KR102224660B1 - The Door and door's manufacturing Method using SMC and Presses(Compression Process) for railway electric vehicles, subway and trains - Google Patents

Abstract

An objective of the present invention is to manufacture a door used in subways, electromotive vehicles, and trains with a press, and provide an electromotive vehicle door including an inner panel and an outer panel, wherein the inner panel and the outer panel are formed of a flame-retardant sheet molding compound (SMC) material, a honeycomb core is sandwiched and bonded between the inner panel and the outer panel with an adhesive, and a plurality of coupling portions are formed on corresponding surfaces of the inner panel and the outer panel. The present invention relates to a method of manufacturing a flame-retardant door for subways, electromotive vehicles, and trains by using a press, and a door therefor, in which a door panel is press-molded at a high temperature and a high pressure with the SMC material, so that excessive manpower and a time loss are reduced as compared with an existing product manufacturing scheme.

Description

The Door and Door's Manufacturing Method using SMC and Presses (Compression Process) for railway electric vehicles, subway and trains}

The present invention is for manufacturing entrance doors used in subways, trains, and trains by press, and more specifically, SMC sheets are made of SMC (Sheet Molding Compound) material in a mold (steel mold) installed in a hydraulic or pneumatic press. The present invention relates to a method of manufacturing an entrance door for an electric vehicle using SMC and a press, and a method of manufacturing an entrance door for an electric vehicle using SMC and a press that can reduce excessive manpower and time loss compared to the existing door manufacturing method by forming a molded product at high temperature and high pressure by operating a laying press.

Conventionally, a door panel used in subways, trains, trains, etc. was made of aluminum or stainless steel, and the door panel sandwiched between the inner and outer panels using honeycomb was manufactured and used, but the weight per product was large, and the door was operated accordingly. The system's capacity was also large, and cost increase was inevitable, and there was a problem that the inner plate and the outer plate were peeled off due to shaking during operation.

Looking at the prior art in this field, the method of forming a phenolic honeycomb sandwich panel for interior (hereinafter referred to as "prior art") of Korean Patent Publication No. 10-2004-0062816 (published date: 2004.07.09) uses FRP material. In the manufacturing method of forming a panel by,

A process of forming a mold in the shape and shape of the product to be made, and applying release wax to the mold surface to facilitate the demolding of the product to be molded later, and

A process of curing by applying a gel coat of a selected color to the mold surface to which the release wax is applied,

The process of curing by matching a mat made of glass fiber and phenol resin to the gel coat coating layer, and

After placing the honeycomb core on the surface of the mat, the resin-soaked glass fibers are matched on the honeycomb, and non-wet glass fibers are laminated on the upper surface thereof;

The process of laminating a release film, breather, and suction film on the surface of the non-wet glass fiber and then completely sealing it using a sealant,

A process of completely sealing the mold surface and the laminated sheet layer with a sealant, followed by vacuum suction compression, and

The step of forming a panel by curing at 80 to 120° C. after vacuum suction and compression,

The process of cutting the irregular border after demolding the molded panel from the mold,

Sending (polishing) treatment to remove the wax component from the surface of the cut panel, and

A method of manufacturing an FRP phenolic resin panel for interior use in which the panel is manufactured by inspecting and packaging the sent panel has been disclosed.

The prior art relates to a method for manufacturing a phenolic resin panel used in subways, trains, trains, and building doors.It suppresses toxic gases generated in the event of a fire, and the surface is clean during molding, and the desired color can be freely selected during manufacturing. It can be seen that it is about a method of manufacturing an FRP phenolic resin panel for interior use that makes the FRP (fiberglass reinforced plastic) panel molding simple.

The prior art thus achieved is ① a process in which the operator manually applies a gel coat of a selected color to the mold surface on which the release wax is applied and hardens, ② hardens by matching a mat made of glass fiber and phenolic resin to the gel coat coating layer. Process, ③ After placing the honeycomb core on the surface of the mat, match the glass fiber soaked with resin on the honeycomb and laminate the non-wet glass fiber on the upper surface of the honeycomb. ④ A release film, breather, and suction on the surface of the non-wet glass fiber. The process of completely sealing the film with a sealant after laminating the film, ⑤ the process of vacuum suction compression after completely sealing the mold surface and the laminated sheet layer with a sealant, ⑥ curing at 80~120℃ after vacuum suction compression to form a panel. Process, ⑦ The process of cutting irregular edges after removing the molded panel from the mold, ⑧ The process of sending (polishing) and paint coating to remove the wax component from the surface of the cut panel, ⑨Inspecting the sent panel , The panel is manufactured through the packaging process.

The prior art manufactured as described above is inconvenient in that the worker must manually perform the work.

In other words, in order to form the FRP panel, the working time is delayed because the working process is performed by placing a mat made of glass fiber and phenol resin on the gel coat coating layer applied on the mold until it reaches a predetermined thickness and then hardening it after impregnation. There is a problem in that the productivity of the product is not only lowered, but also the production amount is changed according to the skill level of the worker.

Republic of Korea Patent Publication No. 10-2004-0062816

The present invention is to solve the above problems, and a flame-retardant SMC (Sheet Molding Compound) sheet is placed on a hydraulic press using a press, and a mold (steel mold) is installed, and a hydraulic press is operated to form a molded product at high temperature and high pressure. As a CROSE MOLD type, the outer panel and the inner panel of the product are molded into a desired shape. At the same time, male and female shapes are made on the inner side of the inner and outer panels to be sandwiched, so that when the outer panel and the inner panel are mated together, they are naturally at that position. By allowing it to be assembled, it has superior strength of the sandwich panel compared to the existing molding method, and the exact bonding to the position of the bonding part is achieved. It relates to a method of manufacturing an entrance door for an electric vehicle using SMC and a press for the purpose of reducing weight (lightening weight), improving productivity, improving price competitiveness, and securing high-quality products, and the door.

The present invention is a solution for achieving the above object, in the method of manufacturing a flame-retardant SMC door panel using a press,

A press preparation step of heating heat at 130° C. to 150° C. in a press mold consisting of one or two sets of outer panels or inner panel shapes of the entrance door;

Applying a releasing agent to the inside of the press mold heated at 130°C to 150°C so that the molded product is smoothly demolded;

Cutting the flame-retardant SMC sheet according to the product weight and mold shape, and installing the flame-retardant SMC sheet in a heated press mold;

Demolding the molded inner panel or outer panel by pressing and curing the flame-retardant SMC sheet installed in the press mold with a predetermined pressure;

Cooling the molded panel using a cooling jig for a predetermined period of time to maintain the flatness of the molded panel surface;

A sandwich process of fixing and installing a core prepared between the molded inner panel and the outer panel with an adhesive;

It characterized in that it comprises a; step of forming an SMC electric train entrance door by placing the core is sandwiched and the panel combined with the inner panel and the outer panel on a press and pressurized for 10 to 50 minutes.

The core sandwiched between the inner panel and the outer panel is characterized in that it is made of any one of paper, aluminum, and phenolic resin honeycomb.

The adhesive for fixing the core is characterized in that the adhesive film or foam type bond.

The inner panel and the outer panel forming the entrance door of the electric vehicle are characterized in that a protruding concave-convex coupling portion is formed on an inner surface corresponding to each other.

The inner panel and the outer panel forming the entrance door of the electric vehicle are characterized in that the groove is formed so that the connecting member is fitted to the inner surface corresponding to each other.

The present invention as described above uses SMC and press to reduce excessive manpower and time loss compared to the existing product manufacturing method by molding the door panel into a mold installed in a hydraulic or pneumatic press made of SMC (Sheet Molding Compound) material. It is possible to provide a method of manufacturing entrance doors for electric vehicles and its panels.

The present invention has an existing flame-retardant performance and weight reduction by press-molding the door of an SMC (Sheet Molding Compound) material, thereby reducing weight, as well as freely implementing the shape and pattern of the door, and has the effect of increasing productivity due to a short molding cycle. .

In addition, even if the operation system of the door device does not use an existing expensive high-performance device, there is an effect that it is possible to use it stably as a low-cost system.

In particular, the present invention has the effect of being able to produce high-quality products in various patterns with a small number of personnel when manufacturing entrance doors for electric vehicles and trains.

1 is a diagram showing a manufacturing process diagram of an entrance door for a train using the SMC of the present invention,
Figure 2 shows the inner panel and the outer panel of the entrance door of the train according to the present invention,
3 is an exemplary view showing the entrance door of a train according to the present invention,
Figure 4 is a cross-sectional view of the present invention taken along line AA of Figure 3,
5 and 6 are diagrams illustrating an electric vehicle entrance door coupling structure according to another embodiment of the present invention.

Hereinafter, an embodiment of the present invention will be described in detail.

The flame-retardant SMC (SHEET MOULDING COMPOUND) used in the present invention is a fiber-reinforced plastic and is used as a sheet in a semi-gel (GEL) state made by impregnating glass fiber with a flame-retardant resin flame-retardant additive.

Flame-retardant SMC has excellent moldability, excellent smoothness and dimensional stability after molding, and makes it possible to produce product stability, beautiful surface, and complex shapes through a molding method using a cross mold (CROSE MOLD) mold when molding a molded product.

In addition, the present invention has the advantage of having good dimensional stability and precision, excellent part reproducibility and high productivity due to short molding cycles by molding a molded product with a press mold using a flame-retardant SMC sheet.

In addition, since the entrance door of the electric vehicle using the flame-retardant SMC sheet of the present invention can be applied to the rear or front ribs (RIB/strength) and insert nuts or bolts, there is no need to assemble brackets/tab sheets/patches, etc. It is possible to apply various textures by putting it in, and the flame-retardant SMC sheet can also be molded into the color desired by the consumer.

The method for manufacturing an electric vehicle entrance door according to the present invention as described above,

Step 1: Press mold heating and release agent application step

Heat is heated at 130° C. to 150° C. in a press mold having the shape of the train entrance door 10, the inner panel 11 or the outer panel 12.

At this time, there is a passage through which oil or hot water moves inside the mold, so the temperature of the mold itself rises as a whole.

In addition, the mold can be designed by manually demolding according to the product shape and demoulding conditions.

The press mold configured as described above is heated to a temperature of 130 to 150°C to prepare press molding.

In addition, in the mold, a release agent is applied to the surface of the mold heated to the above temperature so that the molded product can be removed smoothly.

The press mold used in this process is prepared in one or two sets. That is, when the mold is one set, the grooves of the coupling portions formed on the inner panel 11 and the outer panel 12 of the train door 10 are formed in the same concave shape, so that the inner panel 11 and the outer panel 12 ), the inner panel 11 and the outer panel 12 can be molded into one press mold so that they can be combined using a connecting member when combining).

In addition, in the case of two sets of press molds, each press mold is formed so that the inner panel 11 and the outer panel 12 can be respectively formed so that the inner and outer panels can be respectively formed.

When the press mold is two sets, a press mold capable of forming a panel such that a groove is formed on the inner surface of one of the inner panel 11 and the outer panel 12, and a protrusion that fits into the groove is formed on the other inner surface. Prepare.

Second process: step of installing the flame-retardant SMC sheet to the press mold

The press mold prepared in the first process is heated to a predetermined temperature, the flame-retardant SMC sheet is cut to fit the product weight and the mold shape, and the flame-retardant SMC sheet is installed in the heated press mold.

At this time, the SMC sheet is impregnated with a flame-retardant additive to form a sheet in a semi-gel (GEL) state, so that it can penetrate evenly into the mold when pressed.

In addition, the SMC sheet is charged after cutting by measuring the weight. At this time, when pressing using a press, adjust and set the pressing pressure in consideration of the size and thickness of the product.

3rd process: SMC sheet pressurized and panel forming step

The flame-retardant SMC sheet installed in the mold is pressed through a press adjusted to a predetermined pressure, but at this time, the product is cured by holding the sheet at a temperature of 130 to 150° C. for 10 to 50 minutes. The pressurization temperature and pressurization time of the press are adjusted according to the thickness of the panel to be molded, and if pressurized at 130℃ for less than 10 minutes, the amount that cannot be molded occurs. It is preferable to carry out between 10 to 50 minutes at a temperature of 130 to 150 °C because the problem occurs.

In this process, the panel formed by pressing the SMC sheet with a press may be an inner panel or an outer panel of an electric vehicle.

That is, when forming the inner panel 11, the press mold is formed by installing the inner panel forming mold, and when forming the outer panel 12, the press mold is installed and the outer panel forming mold is installed to manufacture the panel.

At this time, a plurality of protruding concave-convex coupling portions 15 are formed inside the inner panel 11 or the outer panel 12 to be molded, respectively, so that the coupling portion 15 when the inner panel 11 and the outer panel 12 are joined later. Will be used as.

In addition, the protrusion size of the coupling portion 15 is formed to be a size that can be embraced when the thickness of the core 13 installed between the inner panel 11 and the outer panel 12 is coupled.

That is, the coupling portion 15 of the inner panel 11 and the outer panel 12 is sized so that both sides of the core 13 installed inside the inner panel 11 and the outer panel 12 are in close contact with each other to be fixed. Is formed. In the case where the plurality of protruding concave-convex coupling portions 15 are formed on the inner panel 11 or the outer panel 12 formed as described above, the inner panel and the outer panel are formed in two sets of presses, respectively.

In addition, when the mold is used in one set in this process, the inner panel and the outer panel are formed in the same shape in one mold, and the coupling part is formed in a concave shape, and when combined, the concave groove formed so as to correspond to the inner surface of the inner panel 11 and the outer panel 12 The connecting member 16 is inserted into and coupled.

In the present invention, when the mold is used as a set, there is an advantage that the inner panel 11 and the outer panel 12 can be molded into one mold.

Process 4: demoulding and cooling of molded products

In the third process, the inner panel 11 or the outer panel 12 molded at high temperature and high pressure is demolded from the mold. At this time, a hydraulic pin, an air ejection, or a manual operation is used for the demolding.

If necessary, the demolded product is cooled using a cooling jig for a certain period of time to maintain flatness.

In addition, by-products (burr/BURR) generated during molding are removed using an appropriate tool.

Step 5: installing a core between the inner panel and the outer panel made of SMC material

The prepared core 13 between the molded inner panel 11 and the outer panel 12 is fixedly installed with an adhesive 14 to form a sandwich panel.

The sandwiched core is formed so that one side corresponds to the inner surface of the inner panel 11 and the other side corresponds to the inner surface of the outer panel, and then the both sides of the core 13, the inner panel inner surface, and the outer panel inner surface are glued ( 14).

In this case, a concave groove may be formed in both the case where the inner surface of the inner panel and the outer panel is formed with irregularities and the corresponding portions of the inner panel and the outer panel.

Therefore, when the inner panel and the outer panel are formed with irregularities, the inner panel and the outer panel are matched to each other, and when they are combined, the inner panel and the inner surface of the inner panel are combined so that the irregularities of the inner panel are fitted with each other.

In addition, if the same shape of grooves are formed in the corresponding portions of the inner panel and the outer panel, the connecting member 16 is inserted into the groove on either side of the inner panel and the outer panel, and then the inner panel and the outer panel are combined. ) Is firmly fixed.

The core sandwiched between the inner panel and the outer panel is made of honeycomb, but may be formed of any one of paper, aluminum, and phenolic resin.

In addition, the adhesive 14 is applied to the inner panel 11 or the outer panel 12, and the inner panel or outer panel 12 that is placed on the other side after applying an adhesive film or foam bond on the inner surface and the irregularities or grooves formed on the inner surface thereof. After applying an adhesive film or foam type bond on the inner surface of the panel, the core 13, the inner panel 11, and the outer panel 12 are combined to install the core.

At this time, the inner panel and the outer panel sandwich the core so that the coupling portions formed on one side of the inner surface correspond to each other.

Step 6: Forming (manufacturing) the entrance door of the train by pressing the panel with the core sandwiched on it with a press

The core 13 is sandwiched between the inner panel 11 and the outer panel 12 forming the entrance door of the train, and the panel combined with the inner panel and the outer panel is put on a press and pressurized for 10 to 50 minutes. To form the train entrance door (10).

Pressing the sandwiched panel for 10 to 50 minutes with a press is performed by pressing for a minimum of 10 minutes to a maximum of 50 minutes depending on the thickness of the product manufactured by the door 10, and the core 13 and the inner and outer panels 11 and 12 are pressed. ) And the concave-convex coupling portion 15 or the coupling portion 15 formed by inserting the connecting member 16 into the groove, and at the same time, it is pressed with a press to prevent the phenomenon of being lifted on the surface to be bonded to each other.

Step 7: Process and paint the exterior of the molded train door

The entrance door 10 adhered by pressing with a press assembles accessories and paints as necessary to form the entrance door of the finished product.

In addition, the entrance door 10 formed as a finished product is formed to be suitable for use by installing handles, rails, glass, and cushion members.

At this time, the entrance door 10 adhered by pressing with a press is provided with a cushion member 17 on the part where the door and the door are in corresponding contact, and the cushion member 17 is an aluminum member made of light metal on the cushion member contact surface 18. 2 types of materials can be used by installing.

That is, the cushion member contact surface 18 may be formed of an aluminum material, and the rear portion thereof may be integrally formed with a cushion member made of any one of rubber synthetic resin to be installed on the entrance door.

At this time, the connection member fitted into the groove is not necessarily limited to aluminum, and a connection member made of light metal may be used by selecting one of several materials.

In addition, in manufacturing the entrance door of the electric vehicle according to the present invention, the connecting member 16 may be formed of an aluminum material in the concave portion formed on the inner panel and the outer panel to form a coupling portion 15.

Hereinafter, the present invention will be described based on the true drawings of the present invention.

1 is a diagram showing a manufacturing process diagram of an entrance door for a train using the SMC of the present invention, ① heating a press mold and applying a release agent → ② installing a flame-retardant SMC sheet in a press mold → ③ pressing an SMC sheet with a press and forming a panel → ④ Demolition and molding product cooling step → ⑤ Installing the core between the inner and outer panels of SMC material → ⑥ Pressing the sandwiched panel with the core to form (manufacture) the entrance door of the train → ⑦ Open the molded door It is possible to manufacture an entrance door for a train or train in the process sequence of processing, painting the exterior surface, and installing the cushion member.

The entrance door 10 of the train or train of the present invention molded in this way is made of SMC (Sheet Molding Compound) material, so that it has flame retardancy and at the same time reduces the weight of the door (door), so that the friction caused by the weight when the door 10 is operated. It has the effect of preventing noise by reducing the coefficient and making it operate smoothly.

In addition, the present invention forms the inner panel 11 or the outer panel 12 by pressing the SMC sheet having flame-retardant properties to form the press mold in various patterns and press it, so that the shape and pattern of the door 10 are free and molded. The short cycle has the effect of increasing productivity.

2 is a view showing the inner and outer panels of the entrance door of the electric vehicle according to the present invention. By pressing and molding using SMC sheet, it is possible to shorten the manufacturing time with various patterns compared to the conventional manufacturing method.

In the present invention, a flame-retardant SMC sheet is placed on a heated press mold and then pressurized to form the inner panel 11 and the outer panel 12 in the same manner.

At this time, the thickness of the inner panel 11 and the outer panel 12 to be molded is formed by placing several sheets of SMC on the press mold to form the thickness to be molded.

The SMC sheet placed on the press mold is impregnated with a flame retardant additive to form a sheet in a semi-gel (GEL) state, so that it can evenly permeate the mold when pressing.

The flame-retardant SMC sheet placed on the mold is pressed with a press, but at this time, the product is cured by holding it at a temperature of 130 to 150° C. for 10 to 50 minutes.

In addition, a plurality of concave-convex coupling portions are formed at positions corresponding to each other inside the inner panel 11 and the outer panel 12 formed by pressing, and the coupling portion 15 is coupled and fixed while sandwiching the core 13.

The inner panel 11 and the outer panel 12, which are molded using the SMC material of the present invention, are formed to form patterns and molds to be expressed and press them to express various patterns.

3 is an exemplary view showing a front view of an entrance door for a train according to the present invention, and FIG. 4 is a cross-sectional view taken along line A-A of FIG. 3.

In the present invention, as can be seen in FIG. 4, the inner panel 11 and the outer panel 12 are formed using a flame-retardant SMC sheet when forming the train entrance door 10 or the train entrance door. After fixing the core 13 between the panels 12 with an adhesive, the door is formed by pressing it with a press.

The core 13 sandwiched between the inner panel 11 and the outer panel 12 of the present invention is firmly adhered and pressed by the adhesive 14 applied to the inner surface of the inner panel 11 and the outer panel 12. It is bonded more firmly by the press that is used.

The core 13 sandwiched between the inner panel 11 and the outer panel 12 is formed in a honeycomb shape, and may be formed of paper, aluminum, phenolic resin, or the like.

In addition, both sides of the honeycomb to be sandwiched are formed to correspond to the shapes of the corresponding inner panel 11 and outer panel 12 so as to have more adhesion when sandwiching.

In this way, the present invention uses a press to form a press at a high temperature and high pressure using a flame-retardant SMC (Sheet Molding Compound) sheet to reduce the weight of the door 10, improve productivity, improve price competitiveness, and improve quality.

5 and 6 are diagrams showing the connection structure of an electric vehicle entrance door according to another embodiment of the present invention. An aluminum member by forming the same groove on both sides of the coupling portion 15 formed inside the inner panel 11 and the outer panel 12 By inserting the connecting member 16 made of, the coupling portion 15 is formed.

In this way, if the coupling part 15 formed on the inner side of the inner panel 11 and the outer panel 12 is formed in the same groove on both sides, a separate connecting member is required, but the mold can form the inner and outer panels with only one set. Therefore, the mold manufacturing cost can be reduced, and there is an advantage in that it is possible to continuously mold the inner and outer panels since there is no need to replace the mold in the press to form the outer panel while forming the inner panel.

In addition, as shown in Fig. 6 of the present invention, if the cushion member contact surface 18 of the cushion member 17 where the entrance door of the train or train is in contact with each other is made of aluminum and the rest of the cushion member is made of rubber, the durability of the cushion member is improved. In use, it prevents the contact surface from being cut off.

In the present invention, the SMC (Sheet Molding Compound) material is used to form an SMC sheet on a mold (steel mold) installed in a hydraulic or pneumatic press to form a molded product at high temperature and high pressure. Compared to the manufacturing method, it has the advantage of reducing excessive manpower and time loss, and allowing the color and design of the door to be freely made.

10: Entrance door 11: Internal panel
12: outer panel, 13: core
14: adhesive 15: bonding portion
16: connection member 17: cushion member
18: door contact surface

Claims (9)

In the method of manufacturing a flame-retardant SMC door panel using a press,
A press preparation step of heating heat to 130° C. to 150° C. in a pair of press molds formed in the shape of an outer panel or an inner panel of an electric vehicle entrance door;
Applying a releasing agent to the inside of the press mold heated to 130° C. to 150° C. so that the molded product is smoothly demolded;
Cutting the flame-retardant SMC sheet according to the product weight and mold shape, impregnating the flame-retardant SMC sheet with a flame-retardant additive to form a sheet in a semi-gel state, and installing the flame-retardant SMC sheet in a heated press mold;
Demolding the molded inner panel or outer panel by pressing and curing the flame-retardant SMC sheet installed in the press mold with a predetermined pressure;
Cooling the molded panel using a cooling jig for a predetermined period of time to maintain the flatness of the molded panel surface;
A sandwich process of fixing and installing the core prepared between the molded inner panel and the outer panel with an adhesive film or a foamed bond adhesive;
And a step of forming an SMC train door by sandwiching the core and forming a plurality of coupling portions on the surfaces corresponding to the inner panel and the outer panel, placing the combined panel on a press and pressing for 10 to 50 minutes to form an SMC train door. A method for manufacturing entrance doors for electric vehicles using SMC and press. The method of claim 1,
The core sandwiched between the inner panel and the outer panel is made of any one of paper, aluminum, and phenolic resin honeycomb. delete An entrance door for an electric vehicle using SMC and a press, characterized in that manufactured by the manufacturing method of claim 1. The method of claim 4,
An entrance door for an electric vehicle using an SMC and a press, characterized in that the inner panel and the outer panel forming the electric vehicle entrance door are formed with a protruding concave-convex portion on an inner surface corresponding to each other. delete The method of claim 4,
An entrance door for an electric vehicle using an SMC and a press, characterized in that the coupling part formed inside the inner panel and the outer panel is made of the same upper and lower grooves, and a connecting member is inserted into the groove to constitute a coupling part. The method of claim 4,
An electric vehicle entrance door using an SMC and a press, characterized in that a cushion member is installed at a portion that contacts each other, and the cushion member contact surface of the cushion member is made of aluminum. The method of claim 7,
The connecting member fitted in the groove is an entrance door for an electric vehicle using SMC and a press, characterized in that it is made of light metal made of aluminum.

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