.
  • Known car bodies of rail vehicles consist of a conventional construction of a tubular structure with two end walls, which are usually designed as a transition to an adjacent car body.
  • the front wall can also be designed as a driver's cab.
  • the car body consists of an underframe (also known as an underbody), two side walls and a roof.
  • the assemblies in particular the side walls and the roof, have a load-bearing, skeletal support structure in which lightweight steel profiles are connected to one another or to a thin sheet that forms the outer cladding using known welding processes.
  • the car body of a rail vehicle which essentially consists of horizontal and vertical walls, the horizontal walls serving to form a floor and a roof and the vertical walls, in particular forming side walls, enabling the installation of at least one window and one entrance door through corresponding cutouts.
  • modules are used for the production of the car body, which are made of fiber-reinforced plastic and which form half modules in the section perpendicular to the longitudinal axis of the car body.
  • the entire car body consists of a large number of two-half modules, which are connected to one another by suitable means.
  • the half-modules particularly preferably have an inner wall and an outer wall, which surround a core layer, which is designed with good properties in terms of heat and sound insulation.
  • the inner wall and the outer wall are preferably made of fiber-reinforced plastic.
  • the fiber-reinforced plastics particularly preferably include glass, carbon, aramid and/or natural fibers.
  • the plastics provided as the matrix preferably include epoxy resins, unsaturated polyester resins, vinyl ester resins or phenolic resins.
  • the body consists of modular sub-segments that are connected to one another in such a way that the segment modules also form part of the body roof.
  • the sub-segments have an angled extension.
  • the individual modules are each assembled in a superimposed form. Due to the use of classic construction materials such as steel, severe corrosion occurs in the overlapping or joint area of the adjoining sub-segments or segment modules.
  • the prefabrication of the three-dimensionally shaped sub-segments and the profiles connecting them also requires a high level of manufacturing accuracy.
  • connection segments used and the segment modules are made of different steels or steel alloys, premature contact corrosion can occur.
  • the car body for a passenger rail vehicle has several car body modules that are closed in the circumferential direction about a longitudinal axis, with adjacent car body modules being connected to one another via ring-like coupling modules that are closed in the circumferential direction.
  • the car body modules themselves are made up of several modular elements that are connected to one another.
  • the roof elements can be designed as surface elements and can be designed as fiber-reinforced plastic or sandwich elements.
  • a modular car body of a rail vehicle is made of fiber composite construction, the car body being formed from standardized modules such as a roof panel, top flange, window pillar, door post, side wall support, base panel and stair module.
  • the individual modules are largely used as Sandwich executed with lost foam core.
  • the roof panels essentially consist of a foam core, which is bordered on both sides with laminated fiber composite layers.
  • the WO2016/135092 A1 a multi-layer skin panel eg for a train.
  • the object of the invention is to provide a roof for a car body which overcomes the disadvantages of the prior art.
  • the roof segment is designed for constructing a roof of a car body for a rail vehicle.
  • the roof segment is preferably designed in the form of a plate, shell or half-shell.
  • the roof segments from which the roof of a car body for a rail vehicle is formed can preferably be connected to upper longitudinal beams.
  • the roof segment consists of an outer wall and an inner wall spaced apart therefrom. This advantageously optimizes insulation properties such as sound and heat insulation.
  • At least two roof segments are designed in such a way that the protruding area of the outer wall or inner wall of one roof segment is connected to the non-protruding area of the outer wall or inner wall of the adjacent roof segment in a positive, non-positive and/or material connection is. Manufacturing tolerances can advantageously be compensated for in this way.
  • a further advantage is that a lower throughput time is achieved by manufacturing teams for the manufacture of the roof, the roof segments along the Longitudinal axis of the car body from both ends of the car body, ie from the outside to the inside, without interfering with each other.
  • the width of the roof segments preferably essentially corresponds to the width of the car body. This advantageously increases the stability of the car body, in that no further fillers or connecting elements are required. Alternatively, the width of the roof segments is less than the width of the car body.
  • the roof segment consists at least partially of fiber-reinforced plastic composite (FRP).
  • FRP fiber-reinforced plastic composite
  • a first aspect of the invention relates to the design of the roof segments which, when connected to one another, form a structural flat roof of a car body of a rail vehicle.
  • the roof segments are preferably designed in the form of plates.
  • the individual roof segments of the roof of the car body are designed as standard-type roof segments, heating-ventilation-air-conditioning type roof segments or end-type roof segments.
  • the roof includes at least one standard type roof segment, at least one HVAC type roof segment, and at least one end type roof segment, respectively.
  • the heating/ventilation/air conditioning type roof segment preferably has at least one cutout for an air conditioning unit.
  • At least one standard-type roof segment and at least one heating-ventilation-air-conditioning-type roof segment are preferably arranged alternately.
  • at least two standard type roof segments follow one another.
  • at least two heating-ventilation-air-conditioning-type roof segments follow one another.
  • the roof of a car body comprises two end-type roof segments.
  • the end-type roof segments represent the front and rear ends and thus the end of the roof in the longitudinal direction of the car.
  • the roof segments are preferably made of FRP materials.
  • the roof segments comprise at least one outer and one inner wall.
  • the outer wall is understood as meaning that surface which closes off the car body on the outside and which is in connection with the environment outside the car body.
  • the inner wall is understood as meaning that surface which is in contact with the car body interior and thus the passenger compartment.
  • the inner and outer walls of the roof segments are parallel to one another and are each made of one or more layers of at least one FRP material.
  • the inner and the outer wall are preferably manufactured with a multi-axial fiber orientation, particularly preferably a bidirectional fiber orientation, very particularly preferably in a 0°/90° orientation.
  • the fibers are preferably introduced into the fiber-reinforced plastic composite of the roof segments as a roving and/or fleece and/or fabric and/or scrim and/or mesh.
  • reinforcing elements are arranged between the inner and outer wall of the roof segments, these being designed as rectangular hollow profiles.
  • edges of the rectangular hollow profiles are preferably arranged parallel to the edges of the roof segments.
  • the rectangular hollow profiles are produced in one or more layers from at least one FRP material.
  • the rectangular hollow profiles are manufactured with a bidirectional fiber orientation.
  • the rectangular hollow profiles also have a core filling, designed as a foam core.
  • the core filling preferably serves to transfer weight and shear forces.
  • the rectangular hollow profiles are filled with a rigid foam.
  • a flat core material designed as a foam core, is arranged between the inner and outer wall of the roof segment between the rectangular hollow profiles in order to ensure the structural strength and thus the accessibility.
  • the core material of a roof segment is preferably a hard foam panel educated.
  • the individual roof segments are preferably produced in a pressing process, the joining of the rectangular hollow profiles with either the inner or the outer wall of the roof segment also being effected by gluing.
  • the inner wall of the roof segment can also be joined by gluing.
  • the inner and outer wall of a roof segment each have at least one of their sides, which is aligned perpendicular to the longitudinal axis of the car body, hereinafter referred to as the longitudinal side, an area in which they protrude beyond the rectangular hollow profiles in such a way that a form-fitting connection between adjacent roof segments can be made.
  • this preferred embodiment allows individual roof segments to be joined to the roof of the car body in analogy to methods known from the prior art for floor coverings such as parquet or laminate (click parquet or click laminate).
  • an area of the inner wall protrudes over the rectangular hollow profiles essentially over the entire length of the longitudinal side, and on the longitudinal side opposite this longitudinal side, an area of the outer wall protrudes over the rectangular hollow profiles essentially over the entire length of the longitudinal side .
  • the individual roof segments are joined to form the roof of the car body, beginning with the end-type roof segments arranged at the two end regions of a car body.
  • a next roof segment (standard type or heating, ventilation and air conditioning type roof segment) is arranged on each of these roof segments in such a way that the area of the outer wall of the end-type roof segment that protrudes beyond the rectangular hollow profiles touches the outer wall of the next roof segment at least indirectly via a layer of adhesive.
  • the area of the inner wall of the next roof segment that protrudes beyond the rectangular hollow profiles touches the inner wall of the end-type roof segment at least indirectly via a layer of adhesive.
  • the individual roof segments are joined from the outside, ie the end regions of the car body, beginning inwards, ie towards the center of the car body.
  • the roof segment which is arranged in the middle of the roof of the car body, is accordingly designed in such a way that its outer wall does not have any area projecting beyond the rectangular hollow sections, and its inner wall projects beyond the rectangular hollow sections on both longitudinal sides of this roof segment. Furthermore, it is particularly preferable for adjacent rectangular hollow profiles of adjacent roof segments to be cohesively bonded to one another, in particular by means of an adhesive connected, which advantageously results not only in improved stability of the connection but also a possibility of compensating for manufacturing tolerances. For the realization of the invention, it is also expedient to combine the above-described inventive configurations, embodiments and features of the claims in any arrangement with one another, as long as the resulting subject matter belongs to the scope of protection defined by the claims.
  • figure 1 shows an exploded view of a car body 1 in which the roof segments according to the invention as a standard type roof segment 201, end type roof segment 202 and heating-ventilation-air conditioning type roof segment 203 are installed.
  • the following components of the car body are also shown: the upper longitudinal members 601 and the lower longitudinal members 602, the side wall segments 301, the vertical columns 304, the end wall 501 and the floor segments 401.
  • FIG 2 shows a standard type roof segment 201 of the car body in an exploded perspective view ( Figure 2A ) and a cross section through two adjacent standard type roof segments 201 ( Figure 2B ) during installation.
  • the Standard type roof segment 201 is manufactured with an overall height of 50 mm.
  • the standard type roof segment 201 has an inner wall 205 and an outer wall 204, with a total thickness of 1.0 mm and 2.0 mm, respectively, consisting of individual layers with a thickness of 0.5 mm and a basis weight of 400 g/m 2 .
  • the carbon fibers are incorporated into the epoxy resin plastic matrix in the form of a bidirectional fabric and run in the 0° and 90° directions.
  • rectangular hollow profiles 207 are arranged as reinforcement elements along the outer edges of the roof segment 201 and glued to the outer wall 204 .
  • the rectangular hollow profiles 207 with a size of 100 mm ⁇ 46.5 mm and a wall thickness of 1.5 mm are braided directly onto a PET rigid foam core (pull braiding process) in a braiding process, with the fibers running at an angle of ⁇ 45°. Have direction and are embedded in a thermoset matrix of epoxy resin.
  • a flat core material 206 embodied as a PET rigid foam core made of Airex T90.60 is arranged and glued to the outer wall 204 .
  • a standard-type roof segment 201 is completed in a pressing process to connect to the inner wall 205 and form the final shape of the standard-type roof segment 201 including the joints 208 for connecting to other roof segments (not shown).
  • Figure 2B clarifies the form-fit connection between adjacent standard-type roof segments 201 via the joints 208 in addition to the material-fit adhesive connection after assembly.
  • FIG 3 shows a heating, ventilation and air conditioning roof segment 203 of the car body in a perspective exploded view.
  • the heating, ventilation and air conditioning technology roof segment 203 is manufactured with an overall height of 50 mm.
  • the heating, ventilation and air conditioning technology roof segment 203 has an inner wall 205 and an outer wall 204 with a total thickness of 1.0 mm and 2.0 mm, respectively. consisting of individual layers with a thickness of 0.5 mm and a basis weight of 400 g/m 2 .
  • the carbon fibers are incorporated into the epoxy resin plastic matrix in the form of a bidirectional fabric and run in the 0° and 90° directions.
  • rectangular hollow profiles 207 are arranged as reinforcement elements along the outer edges of the heating, ventilation and air conditioning technology roof segment 203 and are glued to the outer wall 204 .
  • the rectangular hollow profiles 207 with a size of 100 mm ⁇ 46.5 mm and a wall thickness of 1.5 mm are braided directly onto a PET rigid foam core (pull braiding process) in a braiding process, with the fibers running at an angle of ⁇ 45°. Have direction and are embedded in a thermoset matrix of epoxy resin.
  • a flat core material 206 designed as a PET rigid foam core made of Airex T90.60, is arranged and glued to the outer wall 204. This is a classic structural bonding with a bonding gap of 0.25 - 0.40 mm.
  • a heating, ventilation and air conditioning roof segment 203 is completed in a pressing process in order to create the connection with the inner wall 205 and the final shape of the heating, ventilation and air conditioning technology roof segment 203 including the joints 208 for connecting to other roof segments 203 (not shown) to train.
  • the heating, ventilation and air conditioning technology roof segment 203 includes recesses 209 which are arranged continuously in the inner wall 205, the outer wall 204 and the core material 206 and are used for ventilation.
  • figure 4 12 shows an end-type roof segment 202 of the car body in an exploded perspective view.
  • the end-type roof segment 202 is manufactured with an overall height of 50 mm.
  • the end-type roof segment 202 has an inner wall 205 and an outer wall 204, with a total thickness of 1.0 mm and 2.0 mm, respectively, consisting of individual layers with a thickness of 0.5 mm and a basis weight of 400 g/m 2 .
  • the carbon fibers are introduced into the plastic matrix made of epoxy resin in the form of a bidirectional fabric and run in 0° and 90° direction.
  • rectangular hollow profiles 207 are arranged as reinforcement elements along the outer edges of the end-type roof segment 202 and glued to the outer wall 204 .
  • the rectangular hollow profiles 207 with a size of 100 mm ⁇ 46.5 mm and a wall thickness of 1.5 mm are braided directly onto a PET rigid foam core (pull braiding process) in a braiding process, with the fibers running at an angle of ⁇ 45°. Have direction and are embedded in a thermoset matrix of epoxy resin.
  • a flat core material 206 designed as a PET rigid foam core made of Airex T90.60, is arranged between the inner wall 205 and the outer wall 204 and the frame made of rectangular hollow profiles filled with PET foam and glued to the outer wall. This is a classic structural bonding with a bonding gap of 0.25 - 0.40 mm.
  • An end-type roof segment 202 is completed in a pressing process in order to connect to the inner wall 205 and form the final shape of the end-type roof segment 202 including the joints 208 for connecting to other roof segments 202 (not shown). Furthermore, the end-type roof segment 202 includes recesses 209 which are arranged continuously in the inner wall 205, the outer wall 204 and the core material 206 and are used for ventilation.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Body Structure For Vehicles (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)
  • Building Awnings And Sunshades (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Description

Die Erfindung betrifft die Dachsegmente eines Wagenkastens, wobei mehrere Dachsegmente das Dach des Wagenkastens bilden und für ein Schienenfahrzeug zur Personenbeförderung, insbesondere für den Einsatz im Kurzstreckenbetrieb, wie bei U- und S-Bahnen, bei denen die Schienenfahrzeuge oder die aus ihnen gebildeten Zugeinheiten in kurzen Intervallen beschleunigt und abgebremst werden müssen, eingesetzt werden.The invention relates to the roof segments of a car body, with several roof segments forming the roof of the car body and for a rail vehicle for passenger transport, in particular for use in short-distance operations, such as on underground and suburban trains, in which the rail vehicles or the train units formed from them in have to be accelerated and braked at short intervals.

Bekannte Wagenkästen von Schienenfahrzeugen bestehen in konventioneller Bauweise aus einer röhrenförmigen Konstruktion mit zwei Stirnwänden, die im Regelfall als Übergang zu einem benachbarten Wagenkasten ausgebildet sind. Alternativ kann die Stirnwand auch als Führerhaus ausgebildet sein.Known car bodies of rail vehicles consist of a conventional construction of a tubular structure with two end walls, which are usually designed as a transition to an adjacent car body. Alternatively, the front wall can also be designed as a driver's cab.

In konventioneller Bauweise besteht der Wagenkasten aus einem Untergestell (auch Unterboden genannt), zwei Seitenwänden sowie einem Dach. Dabei weisen die Baugruppen, insbesondere die Seitenwände und das Dach, eine tragende, skelettartige Tragstruktur auf, bei der Stahlleichtbauprofile miteinander oder mit einem Dünnblech, das die äußere Verkleidung bildet, mit bekannten Schweißverfahren verbunden sind.In conventional construction, the car body consists of an underframe (also known as an underbody), two side walls and a roof. The assemblies, in particular the side walls and the roof, have a load-bearing, skeletal support structure in which lightweight steel profiles are connected to one another or to a thin sheet that forms the outer cladding using known welding processes.

Für die Tragstruktur und die Verkleidung werden neben Stahl- und Stahlleichtbauprofilen und Dünnblechen zunehmend leichte und korrosionsresistente Werkstoffe aus Aluminium oder Aluminiumlegierungen verwendet. Dabei wird das Aluminium zum Erhalt einer höheren Stabilität als Kammerprofil verbaut. Allerdings weisen auch Aluminium-Bauteile bei falschem Einbau eine Anfälligkeit für Korrosion auf.In addition to steel and lightweight steel profiles and thin sheets, light and corrosion-resistant materials made of aluminum or aluminum alloys are increasingly being used for the supporting structure and cladding. The aluminum is installed as a chamber profile to obtain greater stability. However, aluminum components are also susceptible to corrosion if installed incorrectly.

Nachteile dieser Differenzialbauweise sind der hohe Aufwand für die Fertigung der Elemente der Tragstruktur und der Verkleidung und die hohe Korrosionsanfälligkeit durch die form- oder stoffschlüssige Verbindung der Stahl- oder Stahlleichtbauteile untereinander oder mit anderen Werkstoffen. So kommt es in Folge der Kondenswasserbildung insbesondere im Bereich der Fenster- und Türausschnitte in den Seitenwänden zu starker Korrosion, so dass die tragenden Baugruppen im Bereich der Seitenwände beziehungsweise im Übergangsbereich zwischen Dach und Seitenwand regelmäßig nach ca. 15 bis 17 Jahren ausgetauscht werden müssen.Disadvantages of this differential design are the high cost of manufacturing the elements of the supporting structure and the cladding and the high susceptibility to corrosion due to the positive or material connection of the steel or lightweight steel components with each other or with other materials. As a result of the formation of condensation, there is severe corrosion, especially in the area of the window and door cutouts in the side walls, so that the load-bearing assemblies in the area of the side walls or in the transition area between the roof and side wall have to be replaced regularly after about 15 to 17 years.

Neben der klassischen Skelettbauweise, insbesondere für die Baugruppen Dach und Seitenwand, gibt es seit Jahren Bemühungen, alternative Konstruktionsprinzipien in die Praxis überzuleiten.In addition to the classic skeleton construction, especially for the roof and side wall assemblies, efforts have been made for years to put alternative construction principles into practice.

So ist aus der DE 196 19 212 A1 der Wagenkasten eines Schienenfahrzeuges bekannt, der im Wesentlichen aus horizontalen und vertikalen Wandungen besteht, wobei die horizontalen Wandungen dem Bilden eines Bodens sowie eines Daches dienen und die vertikalen, insbesondere Seitenwände bildenden Wandungen, den Einbau mindestens eines Fensters und einer Eingangstür durch entsprechende Ausschnitte ermöglichen.That's it DE 196 19 212 A1 the car body of a rail vehicle is known, which essentially consists of horizontal and vertical walls, the horizontal walls serving to form a floor and a roof and the vertical walls, in particular forming side walls, enabling the installation of at least one window and one entrance door through corresponding cutouts.

Dabei werden für die Fertigung des Wagenkastens Module verwendet, die aus faserverstärktem Kunststoff gebildet sind und die im Schnitt senkrecht zur Wagenkastenlängsachse jeweils hälftige Module bilden.In this case, modules are used for the production of the car body, which are made of fiber-reinforced plastic and which form half modules in the section perpendicular to the longitudinal axis of the car body.

Jeweils zwei dieser komplementär angeordneten und in der Fahrzeugquermitte zusammentreffenden, hälftigen Module bilden dabei eine Längssektion.Two of these complementary arranged half-modules meeting in the transverse center of the vehicle form a longitudinal section.

Der gesamte Wagenkasten besteht aus einer Vielzahl von jeweils zwei hälftigen Modulen, die untereinander mit geeigneten Mitteln verbunden sind. Die hälftigen Module weisen dabei besonders bevorzugt eine Innenwand und eine Außenwand auf, die eine Kernschicht umgeben, wobei diese mit guten Eigenschaften hinsichtlich Wärme- und Schallisolierung ausgebildet ist. Bevorzugt sind die Innenwand und die Außenwand aus faserverstärktem Kunststoff gefertigt. Besonders bevorzugt umfassen die faserverstärkten Kunststoffe Glas-, Kohlenstoff-, Aramid- und / oder Naturfasern. Bevorzugt umfassen die als Matrix vorgesehenen Kunststoffe Epoxidharze, ungesättigte Polyesterharze, Vinylesterharze oder Phenolharze.The entire car body consists of a large number of two-half modules, which are connected to one another by suitable means. The half-modules particularly preferably have an inner wall and an outer wall, which surround a core layer, which is designed with good properties in terms of heat and sound insulation. The inner wall and the outer wall are preferably made of fiber-reinforced plastic. The fiber-reinforced plastics particularly preferably include glass, carbon, aramid and/or natural fibers. The plastics provided as the matrix preferably include epoxy resins, unsaturated polyester resins, vinyl ester resins or phenolic resins.

Ein Nachteil dieser Konstruktionsbauweise resultiert aus der Größe der dreidimensional ausgebildeten Module. Zudem bilden die aneinandergrenzenden Modulhälften im Bereich des Wagenkastenbodens und im Dachbereich einen durchgehenden Stumpfstoß, so dass bei üblichen Belastungssituationen, bei denen der Wagenkasten auf Torsion beansprucht wird, mit einer frühzeitigen Ermüdung des Werkstoffes in dieser Fügezone gerechnet werden muss.A disadvantage of this type of construction results from the size of the three-dimensional modules. In addition, the adjoining module halves form a continuous butt joint in the area of the car body floor and in the roof area, so that in the usual load situations in which the car body is subjected to torsion, premature fatigue of the material in this joint zone must be expected.

Aus der GB 2 030 934 A ist eine Karosserie für ein Fahrzeug und ein mit dieser Karosserie ausgestattetes Fahrzeug bekannt.From the GB 2 030 934 A a body for a vehicle and a vehicle equipped with this body are known.

Dabei besteht die Karosserie aus modularen Teilsegmenten, die aneinandergrenzend so miteinander verbunden sind, dass die Segmentmodule zugleich einen Teilbereich des Karosseriedaches bilden. Dazu weisen die Teilsegmente eine abgewinkelte Verlängerung auf.The body consists of modular sub-segments that are connected to one another in such a way that the segment modules also form part of the body roof. For this purpose, the sub-segments have an angled extension.

Um der Karosserie die notwendige Festigkeit zu verleihen, werden die einzelnen Module jeweils in überlagerter Form montiert. Durch die Verwendung klassischer Konstruktionswerkstoffe, wie Stahl, kommt es in dem Überlapp- bzw. Stoßbereich der aneinandergrenzenden Teilsegmente bzw. Segmentmodule zu starken Korrosionserscheinungen. Auch erfordert die Vorfertigung der dreidimensional geformten Teilsegmente und der sie verbindenden Profile eine hohe Fertigungsgenauigkeit.In order to give the body the necessary strength, the individual modules are each assembled in a superimposed form. Due to the use of classic construction materials such as steel, severe corrosion occurs in the overlapping or joint area of the adjoining sub-segments or segment modules. The prefabrication of the three-dimensionally shaped sub-segments and the profiles connecting them also requires a high level of manufacturing accuracy.

Beim Verschweißen der Teilsegmente untereinander, beziehungsweise mit den sie verbindenden Profilen, werden vergleichsweise große Wärmemengen in die Konstruktionsteile eingebracht, was zu stärkerem Verzug und daraus resultierenden Fertigungsungenauigkeiten führt. Ebenso wird durch die vergleichsweise große Wärmeeinflusszone das Gefüge geschwächt. Durch den ungewollten Wärmeeintrag kommt es zudem regelmäßig zum Ausbeulen oder Verformen der dünnwandigen, die Wagenkastenaußenhaut bildenden Segmentmodule. Diese Bereiche mit den signifikanten Verformungen müssen durch weiteren Wärmeeintrag und den Eintrag mechanischer Energie (Normalglühen, Spannungsarmglühen, Richten) aufwendig nachgearbeitet werden. Zudem ist es im Regelfall erforderlich, die sichtbaren Außenflächen aufwendig zu spachteln und zu verschleifen, um einen ansprechenden Gesamteindruck des Wagenkastens zu realisieren.When welding the sub-segments to each other or to the profiles connecting them, comparatively large amounts of heat are introduced into the structural parts, which leads to greater distortion and the resulting manufacturing inaccuracies. The structure is also weakened by the comparatively large heat-affected zone. through the Unwanted heat input also regularly leads to bulging or deformation of the thin-walled segment modules that form the outer skin of the car body. These areas with the significant deformations have to be laboriously reworked by further heat input and the input of mechanical energy (normalizing, stress-relief annealing, straightening). In addition, it is usually necessary to putty and grind the visible outer surfaces in order to achieve an attractive overall impression of the car body.

Falls die Segmentmodule untereinander beziehungsweise mit den angrenzenden Profilen durch Schraub- oder Nietverbindungen verbunden werden, so wird dadurch die Gefahr der Spaltkorrosion in der Verbindungszone stark gefördert. Da zudem die verwendeten Verbindungssegmente und die Segmentmodule aus unterschiedlichen Stählen bzw. Stahllegierungen bestehen, kann es zu frühzeitiger Kontaktkorrosionsbildung kommen.If the segment modules are connected to each other or to the adjacent profiles by screw or rivet connections, the risk of crevice corrosion in the connection zone is greatly increased. Since the connection segments used and the segment modules are made of different steels or steel alloys, premature contact corrosion can occur.

Aus der DE 10 2009 045 202 B4 ist ein modularer Wagenkasten in Leichtbauweise bekannt, der insbesondere für den Einsatz in Hochgeschwindigkeits-Schienenfahrzeugen konzipiert ist.From the DE 10 2009 045 202 B4 a modular car body in lightweight construction is known, which is designed in particular for use in high-speed rail vehicles.

Dazu weist der Wagenkasten für ein Personen-Schienenfahrzeug mehrere, in Umfangsrichtung um eine Längsachse geschlossene, Wagenkastenmodule auf, wobei benachbarte Wagenkastenmodule über in Umfangsrichtung geschlossene, ringartige Kopplungsmodule miteinander verbunden sind. Die Wagenkastenmodule selbst sind aus mehreren Modulelementen gebildet, die miteinander verbunden sind. Die Dachelemente können als Flächenelemente ausgebildet und als Faserverbundkunststoff oder Sandwichelement ausgeführt sein.For this purpose, the car body for a passenger rail vehicle has several car body modules that are closed in the circumferential direction about a longitudinal axis, with adjacent car body modules being connected to one another via ring-like coupling modules that are closed in the circumferential direction. The car body modules themselves are made up of several modular elements that are connected to one another. The roof elements can be designed as surface elements and can be designed as fiber-reinforced plastic or sandwich elements.

Aus der gattungsgemäßen EP 1 138 567 A2 ist es bekannt, dass ein modular aufgebauter Wagenkasten eines Schienenfahrzeuges in Faserverbundbauweise ausgeführt wird, wobei der Wagenkasten aus standardisierten Modulen, wie Dachplatte, Obergurt, Fenstersäule, Türpfosten, Seitenwandträger, Bodenplatte und Treppenmodul gebildet ist. Die einzelnen Module werden weitestgehend als Sandwich mit verlorenen Schaumkern ausgeführt. Die Dachplatten bestehen dabei im Wesentlichen aus einem Schaumkern, der beidseitig mit laminieren Faserverbund-schichten eingefasst ist.From the generic EP 1 138 567 A2 it is known that a modular car body of a rail vehicle is made of fiber composite construction, the car body being formed from standardized modules such as a roof panel, top flange, window pillar, door post, side wall support, base panel and stair module. The individual modules are largely used as Sandwich executed with lost foam core. The roof panels essentially consist of a foam core, which is bordered on both sides with laminated fiber composite layers.

Ferner zeigt die WO2016/135092 A1 ein mehrschichtiges Außenhautpaneel z.B. für einen Zug.Furthermore, the WO2016/135092 A1 a multi-layer skin panel eg for a train.

Aufgabe der Erfindung ist es, ein Dach für einen Wagenkasten bereitzustellen, welches die Nachteile des Stands der Technik überwindet.The object of the invention is to provide a roof for a car body which overcomes the disadvantages of the prior art.

Erfindungsgemäß wird die Aufgabe durch ein Dach für einen Wagenkasten gemäß dem unabhängigen Anspruch 1 gelöst. Vorteilhafte Ausgestaltungen der Erfindung sind in den abhängigen Ansprüchen angegeben.According to the invention, the object is achieved by a roof for a car body according to independent claim 1. Advantageous developments of the invention are specified in the dependent claims.

Erfindungsgemäß ist das Dachsegment zum Aufbau eines Daches eines Wagenkastens für ein Schienenfahrzeug konzipiert. Bevorzugt ist das Dachsegment platten-, schalen- oder halb-schalenförmig ausgebildet.According to the invention, the roof segment is designed for constructing a roof of a car body for a rail vehicle. The roof segment is preferably designed in the form of a plate, shell or half-shell.

Bevorzugt können die Dachsegmente, aus denen das Dach eines Wagenkastens für ein Schienenfahrzeug gebildet wird, mit oberen Längsträgern verbunden werden.The roof segments from which the roof of a car body for a rail vehicle is formed can preferably be connected to upper longitudinal beams.

Erfindungsgemäß besteht das Dachsegment aus einer Außenwand und einer dazu beabstandeten Innenwand. Vorteilhaft werden dadurch Dämmeigenschaften wie Schall- und Wärmedämmung optimiert.According to the invention, the roof segment consists of an outer wall and an inner wall spaced apart therefrom. This advantageously optimizes insulation properties such as sound and heat insulation.

Zur Fertigung eines Daches eines Wagenkastens sind mindestens zwei Dachsegmente derart ausgestaltet, dass der überragende Bereich der Außenwand bzw. Innenwand des einen Dachsegmentes form-, kraft- und / oder stoffschlüssig mit dem nicht-überragenden Bereich der Außenwand bzw. Innenwand des benachbarten Dachsegmentes miteinander verbunden ist. Vorteilhaft können dadurch Fertigungstoleranzen ausgeglichen werden. Weiterhin vorteilhaft wird dadurch eine geringere Durchlaufzeit erreicht, indem Fertigungsteams zur Fertigung des Daches die Dachsegmente entlang der Wagenkastenlängsachse von beiden Enden des Wagenkastens, d.h. von außen nach innen einbauen können, ohne sich gegenseitig zu behindern.To produce a roof of a car body, at least two roof segments are designed in such a way that the protruding area of the outer wall or inner wall of one roof segment is connected to the non-protruding area of the outer wall or inner wall of the adjacent roof segment in a positive, non-positive and/or material connection is. Manufacturing tolerances can advantageously be compensated for in this way. A further advantage is that a lower throughput time is achieved by manufacturing teams for the manufacture of the roof, the roof segments along the Longitudinal axis of the car body from both ends of the car body, ie from the outside to the inside, without interfering with each other.

Bevorzugt entspricht die Breite der Dachsegmente im Wesentlichen der Breite des Wagenkastens. Vorteilhaft ist dadurch die Stabilität des Wagenkastens erhöht, indem keine weiteren Füllmittel oder Verbindungselemente benötigt werden. Alternativ ist die Breite der Dachsegmente geringer als die Breite des Wagenkastens.The width of the roof segments preferably essentially corresponds to the width of the car body. This advantageously increases the stability of the car body, in that no further fillers or connecting elements are required. Alternatively, the width of the roof segments is less than the width of the car body.

Erfindungsgemäß besteht das Dachsegment zumindest teilweise aus faserverstärktem Kunststoff-verbund (FKV). Vorteilhaft wird dadurch bei gleichbleibender Stabilität das Gewicht des Wagenkastens erheblich reduziert, wodurch wiederum eine Erhöhung der Nutzlast des Schienenfahrzeuges ermöglicht wird. Durch die Erhöhung der Nutzlast können insbesondere bei U-Bahnen aufgrund der vorgegebenen Zuglängen und Taktzeiten in der gleichen Zeit deutlich mehr Personen befördert werden.According to the invention, the roof segment consists at least partially of fiber-reinforced plastic composite (FRP). The advantage of this is that the weight of the car body is significantly reduced while the stability remains the same, which in turn makes it possible to increase the payload of the rail vehicle. By increasing the payload, significantly more people can be transported in the same amount of time, especially on underground trains, due to the specified train lengths and cycle times.

Ein erster Aspekt der Erfindung betrifft die Ausführung der Dachsegmente, die miteinander verbunden ein strukturelles Flachdach eines Wagenkastens eines Schienenfahrzeugs bilden. Bevorzugt sind die Dachsegmente plattenförmig ausgebildet.A first aspect of the invention relates to the design of the roof segments which, when connected to one another, form a structural flat roof of a car body of a rail vehicle. The roof segments are preferably designed in the form of plates.

Die einzelnen Dachsegmente des Daches des Wagenkastens sind als Standardtyp-Dachsegmente, Heizung-Lüftung-Klimatechniktyp-Dachsegmente oder Endtyp-Dachsegmente ausgebildet. Bevorzugt beinhaltet das Dach jeweils mindestens ein Standardtyp-Dachsegment, mindestens ein Heizung-Lüftung-Klimatechniktyp-Dachsegment und mindestens ein Endtyp-Dachsegment. Bevorzugt weist das Heizung-Lüftung-Klimatechniktyp-Dachsegment mindestens eine Aussparung für ein Klimaanlagenaggregat auf.The individual roof segments of the roof of the car body are designed as standard-type roof segments, heating-ventilation-air-conditioning type roof segments or end-type roof segments. Preferably, the roof includes at least one standard type roof segment, at least one HVAC type roof segment, and at least one end type roof segment, respectively. The heating/ventilation/air conditioning type roof segment preferably has at least one cutout for an air conditioning unit.

Bevorzugt sind mindestens ein Standardtyp-Dachsegment und mindestens ein Heizung-Lüftung-Klimatechniktyp-Dachsegment jeweils abwechselnd angeordnet. Alternativ folgen mindestens zwei Standardtyp-Dachsegmente aufeinander. In einer weiteren alternativen Ausführungsform folgen mindestens zwei Heizung-Lüftung-Klimatechniktyp-Dachsegmente aufeinander. In einer weiteren alternativen Ausführungsform gibt es mehr Standardtyp- als Heizung-Lüftung-Klimatechniktyp-Dachsegmente. In einer weiteren alternativen Ausführungsform gibt es mehr Heizung-Lüftung-Klimatechniktyp-Dachsegmente als Standardtyp-Dachsegmente.At least one standard-type roof segment and at least one heating-ventilation-air-conditioning-type roof segment are preferably arranged alternately. Alternatively, at least two standard type roof segments follow one another. In According to a further alternative embodiment, at least two heating-ventilation-air-conditioning-type roof segments follow one another. In another alternative embodiment, there are more standard than HVAC type roof segments. In another alternative embodiment, there are more HVAC type roof segments than standard type roof segments.

Bevorzugt umfasst das Dach eines Wagenkastens zwei Endtyp-Dachsegmente. Die Endtyp-Dachsegmente stellen dabei die vorderen und hinteren Enden und somit den Abschluss des Daches in Wagenlängsrichtung dar.Preferably, the roof of a car body comprises two end-type roof segments. The end-type roof segments represent the front and rear ends and thus the end of the roof in the longitudinal direction of the car.

Bevorzugt werden die Dachsegmente aus FKV-Werkstoffen ausgebildet.The roof segments are preferably made of FRP materials.

Erfindungsgemäß umfassen die Dachsegmente mindestens eine Außen- und eine Innenwand.According to the invention, the roof segments comprise at least one outer and one inner wall.

Im Sinne der Erfindung wird unter der Außenwand jene Fläche verstanden, welche den Wagenkasten nach außen abschließt und welche in Verbindung mit der Umgebung außerhalb des Wagenkastens steht. Im Sinne der Erfindung wird unter der Innenwand jene Fläche verstanden, welche in Kontakt mit dem Wagenkasteninnenraum und somit dem Fahrgastraum steht.For the purposes of the invention, the outer wall is understood as meaning that surface which closes off the car body on the outside and which is in connection with the environment outside the car body. For the purposes of the invention, the inner wall is understood as meaning that surface which is in contact with the car body interior and thus the passenger compartment.

Bevorzugt sind die Innen- und die Außenwand der Dachsegmente parallel zueinander und jeweils ein- oder mehrlagig aus mindestens einem FKV-Werkstoff ausgebildet.Preferably, the inner and outer walls of the roof segments are parallel to one another and are each made of one or more layers of at least one FRP material.

Bevorzugt sind die Innen- und die Außenwand mit mehrachsiger Faserausrichtung, besonders bevorzugt bidirektionaler Faserausrichtung, ganz besonders bevorzugt in 0°/90°-Orientierung, gefertigt.The inner and the outer wall are preferably manufactured with a multi-axial fiber orientation, particularly preferably a bidirectional fiber orientation, very particularly preferably in a 0°/90° orientation.

Bevorzugt werden die Fasern in den faserverstärkten Kunststoffverbund der Dachsegmente als Roving und / oder Vlies und / oder Gewebe und / oder Gelege und / oder Geflecht eingebracht.The fibers are preferably introduced into the fiber-reinforced plastic composite of the roof segments as a roving and/or fleece and/or fabric and/or scrim and/or mesh.

Erfindungsgemäß sind zwischen der Innen- und der Außenwand der Dachsegmente Verstärkungselemente angeordnet, wobei diese als rechteckige Hohlprofile ausgeführt sind.According to the invention, reinforcing elements are arranged between the inner and outer wall of the roof segments, these being designed as rectangular hollow profiles.

Bevorzugt sind die Kanten der rechteckigen Hohlprofile parallel zu den Kanten der Dach-segmente angeordnet.The edges of the rectangular hollow profiles are preferably arranged parallel to the edges of the roof segments.

Erfindungsgemäß werden die rechteckigen Hohlprofile ein- oder mehrlagig aus mindestens einem FKV-Werkstoff hergestellt.According to the invention, the rectangular hollow profiles are produced in one or more layers from at least one FRP material.

Erfindungsgemäß sind die rechteckigen Hohlprofile mit bidirektionaler Faserausrichtung gefertigt.According to the invention, the rectangular hollow profiles are manufactured with a bidirectional fiber orientation.

Erfindungsgemäß weisen die rechteckigen Hohlprofile zusätzlich eine Kernfüllung auf, ausgebildet als Schaumkern.According to the invention, the rectangular hollow profiles also have a core filling, designed as a foam core.

Bevorzugt dient die Kernfüllung zur Übertragung von Gewichts- und Schubkräften.The core filling preferably serves to transfer weight and shear forces.

Erfindungsgemäß sind die rechteckigen Hohlprofile mit einem Hartschaumstoff gefüllt.According to the invention, the rectangular hollow profiles are filled with a rigid foam.

Erfindungsgemäß ist zwischen den rechteckigen Hohlprofilen ein flächiger Kernwerkstoff, ausgebildet als Schaumkern, zwischen der Innen- und der Außenwand des Dachsegmentes angeordnet, um die strukturelle Festigkeit und damit die Begehbarkeit zu gewährleisten.According to the invention, a flat core material, designed as a foam core, is arranged between the inner and outer wall of the roof segment between the rectangular hollow profiles in order to ensure the structural strength and thus the accessibility.

Bevorzugt ist der Kernwerkstoff eines Dachsegmentes als Hartschaumstoffplatte ausgebildet.The core material of a roof segment is preferably a hard foam panel educated.

Bevorzugt erfolgt die Herstellung der einzelnen Dachsegmente in einem Pressverfahren, wobei das Fügen der rechteckigen Hohlprofile mit entweder der Innen- oder der Außenwand des Dachsegmentes zusätzlich durch Kleben erfolgt. Optional erfolgt das Fügen der Innenwand des Dachsegmentes zusätzlich durch Kleben.The individual roof segments are preferably produced in a pressing process, the joining of the rectangular hollow profiles with either the inner or the outer wall of the roof segment also being effected by gluing. Optionally, the inner wall of the roof segment can also be joined by gluing.

Bevorzugt weisen die Innen- und die Außenwand eines Dachsegmentes jeweils zumindest an einer ihrer Seiten, die senkrecht zur Wagenkastenlängsachse ausgerichtet ist, im Folgenden als Längsseite bezeichnet, einen Bereich auf, in dem sie die rechteckigen Hohlprofile dergestalt überragen, dass eine formschlüssige Verbindung zwischen benachbarten Dachsegmenten hergestellt werden kann. Vorteilhaft erlaubt diese bevorzugte Ausführungsform das Fügen einzelner Dachsegmente zum Dach des Wagenkastens in Analogie zu aus dem Stand der Technik für Bodenbeläge wie Parkett oder Laminat bekannten Verfahren (Klick-Parkett bzw. Klick-Laminat). Besonders bevorzugt überragt an einer der beiden Längsseiten eines einzelnen Dachsegmentes ein Bereich der Innenwand im Wesentlichen über die gesamte Längenausdehnung der Längsseite die rechteckigen Hohlprofile, und an der dieser Längsseite gegenüberliegenden Längsseite überragt ein Bereich der Außenwand die rechteckigen Hohlprofile im Wesentlichen über die gesamte Längenausdehnung der Längsseite. Des Weiteren besonders bevorzugt erfolgt das Fügen der einzelnen Dachsegmente zum Dach des Wagenkastens beginnend mit den an den beiden Endbereichen eines Wagenkastens angeordneten Endtyp-Dachsegmenten. An diesen Dachsegmenten wird jeweils ein nächstes Dachsegment (Standardtyp- oder Heizung-Lüftung-Klimatechniktyp-Dachsegment) so angeordnet, dass der die rechteckigen Hohlprofile überragende Bereich der Außenwand des Endtyp-Dachsegments die Außenwand des nächsten Dachsegmentes zumindest mittelbar über eine Schicht eines Klebstoffs berührt. Desgleichen berührt der die rechteckigen Hohlprofile überragende Bereich der Innenwand des nächsten Dachsegmentes die Innenwand des Endtyp-Dachsegmentes zumindest mittelbar über eine Schicht eines Klebstoffs. Mit anderen Worten erfolgt das Fügen der einzelnen Dachsegmente von außen, also den Endbereichen des Wagenkastens, beginnend nach innen, also zur Mitte des Wagenkastens, hin. Das Dachsegment, das in der Mitte des Daches des Wagenkastens angeordnet ist, ist dementsprechend so gestaltet, dass seine Außenwand keinen die rechteckigen Hohlprofile überragenden Bereich aufweist, und seine Innenwand die rechteckigen Hohlprofile an beiden Längsseiten dieses Dachsegmentes überragt. Des Weiteren besonders bevorzugt sind benachbarte rechteckige Hohlprofile benachbarter Dachsegmente stoffschlüssig, insbesondere mittels eines Klebstoffs, miteinander verbunden, wodurch sich vorteilhaft neben einer verbesserten Stabilität der Verbindung auch eine Möglichkeit zum Ausgleich von Fertigungstoleranzen ergibt. Für die Realisierung der Erfindung ist es auch zweckmäßig, die vorbeschriebenen erfindungs-gemäßen Ausgestaltungen, Ausführungsformen und Merkmale der Ansprüche in jeder Anordnung miteinander zu kombinieren, solange der resultierende Gegenstand zum Schutzumfang gehört, der durch die Ansprüche definiert ist.Preferably, the inner and outer wall of a roof segment each have at least one of their sides, which is aligned perpendicular to the longitudinal axis of the car body, hereinafter referred to as the longitudinal side, an area in which they protrude beyond the rectangular hollow profiles in such a way that a form-fitting connection between adjacent roof segments can be made. Advantageously, this preferred embodiment allows individual roof segments to be joined to the roof of the car body in analogy to methods known from the prior art for floor coverings such as parquet or laminate (click parquet or click laminate). Particularly preferably, on one of the two longitudinal sides of an individual roof segment, an area of the inner wall protrudes over the rectangular hollow profiles essentially over the entire length of the longitudinal side, and on the longitudinal side opposite this longitudinal side, an area of the outer wall protrudes over the rectangular hollow profiles essentially over the entire length of the longitudinal side . Furthermore, particularly preferably, the individual roof segments are joined to form the roof of the car body, beginning with the end-type roof segments arranged at the two end regions of a car body. A next roof segment (standard type or heating, ventilation and air conditioning type roof segment) is arranged on each of these roof segments in such a way that the area of the outer wall of the end-type roof segment that protrudes beyond the rectangular hollow profiles touches the outer wall of the next roof segment at least indirectly via a layer of adhesive. Likewise, the area of the inner wall of the next roof segment that protrudes beyond the rectangular hollow profiles touches the inner wall of the end-type roof segment at least indirectly via a layer of adhesive. In other words, the individual roof segments are joined from the outside, ie the end regions of the car body, beginning inwards, ie towards the center of the car body. The roof segment, which is arranged in the middle of the roof of the car body, is accordingly designed in such a way that its outer wall does not have any area projecting beyond the rectangular hollow sections, and its inner wall projects beyond the rectangular hollow sections on both longitudinal sides of this roof segment. Furthermore, it is particularly preferable for adjacent rectangular hollow profiles of adjacent roof segments to be cohesively bonded to one another, in particular by means of an adhesive connected, which advantageously results not only in improved stability of the connection but also a possibility of compensating for manufacturing tolerances. For the realization of the invention, it is also expedient to combine the above-described inventive configurations, embodiments and features of the claims in any arrangement with one another, as long as the resulting subject matter belongs to the scope of protection defined by the claims.

Nachfolgend soll die Erfindung anhand eines Ausführungsbeispiels eingehender erläutert werden. Das Ausführungsbeispiel soll dabei die Erfindung beschreiben, ohne diese zu beschränken.The invention will be explained in more detail below using an exemplary embodiment. The exemplary embodiment is intended to describe the invention without restricting it.

Anhand von Zeichnungen wird die Erfindung näher erläutert. Dabei zeigen:

Fig. 1
Sprengbild eines Wagenkastens mit den erfindungsgemäßen Dachsegmenten,
Fig. 2
Standardtyp-Dachsegment des Wagenkastens in einer perspektivischen Sprengansicht und in einer perspektivischen Ansicht im zusammengesetzten Zustand,
Fig. 3
Heizung-Lüftung-Klimatechniktyp-Dachsegment des Wagenkastens in einer perspektivischen Sprengansicht,
Fig. 4
Endtyp-Dachsegment des Wagenkastens in einer perspektivischen Sprengansicht.
The invention is explained in more detail with reference to drawings. show:
1
Explosive diagram of a car body with the roof segments according to the invention,
2
standard type roof segment of the car body in an exploded perspective view and in an assembled perspective view,
3
Heating-ventilation-air conditioning type roof segment of the car body in an exploded perspective view,
4
Car body end-type roof segment in an exploded perspective view.

Figur 1 zeigt ein Sprengbild eines Wagenkastens 1, in welchem die erfindungsgemäßen Dachsegmente als Standardtyp-Dachsegment 201, Endtyp-Dachsegment 202 und Heizung-Lüftung-Klimatechniktyp-Dachsegment 203 eingebaut sind. Weiterhin sind folgende Komponenten des Wagenkastens dargestellt: Die oberen Längsträger 601 und die unteren Längsträger 602, die Seitenwandsegmente 301, die vertikalen Säulen 304, die Stirnwand 501 sowie die Bodensegmente 401. figure 1 shows an exploded view of a car body 1 in which the roof segments according to the invention as a standard type roof segment 201, end type roof segment 202 and heating-ventilation-air conditioning type roof segment 203 are installed. The following components of the car body are also shown: the upper longitudinal members 601 and the lower longitudinal members 602, the side wall segments 301, the vertical columns 304, the end wall 501 and the floor segments 401.

Figur 2 zeigt ein Standardtyp-Dachsegment 201 des Wagenkastens in einer perspektivischen Sprengansicht (Fig. 2A) sowie einen Querschnitt durch zwei benachbarte Standardtyp-Dachsegmente 201 (Fig. 2B) bei der Montage. Das Standardtyp-Dachsegment 201 wird mit einer Bauhöhe von 50 mm gefertigt. Das Standardtyp-Dachsegment 201 weist eine Innenwand 205 und eine Außenwand 204 auf, mit einer Gesamtdicke von 1,0 mm bzw. 2,0 mm, bestehend aus Einzellagen mit einer Dicke von 0,5 mm und einem Flächengewicht von 400 g / m2. Die Kohlenstofffasern sind in Form von bidirektionalem Gelege in die Kunststoffmatrix aus Epoxidharz eingebracht und verlaufen in 0°- und 90°-Richtung. Zwischen der Innenwand 205 und der Außenwand 204 des Standardtyp-Dachsegmentes 201 sind entlang der Außenkanten des Dachsegmentes 201 rechteckige Hohlprofile 207 als Verstärkungselemente angeordnet und mit der Außenwand 204 verklebt. Dabei handelt es sich um eine klassische Strukturverklebung mit einem Klebespalt von 0,25 - 0,40 mm. Die rechteckigen Hohlprofile 207 mit einer Größe von 100 mm × 46,5 mm mit einer Wandstärke von 1,5 mm werden in einem Flechtverfahren direkt auf einen PET-Hartschaumkern geflochten (Pullbraiding-Verfahren), wobei die Fasern einen Faserverlauf in ± 45°-Richtung aufweisen und in eine duroplastische Matrix aus Epoxidharz eingebettet sind. Zwischen der Innenwand 205 und der Außenwand 204 und dem Rahmen aus rechteckigen, mit PET-Schaum gefüllten, Hohlprofilen wird ein flächiger Kernwerkstoff 206, ausgebildet als PET-Hartschaumkern aus Airex T90.60, angeordnet und mit der Außenwand 204 verklebt. Dabei handelt es sich um eine klassische Strukturverklebung mit einem Klebespalt von 0,25 - 0,40 mm. Die Fertigstellung eines Standardtyp-Dachsegmentes 201 erfolgt in einem Pressverfahren, um die Verbindung mit der Innenwand 205 herzustellen und die endgültige Form des Standardtyp-Dachsegmentes 201 inklusive der Fügestellen 208 für das Verbinden mit weiteren Dachsegmenten (nicht dargestellt) auszubilden. Fig. 2B verdeutlicht die nach der Montage zusätzlich zu der stoffschlüssigen Klebeverbindung bestehende formschlüssige Verbindung zwischen benachbarten Standardtyp-Dachsegmenten 201 über die Fügestellen 208. figure 2 shows a standard type roof segment 201 of the car body in an exploded perspective view ( Figure 2A ) and a cross section through two adjacent standard type roof segments 201 ( Figure 2B ) during installation. The Standard type roof segment 201 is manufactured with an overall height of 50 mm. The standard type roof segment 201 has an inner wall 205 and an outer wall 204, with a total thickness of 1.0 mm and 2.0 mm, respectively, consisting of individual layers with a thickness of 0.5 mm and a basis weight of 400 g/m 2 . The carbon fibers are incorporated into the epoxy resin plastic matrix in the form of a bidirectional fabric and run in the 0° and 90° directions. Between the inner wall 205 and the outer wall 204 of the standard-type roof segment 201 , rectangular hollow profiles 207 are arranged as reinforcement elements along the outer edges of the roof segment 201 and glued to the outer wall 204 . This is a classic structural bonding with a bonding gap of 0.25 - 0.40 mm. The rectangular hollow profiles 207 with a size of 100 mm × 46.5 mm and a wall thickness of 1.5 mm are braided directly onto a PET rigid foam core (pull braiding process) in a braiding process, with the fibers running at an angle of ± 45°. Have direction and are embedded in a thermoset matrix of epoxy resin. Between the inner wall 205 and the outer wall 204 and the frame made of rectangular hollow profiles filled with PET foam, a flat core material 206 embodied as a PET rigid foam core made of Airex T90.60 is arranged and glued to the outer wall 204 . This is a classic structural bonding with a bonding gap of 0.25 - 0.40 mm. A standard-type roof segment 201 is completed in a pressing process to connect to the inner wall 205 and form the final shape of the standard-type roof segment 201 including the joints 208 for connecting to other roof segments (not shown). Figure 2B clarifies the form-fit connection between adjacent standard-type roof segments 201 via the joints 208 in addition to the material-fit adhesive connection after assembly.

Figur 3 zeigt ein Heizung-Lüftung-Klimatechnik-Dachsegment 203 des Wagenkastens in einer perspektivischen Sprengansicht. Das Heizung-Lüftung-Klimatechnik-Dachsegment 203 wird mit einer Bauhöhe von 50 mm gefertigt. Das Heizung-Lüftung-Klimatechnik-Dachsegment 203 weist eine Innenwand 205 und eine Außenwand 204 auf, mit einer Gesamtdicke von 1,0 mm bzw. 2,0 mm, bestehend aus Einzellagen mit einer Dicke von 0,5 mm und einem Flächengewicht von 400 g / m2. Die Kohlenstofffasern sind in Form von bidirektionalem Gelege in die Kunststoffmatrix aus Epoxidharz eingebracht und verlaufen in 0°- und 90°-Richtung. Zwischen der Innenwand 205 und der Außenwand 204 des Heizung-Lüftung-Klimatechnik-Dachsegmentes 203 sind entlang der Außenkanten des Heizung-Lüftung-Klimatechnik-Dachsegmentes 203 rechteckige Hohlprofile 207 als Verstärkungselemente angeordnet und mit der Außenwand 204 verklebt. Dabei handelt es sich um eine klassische Strukturverklebung mit einem Klebespalt von 0,25 - 0,40 mm. Die rechteckigen Hohlprofile 207 mit einer Größe von 100 mm × 46,5 mm mit einer Wandstärke von 1,5 mm werden in einem Flechtverfahren direkt auf einen PET-Hartschaumkern geflochten (Pullbraiding-Verfahren), wobei die Fasern einen Faserverlauf in ± 45°-Richtung aufweisen und in eine duroplastische Matrix aus Epoxidharz eingebettet sind. Zwischen der Innenwand 205 und der Außenwand 204 und dem Rahmen aus rechteckigen, mit PET-Schaum gefüllten, Hohlprofilen 207 wird ein flächiger Kernwerkstoff 206, ausgebildet als PET-Hartschaumkern aus Airex T90.60, angeordnet und mit der Außenwand 204 verklebt. Dabei handelt es sich um eine klassische Strukturverklebung mit einem Klebespalt von 0,25 - 0,40 mm. Die Fertigstellung eines Heizung-Lüftung-Klimatechnik-Dachsegmentes 203 erfolgt in einem Pressverfahren, um die Verbindung mit der Innenwand 205 herzustellen und die endgültige Form des Heizung-Lüftung-Klimatechnik-Dachsegmentes 203 inklusive der Fügestellen 208 für das Verbinden mit weiteren Dachsegmenten 203 (nicht dargestellt) auszubilden. Weiterhin umfasst das Heizung-Lüftung-Klimatechnik-Dachsegment 203 Aussparungen 209, welche jeweils in der Innenwand 205, der Außenwand 204 und dem Kernwerkstoff 206 durchgängig angeordnet sind und der Entlüftung dienen. figure 3 shows a heating, ventilation and air conditioning roof segment 203 of the car body in a perspective exploded view. The heating, ventilation and air conditioning technology roof segment 203 is manufactured with an overall height of 50 mm. The heating, ventilation and air conditioning technology roof segment 203 has an inner wall 205 and an outer wall 204 with a total thickness of 1.0 mm and 2.0 mm, respectively. consisting of individual layers with a thickness of 0.5 mm and a basis weight of 400 g/m 2 . The carbon fibers are incorporated into the epoxy resin plastic matrix in the form of a bidirectional fabric and run in the 0° and 90° directions. Between the inner wall 205 and the outer wall 204 of the heating, ventilation and air conditioning roof segment 203 , rectangular hollow profiles 207 are arranged as reinforcement elements along the outer edges of the heating, ventilation and air conditioning technology roof segment 203 and are glued to the outer wall 204 . This is a classic structural bonding with a bonding gap of 0.25 - 0.40 mm. The rectangular hollow profiles 207 with a size of 100 mm × 46.5 mm and a wall thickness of 1.5 mm are braided directly onto a PET rigid foam core (pull braiding process) in a braiding process, with the fibers running at an angle of ± 45°. Have direction and are embedded in a thermoset matrix of epoxy resin. Between the inner wall 205 and the outer wall 204 and the frame made of rectangular hollow profiles 207 filled with PET foam, a flat core material 206, designed as a PET rigid foam core made of Airex T90.60, is arranged and glued to the outer wall 204. This is a classic structural bonding with a bonding gap of 0.25 - 0.40 mm. A heating, ventilation and air conditioning roof segment 203 is completed in a pressing process in order to create the connection with the inner wall 205 and the final shape of the heating, ventilation and air conditioning technology roof segment 203 including the joints 208 for connecting to other roof segments 203 (not shown) to train. Furthermore, the heating, ventilation and air conditioning technology roof segment 203 includes recesses 209 which are arranged continuously in the inner wall 205, the outer wall 204 and the core material 206 and are used for ventilation.

Figur 4 zeigt ein Endtyp-Dachsegment 202 des Wagenkastens in einer perspektivischen Sprengansicht. Das Endtyp-Dachsegment 202 wird mit einer Bauhöhe von 50 mm gefertigt. Das Endtyp-Dachsegment 202 weist eine Innenwand 205 und eine Außenwand 204 auf, mit einer Gesamtdicke von 1,0 mm bzw. 2,0 mm, bestehend aus Einzellagen mit einer Dicke von 0,5 mm und einem Flächengewicht von 400 g / m2. Die Kohlenstofffasern sind in Form von bidirektionalem Gelege in die Kunststoffmatrix aus Epoxidharz eingebracht und verlaufen in 0°- und 90°-Richtung. Zwischen der Innenwand 205 und der Außenwand 204 des Endtyp-Dachsegmentes 202 sind entlang der Außenkanten des Endtyp-Dachsegmentes 202 rechteckige Hohlprofile 207 als Verstärkungselemente angeordnet und mit der Außenwand 204 verklebt. Dabei handelt es sich um eine klassische Strukturverklebung mit einem Klebespalt von 0,25 - 0,40 mm. Die rechteckigen Hohlprofile 207 mit einer Größe von 100 mm × 46,5 mm mit einer Wandstärke von 1,5 mm werden in einem Flechtverfahren direkt auf einen PET-Hartschaumkern geflochten (Pullbraiding-Verfahren), wobei die Fasern einen Faserverlauf in ± 45°-Richtung aufweisen und in eine duroplastische Matrix aus Epoxidharz eingebettet sind. Zwischen der Innenwand 205 und der Außenwand 204 und dem Rahmen aus rechteckigen, mit PET-Schaum gefüllten, Hohlprofilen wird ein flächiger Kernwerkstoff 206, ausgebildet als PET-Hartschaumkern aus Airex T90.60, angeordnet und mit der Außenwand verklebt. Dabei handelt es sich um eine klassische Strukturverklebung mit einem Klebespalt von 0,25 - 0,40 mm. Die Fertigstellung eines Endtyp-Dachsegmentes 202 erfolgt in einem Pressverfahren, um die Verbindung mit der Innenwand 205 herzustellen und die endgültige Form des Endtyp-Dachsegmentes 202 inklusive der Fügestellen 208 für das Verbinden mit weiteren Dachsegmenten 202 (nicht dargestellt) auszubilden. Weiterhin umfasst das Endtyp-Dachsegment 202 Aussparungen 209, welche jeweils in der Innenwand 205, der Außenwand 204 und dem Kernwerkstoff 206 durchgängig angeordnet sind und der Entlüftung dienen. figure 4 12 shows an end-type roof segment 202 of the car body in an exploded perspective view. The end-type roof segment 202 is manufactured with an overall height of 50 mm. The end-type roof segment 202 has an inner wall 205 and an outer wall 204, with a total thickness of 1.0 mm and 2.0 mm, respectively, consisting of individual layers with a thickness of 0.5 mm and a basis weight of 400 g/m 2 . The carbon fibers are introduced into the plastic matrix made of epoxy resin in the form of a bidirectional fabric and run in 0° and 90° direction. Between the inner wall 205 and the outer wall 204 of the end-type roof segment 202 , rectangular hollow profiles 207 are arranged as reinforcement elements along the outer edges of the end-type roof segment 202 and glued to the outer wall 204 . This is a classic structural bonding with a bonding gap of 0.25 - 0.40 mm. The rectangular hollow profiles 207 with a size of 100 mm × 46.5 mm and a wall thickness of 1.5 mm are braided directly onto a PET rigid foam core (pull braiding process) in a braiding process, with the fibers running at an angle of ± 45°. Have direction and are embedded in a thermoset matrix of epoxy resin. A flat core material 206, designed as a PET rigid foam core made of Airex T90.60, is arranged between the inner wall 205 and the outer wall 204 and the frame made of rectangular hollow profiles filled with PET foam and glued to the outer wall. This is a classic structural bonding with a bonding gap of 0.25 - 0.40 mm. An end-type roof segment 202 is completed in a pressing process in order to connect to the inner wall 205 and form the final shape of the end-type roof segment 202 including the joints 208 for connecting to other roof segments 202 (not shown). Furthermore, the end-type roof segment 202 includes recesses 209 which are arranged continuously in the inner wall 205, the outer wall 204 and the core material 206 and are used for ventilation.

Claims (9)

  1. A roof segment (201, 202, 203) for the construction of a roof of a carriage body (1) for a rail vehicle,
    wherein
    - the roof segment (201, 202, 203) is formed plate-, shell- or half-shell-shaped,
    - the roof segment (201, 202, 203) consists of an outer wall (204) and an inner wall (205) spaced apart therefrom,
    - wherein for manufacturing a roof of a carriage body (1), at least two roof segments (201) are configured such that the projecting portion of the outer wall (204) of one roof segment (201) is connected to the non-projecting portion of the outer wall (204) of the neighboring roof segment (201) and the projecting portion of the inner wall (205) of one roof segment (201) is connected to the non-projecting portion of the inner wall (205) of the neighboring roof segment with a form fit, a force fit and/or an inter-material bond perpendicularly to a longitudinal axis of the carriage body (1), and
    - the roof segment (201, 202, 203) consists at least partially of fiber-reinforced plastic composite,
    - wherein rectangular reinforcing elements (207) are arranged between the inner wall (205) and the outer wall (204) of the roof segment (201, 202, 203) along outer edges of the roof segment (201, 202, 203), the reinforcing elements (207) being in the form of rectangular hollow profiles, wherein the rectangular hollow profiles form at least one frame and wherein a flat core material (206) is arranged between neighboring rectangular hollow profiles (207) between the inner wall (205) and the outer wall (204) of the roof segment (201, 202, 203),
    - wherein the rectangular hollow profiles (207) have a size of 100 mm × 46.5 mm with a wall thickness of 1.5 mm and are braided directly onto a PET rigid foam core in a braiding process or pullbraiding process,
    - wherein the fibers have a fiber orientation in the ±45° direction and are embedded in a thermosetting matrix made from epoxy resin,
    - and wherein a flat core material (206), formed as a PET rigid foam core, is arranged between the inner wall (205) and the outer wall (204) and the frame made of rectangular hollow profiles (207) filled with PET foam and is adhesively bonded to the outer wall (204).
  2. The roof segment (201, 202, 203) according to claim 1, characterized in that the fiber-reinforced plastic composite comprises glass, carbon, aramid, basalt, textile and/or natural fibers in a matrix made from thermoplastics or thermosetting plastics.
  3. The roof segment (201, 202, 203) according to either of claims 1 or 2, characterized in that the thermosetting plastics comprise epoxy resins, unsaturated polyester resins, PU resins, vinyl ester resins or phenolic resins.
  4. The roof segment (201, 202, 203) according to any of claims 1 to 3, characterized in that the fibers of the fiber-reinforced plastic composite are oriented unidirectionally and/or multiaxially.
  5. The roof segment (201, 202, 203) according to any of claims 1 to 4, characterized in that the fibers of the fiber-reinforced plastic composite are introduced as rovings, non-woven fabrics, non-crimp fabrics, woven fabrics and/or meshwork.
  6. The roof segment (201, 202, 203) according to any of claims 1 to 5, characterized in that the plate-, shell- or half-shell-shaped roof segments (201, 202, 203) may be connected to an upper longitudinal beam (601) with a force fit and/or a form fit and/or an inter-material bond.
  7. The roof segment (201, 202, 203) according to any of claims 1 to 6, characterized in that the roof segment (201, 202, 203) comprises a standard-type roof segment (201), a heating-ventilation-air conditioning-type roof segment (203) or an end-type roof segment (202), wherein the ventilation-air conditioning-type roof segment (203) or the end-type roof segment (202) each includes recesses (209) which are provided continuously in the inner wall (205), the outer wall (204) and the core material (206) and serve for ventilation.
  8. A roof of a carriage body (1), characterized in that the roof assembly is built up of roof segments (201, 202, 203) according to any of claims 1 to 7, wherein the roof assembly comprises two end-type roof segments (204), at least one heating-ventilation-air conditioning roof segment (203) and at least two standard-type roof segments (201).
  9. Use of the roof segments (201, 202, 203) according to any of claims 1 to 7 for the construction of a roof for the carriage body (1) of a rail vehicle for transporting passengers for use in short distance operation, such as in underground and suburban railways, in which the rail vehicles or the train units formed of them are speeded up and slowed down at short intervals.
EP18704529.9A 2017-02-09 2018-02-08 Roof segments for the roof of a carriage body Active EP3580109B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102017102564.2A DE102017102564A1 (en) 2017-02-09 2017-02-09 Roof segments for the roof of a car body
PCT/EP2018/053217 WO2018146219A1 (en) 2017-02-09 2018-02-08 Roof segments for the roof of a carriage body

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EP3580109A1 EP3580109A1 (en) 2019-12-18
EP3580109B1 true EP3580109B1 (en) 2023-03-15

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US (1) US11370463B2 (en)
EP (1) EP3580109B1 (en)
JP (1) JP6942806B2 (en)
CN (1) CN110312652A (en)
DE (1) DE102017102564A1 (en)
ES (1) ES2940644T3 (en)
WO (1) WO2018146219A1 (en)

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CN113997965A (en) * 2021-11-19 2022-02-01 中车长春轨道客车股份有限公司 High-speed maglev train, vehicle body cover plate structure and forming method thereof

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ES2940644T3 (en) 2023-05-10
CN110312652A (en) 2019-10-08
US20210331718A1 (en) 2021-10-28
DE102017102564A1 (en) 2018-08-09
JP6942806B2 (en) 2021-09-29
WO2018146219A1 (en) 2018-08-16
US11370463B2 (en) 2022-06-28
EP3580109A1 (en) 2019-12-18

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