技术领域technical field
本发明涉及一种轨道交通车辆用复合材料联系枕梁及其成型方法，属于轨道交通用复合材料设计及工艺技术领域。The invention relates to a composite material connecting bolster for rail transit vehicles and a forming method thereof, and belongs to the technical field of composite material design and technology for rail transit.
背景技术Background technique
联系枕梁位于转向架与车厢中间，枕梁的功能是连接车体和转向架，主要承受和传递车体与转向架的力。枕梁通过螺栓与车体连接，通过空气弹簧、牵引装置与构架相连，抗侧滚扭杆、抗蛇行减振器等都通过相应的支座和螺栓与枕梁和构架连接。同时枕梁在需要作为一个压力容器，存放用于制动的压缩空气。现有转向架联系枕梁是采用金属材料制备的，其本身重量超过500kg，由于金属材质刚性大，在运行中噪音也相对较大。The contact bolster is located between the bogie and the carriage. The function of the bolster is to connect the car body and the bogie, and mainly bear and transmit the force of the car body and the bogie. The corbel is connected to the car body through bolts, and connected to the frame through air springs and traction devices. The anti-roll torsion bar and anti-snake shock absorber are all connected to the corbel and frame through corresponding supports and bolts. At the same time, the corbel needs to be used as a pressure vessel to store compressed air for braking. The existing bogie connecting bolster is made of metal material, and its own weight exceeds 500kg. Due to the high rigidity of the metal material, the noise during operation is relatively large.
发明内容Contents of the invention
本发明的技术解决问题是：克服现有技术的不足，提出一种轨道交通车辆用复合材料联系枕梁及其成型方法。由于联系枕梁相对尺寸较大，既需要承受转向架和车体的载荷，又需要承受内压，因此采用复合材料制备联系枕梁，采用强度高、力学性能好的碳纤维/环氧树脂复合材料。通过结构设计来满足其力学性能要求，通过成型工艺的创新，解决气室成型困难，克服气室内壁边缘的应力集中问题，本发明结构设计与成型工艺相结合，实现了复合材料联系枕梁的复合材料轻量化。The technical problem of the present invention is: to overcome the deficiencies of the prior art, and to propose a composite material contact bolster for rail transit vehicles and a forming method thereof. Due to the relatively large size of the contact bolster, it needs to bear the load of the bogie and car body, as well as the internal pressure, so the composite material is used to prepare the contact bolster, and the carbon fiber/epoxy resin composite material with high strength and good mechanical properties is used . Through structural design to meet its mechanical performance requirements, through the innovation of forming technology, it solves the difficulty of forming the air chamber and overcomes the problem of stress concentration on the edge of the inner wall of the air. Composite materials are lightweight.
本发明的技术解决方案是：Technical solution of the present invention is:
一种轨道交通车辆用复合材料联系枕梁，该联系枕梁包括上壁板、下壁板和气室，气室包括若干个结构单元排列组成的主结构和包覆层，包覆层缠绕在主结构外，气室位于上壁板和下壁板之间；A composite material connecting corbel for a rail transit vehicle. The connecting corbel includes an upper wall plate, a lower wall plate and an air chamber. The air chamber includes a main structure composed of several structural units and a cladding layer. Outside the structure, the air chamber is located between the upper wall and the lower wall;
结构单元为带有顶端通孔、底端通孔和中间通孔的棱柱(单元气室)，棱柱(单元气室)的顶端通孔的内径小于中间通孔，棱柱(单元气室)的底端通孔的内径小于中间通孔，棱柱(单元气室)的顶端通孔的内径与棱柱的底端通孔的内径相同；The structural unit is a prism (unit air chamber) with a top through hole, a bottom end through hole and a middle through hole, the inner diameter of the top through hole of the prism (unit air chamber) is smaller than the middle through hole, and the bottom of the prism (unit air chamber) The inner diameter of the end through hole is smaller than the middle through hole, and the inner diameter of the top through hole of the prism (unit air chamber) is the same as the inner diameter of the bottom through hole of the prism;
相邻的结构单元之间通过环氧胶黏剂粘接而成；Adjacent structural units are bonded by epoxy adhesive;
相邻的结构单元共用的侧壁上带有通孔，该通孔用于连同相邻的结构单元，通孔的形状为圆形，通孔的直径为There is a through hole on the shared side wall of the adjacent structural units, and the through hole is used to connect with the adjacent structural units. The shape of the through hole is circular, and the diameter of the through hole is
结构单元外轮廓的横截面为三角形、正方形、长方形、五边形、六边形中的一种或两种以上的组合；The cross-section of the outer contour of the structural unit is one of triangle, square, rectangle, pentagon, hexagon or a combination of two or more;
所述上壁板的厚度为3-20mm；The thickness of the upper wall plate is 3-20mm;
所述下壁板的厚度为3-20mm；The thickness of the lower wall plate is 3-20mm;
结构单元带有中间通孔部分的壁厚为2～15mm；The wall thickness of the structural unit with the middle through hole is 2-15mm;
包覆层的厚度为5-15mm；The thickness of the cladding layer is 5-15mm;
结构单元外轮廓的边长不超过1000mm，优选200～300mm，结构单元的高度视产品要求而定；The side length of the outer contour of the structural unit does not exceed 1000mm, preferably 200-300mm, and the height of the structural unit depends on the product requirements;
联系枕梁的材料为碳纤维复合材料；碳纤维复合材料的树脂体系为无卤阻燃热固性树脂体系，优选无卤阻燃环氧树脂体系，碳纤维采用T300级、T700级、T800级碳纤维，复合材料阻燃性能满足EN45545-2标准的要求；The material connected with the corbel is carbon fiber composite material; the resin system of carbon fiber composite material is a halogen-free flame-retardant thermosetting resin system, preferably a halogen-free flame-retardant epoxy resin system, and the carbon fiber adopts T300, T700, and T800 The combustion performance meets the requirements of the EN45545-2 standard;
包覆层采用单向碳纤维预浸料；The cladding layer is made of unidirectional carbon fiber prepreg;
一种轨道交通车辆用复合材料联系枕梁的成型方法，该方法的步骤包括：A forming method for rail transit vehicles using composite materials to contact corbels, the steps of the method comprising:
(1)制备结构单元的模具，结构单元的模具的外形面与结构单元的内形面一致，制备联系枕梁的模具，联系枕梁的模具的内形面与联系枕梁的外形面一致；(1) prepare the mold of structural unit, the profile surface of the mold of structural unit is consistent with the internal profile surface of structural unit, prepare the mold of contact corbel, the internal profile surface of the mold of contact corbel is consistent with the profile surface of contact corbel;
(2)使用步骤(1)制备的结构单元的模具成型结构单元，成型时选用无卤阻燃热固性树脂预浸料，优选610B无卤阻燃环氧树脂预浸料，面密度100-200g/m2，优选采用单向碳纤维预浸料，不同预浸料铺层间搭接部位相对错开，成型完成后进行固化，固化温度为130-150℃，固化时间为1-2h，固化完成后得到结构单元；使用结构单元的模具成型结构单元时，先在结构单元的模具上铺放表面膜，然后再铺放碳纤维无卤阻燃环氧树脂单向预浸料；表面膜面密度为200-400g/m2，树脂采用中温固化环氧树脂，树脂体系能够在温度为130-150℃条件下1-3h内完成固化；(2) Use the mold of the structural unit prepared in step (1) to form the structural unit. When molding, select a halogen-free flame-retardant thermosetting resin prepreg, preferably a 610B halogen-free flame-retardant epoxy resin prepreg, with an area density of 100-200g/ m2 , it is preferred to use unidirectional carbon fiber prepregs, and the overlapping parts between different prepregs are relatively staggered. After the molding is completed, it is cured. The curing temperature is 130-150 ° C, and the curing time is 1-2 hours. After the curing is completed, the Structural unit; when using the mold of the structural unit to form the structural unit, first lay the surface film on the mold of the structural unit, and then lay the carbon fiber halogen-free flame-retardant epoxy resin unidirectional prepreg; the surface density of the surface film is 200- 400g/m2 , the resin adopts medium temperature curing epoxy resin, and the resin system can be cured within 1-3 hours at a temperature of 130-150°C;
(3)在步骤(2)得到的结构单元需要与其他结构单元连接的侧壁打孔；(3) The structural unit obtained in step (2) needs to be perforated with the side wall connected with other structural units;
(4)将步骤(3)打孔后的结构单元采用环氧胶黏剂进行粘接，得到主结构；(4) bonding the structural units after punching in step (3) with an epoxy adhesive to obtain the main structure;
(5)在步骤(4)得到的主结构外采用碳纤维无卤阻燃环氧树脂单向预浸料进行缠绕成型，形成包覆层，得到气室；(5) outside the main structure obtained in step (4), the carbon fiber halogen-free flame-retardant epoxy resin unidirectional prepreg is used for winding molding to form a cladding layer to obtain an air chamber;
(6)在步骤(1)制备的联系枕梁的模具上铺放碳纤维无卤阻燃环氧树脂预浸料，形成下壁板层，并进行抽空压实(不进行固化)；(6) Lay carbon fiber halogen-free flame-retardant epoxy resin prepreg on the mold of contact corbel prepared in step (1) to form the lower wall plate layer, and carry out evacuation and compaction (not curing);
(7)在步骤(6)得到的未固化的下壁板层上面铺放中温固化胶膜，在中温固化胶膜上放置步骤(5)得到的气室；中温固化胶膜面密度为200-300g/m2，能够在温度为130-150℃条件下1-3h内完成固化；(7) Lay the medium-temperature curing adhesive film on the uncured lower wall plate layer that step (6) obtains, and place the air chamber that step (5) obtains on the intermediate-temperature curing adhesive film; The surface density of the intermediate-temperature curing adhesive film is 200- 300g/m2 , can be cured within 1-3h at a temperature of 130-150°C;
(8)在步骤(7)的气室上上面铺放中温固化胶膜，在中温固化胶膜上铺放碳纤维无卤阻燃环氧树脂预浸料，形成上壁板层，得到组合体；(8) laying a medium-temperature curing adhesive film on the air chamber of step (7), and laying a carbon fiber halogen-free flame-retardant epoxy resin prepreg on the medium-temperature curing adhesive film to form an upper wall layer to obtain an assembly;
(9)对步骤(8)得到组合体进行热压罐固化成型，得到复合材料联系枕梁，固化压力为0.5～0.8MPa，固化温度130-150℃，固化时间为1～3h。(9) Carry out autoclave curing molding on the assembly obtained in step (8) to obtain a composite material contact bolster. The curing pressure is 0.5-0.8 MPa, the curing temperature is 130-150° C., and the curing time is 1-3 hours.
本发明的有益效果为：The beneficial effects of the present invention are:
(1)本发明提供的一种轨道交通车辆用复合材料联系枕梁的结构及其成型方法，采用碳纤维复合材料，具有质量轻、强度高、耐疲劳、噪音小等优点。枕梁可以承受6bar的压力，同时可以承受16bar的水压试验。(1) The structure and forming method of a composite material contact bolster for a rail transit vehicle provided by the present invention adopts carbon fiber composite material, which has the advantages of light weight, high strength, fatigue resistance, and low noise. The corbel can withstand a pressure of 6bar and can withstand a hydrostatic test of 16bar.
(2)本发明提供的枕梁的内部结构作为气室使用，整个气室由多个结构单元气室组成，每个单元气室壁可以作为支撑结构，支撑来自转向架与车厢的载荷。单元气室的底部采用局部加强的方式进行处理，可以避免应力集中带来的影响。(2) The internal structure of the bolster provided by the present invention is used as an air chamber, and the entire air chamber is composed of a plurality of structural unit air chambers, and the wall of each unit air chamber can be used as a supporting structure to support the load from the bogie and the carriage. The bottom of the unit air chamber is treated with local reinforcement, which can avoid the influence of stress concentration.
(3)本发明成型工艺采用，先单独制造单元气室，后粘接的方式，降低了制造难度，提高制造效率，同时有利于发挥碳纤维复合材料性能与方向有关的特点。每个结构单元气室成型过程中，先铺放一层表面膜，可以提高复合材料的气密性，避免由于微缺陷漏气带来的影响。(3) The molding process of the present invention adopts the method of manufacturing the unit air chamber separately first, and then bonding, which reduces the manufacturing difficulty, improves the manufacturing efficiency, and is conducive to the performance and direction of the carbon fiber composite material. During the forming process of the air chamber of each structural unit, a layer of surface film is laid first, which can improve the airtightness of the composite material and avoid the influence of air leakage due to micro-defects.
(4)在碳纤维复合材料单元气室粘接一体后，采用了缠绕的方式对整体气室进行了缠绕补强，可大幅度提高气室承受内压的能力，降低气室的壁厚，有利于整体减重。(4) After the carbon fiber composite material unit air chamber is bonded together, the whole air chamber is wound and reinforced by winding, which can greatly improve the ability of the air chamber to withstand internal pressure and reduce the wall thickness of the air chamber. Good for overall weight loss.
(5)本发明提供了一种轨道交通车辆用复合材料联系枕梁的结构及其成型方法，属于复合材料结构成型技术领域。所述轨道交通车辆车体裙板结构，包括复合材料上壁板、复合材料下壁板、复合材料整体骨架、抗侧滚扭杆座以及金属镶嵌件组成。上壁板、下壁板及整体骨架之间采用胶结方式连接。整体骨架与上下壁板间采用胶接铆接相结合的方式连接。通过中空的结构设计，可以是联系枕梁作为一个压力容器使用的同时，具有较高的抗压承载能力。可承受6bar的工作压力。采用单元格组合的设计，可以提高整体的刚度，提高枕梁的承载能力和承压能力。每个单元格采打孔连通，可以使枕梁起到很好压力容器的作用，枕梁的内腔容积可达200L。该设计采用采用复合材料及空心结构，可以使枕梁的重量相比金属材料降低30％以上，满足轨道交通车辆的轻量化的要求。(5) The present invention provides a composite material contact bolster structure for rail transit vehicles and a forming method thereof, belonging to the technical field of composite material structure forming. The body skirt structure of the rail transit vehicle comprises an upper wall plate made of composite material, a lower wall plate made of composite material, an integral framework made of composite material, anti-rolling torsion bar seats and metal inserts. The upper wall plate, the lower wall plate and the overall skeleton are connected by cementing. The overall skeleton and the upper and lower wall panels are connected by a combination of glue and riveting. Through the hollow structural design, it can be used as a pressure vessel in connection with the corbel beam, and at the same time have a high compressive bearing capacity. Can withstand 6bar working pressure. The design of unit combination can increase the overall rigidity and improve the bearing capacity and pressure bearing capacity of the corbel. Each cell is connected by punching holes, which can make the corbel beam play a good role as a pressure vessel, and the inner cavity volume of the corbel beam can reach 200L. The design adopts composite materials and hollow structures, which can reduce the weight of the corbel by more than 30% compared with metal materials, and meet the requirements for light weight of rail transit vehicles.
附图说明Description of drawings
图1为实施例1中主结构的主视图；Fig. 1 is the front view of main structure in embodiment 1;
图2为实施例1中主结构的俯视图；Fig. 2 is the top view of main structure in embodiment 1;
图3为实施例1中主结构的左视图；Fig. 3 is the left view of main structure in embodiment 1;
图4为实施例1中结构单元的示意图；Fig. 4 is the schematic diagram of structural unit in embodiment 1;
图5为图4的A-A剖视图。FIG. 5 is a cross-sectional view along line A-A of FIG. 4 .
具体实施方式Detailed ways
一种轨道交通车辆用复合材料联系枕梁的结构，包括整个枕梁采用无卤阻燃碳纤维复合材料制备而成，分为上壁板、下壁板、整体骨架连接而成。整体骨架分为内支撑骨架、外轮廓骨架。整体骨架与上下壁板连接形成气室，内骨架将气室分割为多个小的气室单元。小的气室单元之间通过打孔互相连通，可以作为承压容器。The utility model relates to a structure in which a composite material is used to connect a corbel for a rail transit vehicle, including that the whole corbel is made of a halogen-free flame-retardant carbon fiber composite material, and is divided into an upper wall plate, a lower wall plate, and an integral skeleton connected. The overall skeleton is divided into inner support skeleton and outer contour skeleton. The overall skeleton is connected with the upper and lower wall panels to form an air chamber, and the inner skeleton divides the air chamber into multiple small air chamber units. The small gas chamber units communicate with each other through perforations and can be used as pressure containers.
组成支撑骨架的将整个气室分割为不同等高的气室单元，气室截面形状可以为三角形、正方形、长方形、五边形、六边形等。可根据实际需求进行设计。The supporting frame divides the entire air chamber into air chamber units of different heights, and the cross-sectional shape of the air chamber can be triangular, square, rectangular, pentagonal, hexagonal, etc. Can be designed according to actual needs.
联系枕梁的内部作为压力容器的小气室单元先单独成型，做等高度气室单元。每个气室单元的侧壁互相粘接形成枕梁的支撑骨架。每个气室单元的侧壁与底部连接部位进行倒角设计或局部补强处理。气室结构单元做好后，等高度方向互相粘结，形成中间骨架结构，在中间骨架结构部分采用缠绕方式进行缠绕补强，成型缠绕补强层，再铺放上下盖板，最后一体固化成型。The small air chamber unit connected with the inside of the corbel as a pressure vessel is formed separately first to make an equal-height air chamber unit. The side walls of each air cell unit are bonded to each other to form the supporting skeleton of the corbel. The connection between the side wall and the bottom of each air chamber unit is chamfered or partially reinforced. After the air chamber structure unit is completed, it is bonded to each other in the same height direction to form an intermediate skeleton structure. The intermediate skeleton structure is wound and reinforced by winding, forming a winding reinforcement layer, and then laying the upper and lower cover plates, and finally solidified and formed. .
所述上下壁板的厚度为5～20mm。支撑骨架包括轮廓壁板、内支撑壁板，外轮廓壁板厚度在16～30mm，局部加强区厚度在20～30mm，内支撑骨架的部分，由等高度复合材料盒子粘接而成，盒子的壁厚为2～15mm，盒子的尺寸可根据产品尺寸调整，每个盒子的宽度不超过500mm，长度不过1000mm。每个盒子的长宽优选200～300mm，高度视产品要求而定。The thickness of the upper and lower wall panels is 5-20mm. The supporting frame includes contour wall panels and inner support wall panels. The thickness of the outer profile wall panels is 16-30mm, and the thickness of the local reinforcement area is 20-30mm. The wall thickness is 2-15mm, and the size of the box can be adjusted according to the size of the product. The width of each box should not exceed 500mm, and the length should not exceed 1000mm. The length and width of each box are preferably 200-300 mm, and the height depends on product requirements.
互相粘接一起的立方体的通过打孔连通，孔的尺寸小于等于大于等于开孔位置优选壁板的中心。Cubes bonded to each other are connected by punching holes, and the size of the holes is less than or equal to greater or equal to The opening position is preferably the center of the wall panel.
每个方形结构单元底部与采用大的倒角设计或复合材料局部补强，避免应力集中。The bottom of each square structural unit adopts a large chamfer design or local reinforcement of composite materials to avoid stress concentration.
复合材料采用无卤阻燃热固性树脂体系，纤维采用T300级、T700级、T800级碳纤维，复合材料阻燃性能可以满足EN45545-2标准的要求。The composite material adopts a halogen-free flame-retardant thermosetting resin system, and the fibers use T300, T700, and T800 carbon fibers. The flame-retardant performance of the composite material can meet the requirements of the EN45545-2 standard.
复合材料方形盒子连接好后，缠绕层的厚度为0.5～5mm，缠绕层采用单向碳纤维预浸料。After the square boxes of composite materials are connected, the thickness of the winding layer is 0.5-5 mm, and the winding layer is made of unidirectional carbon fiber prepreg.
一种轨道交通车辆用复合材料联系枕梁的成型方法，包括以下步骤：A forming method for a composite material contact corbel for a rail transit vehicle, comprising the following steps:
(1)制备枕梁模具、结构单元盒子模具(1) Preparation of corbel molds and structural unit box molds
(2)制备无卤阻燃热固性树脂预浸料，优选610B无卤阻燃环氧树脂预浸料，面密度100～200g/m2。(2) Prepare a halogen-free flame-retardant thermosetting resin prepreg, preferably a 610B halogen-free flame-retardant epoxy resin prepreg, with an areal density of 100-200 g/m2 .
(3)制备复合材料盒子，优选采用单向碳纤维预浸料，不同预浸料铺层间搭接部位相对错开。(3) To prepare a composite material box, it is preferable to use unidirectional carbon fiber prepreg, and the overlapping parts between different prepreg layers are relatively staggered.
(4)复合材料盒子铺层完成后，在130℃条件下固化2小时，得固化后的复合材料盒子。(4) After the laminate of the composite material box is completed, it is cured at 130° C. for 2 hours to obtain a cured composite material box.
(5)按照设计部分在复合材料盒子侧壁打孔。(5) Punch holes in the side wall of the composite material box according to the design part.
(6)不同复合材料盒子按照一定的位置采用胶膜粘接，形成复合材料骨架层预制体。(6) Different composite material boxes are bonded with adhesive film according to a certain position to form a composite material skeleton layer prefabricated body.
(7)在骨架预制体外采用碳纤维无卤阻燃环氧树脂单向预浸料进行缠绕成型，形成缠绕补强层，与骨架预制体形成缠绕骨架预制体。(7) The carbon fiber halogen-free flame-retardant epoxy resin unidirectional prepreg is used for winding molding outside the skeleton prefabricated body to form a winding reinforcement layer, which forms a wound skeleton prefabricated body with the skeleton prefabricated body.
(8)在产品模具上铺放预浸料，形成下壁板层，并进行抽空压实。(8) Lay the prepreg on the product mold to form the lower wall layer, and carry out vacuum compaction.
(9)在未固化的下壁板层上面铺放中温固化预浸料，在胶膜上放置缠绕骨架预制体。(9) Lay medium-temperature curing prepreg on the uncured lower wall layer, and place the winding skeleton prefabricated body on the adhesive film.
(10)再预制体上铺放中温固化胶膜，然后铺放中温无卤阻燃预浸料。形成上壁板。(10) Lay a medium-temperature curing adhesive film on the prefabricated body, and then lay a medium-temperature halogen-free flame-retardant prepreg. Form the upper siding.
(11)包覆后进热压罐固化成型。(11) After coating, enter the autoclave for curing and molding.
中空结构通过先制备方盒子，然后将方盒子粘接练成一个内部连通的容器来实现。The hollow structure is realized by first preparing a square box, and then bonding the square box to form an internally connected container.
联系枕梁中空部分的垂直连接部位的补强是通过一体固化成型实现的。The reinforcement of the vertical joints connecting the hollow parts of the corbel is realized through integral solidification molding.
方盒子成型过程中第一层需铺放表面膜，然后再铺预浸料。During the forming process of the square box, the surface film needs to be laid on the first layer, and then the prepreg is laid.
成型过程所用预浸料为碳纤维增强无卤阻燃环氧预浸料。固化需采用热压罐固化，固化压力为0.5MPa以上。The prepreg used in the molding process is carbon fiber reinforced halogen-free flame retardant epoxy prepreg. Curing needs to be cured in an autoclave, and the curing pressure is above 0.5MPa.
一种轨道交通车辆用复合材料联系枕梁的结构包括复合材料制备而成，分为上壁板、下壁板、整体骨架连接而成。整体骨架分为内支撑骨架、外轮廓骨架。整体骨架与上下壁板连接形成气室，内骨架将气室分割为多个小的气室单元。小的气室单元之间通过打孔互相连通，可以作为承压容器。为减小打孔带来的强度损失，孔的形状尽量选择圆形，孔的尺寸小于等于The utility model relates to a structure in which a composite material is used to contact a corbel for a rail transit vehicle. The composite material is composed of an upper wall plate, a lower wall plate, and an integral skeleton connected together. The overall skeleton is divided into inner support skeleton and outer contour skeleton. The overall skeleton is connected with the upper and lower wall panels to form an air chamber, and the inner skeleton divides the air chamber into multiple small air chamber units. The small gas chamber units communicate with each other through perforations and can be used as pressure containers. In order to reduce the strength loss caused by punching, the shape of the hole should be round as much as possible, and the size of the hole should be less than or equal to
为解决枕梁既承受转向架与车厢施加的载荷、又要作为压力容器使用的要求，整个枕梁采用碳纤维复合材料，为满足轨道交通运输的运行环境，复合材料的树脂体系采用无卤阻燃环氧树脂体系。整个枕梁内部做成中空结构，作为气室。其内部结构特征为：组成支撑骨架的将整个气室分割为不同等高的气室单元，气室截面形状可以为三角形、正方形、长方形、五边形、六边形等。可根据实际需求进行设计，为成型方便优选长方形或正方形。In order to solve the requirement that the corbel not only bears the load imposed by the bogie and the car, but also serves as a pressure vessel, the entire corbel is made of carbon fiber composite material. In order to meet the operating environment of rail transportation, the resin system of the composite material adopts halogen-free flame retardant epoxy resin system. The interior of the entire corbel is made into a hollow structure as an air chamber. Its internal structure is characterized by: the entire air chamber is divided into air chamber units of different heights that form the supporting skeleton, and the cross-sectional shape of the air chamber can be triangle, square, rectangle, pentagon, hexagon, etc. It can be designed according to actual needs, and rectangle or square is preferred for molding convenience.
在一可选实施例中，所述上下壁板的厚度为5～20mm。所述支撑骨架包括轮廓壁板、内支撑壁板，外轮廓壁板厚度在16～30mm，局部加强区厚度在20～30mm，内支撑骨架的部分，由等高度复合材料单元气室(盒子)粘接而成，盒子的壁厚为3～15mm，盒子的尺寸可根据产品尺寸调整，每个盒子的宽度不超过500mm，长度不过1000mm。每个盒子的长宽优选200～300mm，高度视产品要求而定。In an optional embodiment, the thickness of the upper and lower wall panels is 5-20mm. The supporting frame includes a profile wall plate and an inner support wall plate, the thickness of the outer profile wall plate is 16-30 mm, the thickness of the local reinforcement area is 20-30 mm, and the part of the inner support frame is composed of an equal-height composite material unit air chamber (box) It is made by bonding. The wall thickness of the box is 3-15mm. The size of the box can be adjusted according to the size of the product. The width of each box does not exceed 500mm and the length does not exceed 1000mm. The length and width of each box are preferably 200-300 mm, and the height depends on product requirements.
在一可选实施例中，所述的结构单元气室的底部采用大的倒角设计或采用局部加厚补强的方式来避免应力集中。In an optional embodiment, the bottom of the air chamber of the structural unit adopts a large chamfer design or adopts a local thickening and reinforcement method to avoid stress concentration.
在一可选实施例中，所述的复合材料采用无卤阻燃热固性树脂体系，纤维采用T300级、T700级、T800级碳纤维，复合材料阻燃性能可以满足EN45545-2标准的要求。In an optional embodiment, the composite material uses a halogen-free flame-retardant thermosetting resin system, and the fibers use T300, T700, and T800 carbon fibers, and the flame-retardant performance of the composite material can meet the requirements of the EN45545-2 standard.
在一可选实施例中，所述复合材料方形盒子连接好后，缠绕层的厚度为0.5～5mm，缠绕层采用单向碳纤维预浸料。In an optional embodiment, after the square boxes of composite materials are connected, the thickness of the wrapping layer is 0.5-5 mm, and the wrapping layer is made of unidirectional carbon fiber prepreg.
在一可选实施例中，所述一种轨道交通车辆用复合材料联系枕梁的成型方法，步骤包括：In an optional embodiment, the forming method of a composite material contact corbel for a rail transit vehicle, the steps include:
(1)制备枕梁模具、结构单元盒子模具(1) Preparation of corbel molds and structural unit box molds
(2)制备无卤阻燃热固性树脂预浸料，优选610B无卤阻燃环氧树脂预浸料，面密度100～200g/m2。(2) Prepare a halogen-free flame-retardant thermosetting resin prepreg, preferably a 610B halogen-free flame-retardant epoxy resin prepreg, with an areal density of 100-200 g/m2 .
(3)制备复合材料盒子，优选采用单向碳纤维预浸料，不同预浸料铺层间搭接部位相对错开。(3) To prepare a composite material box, it is preferable to use unidirectional carbon fiber prepreg, and the overlapping parts between different prepreg layers are relatively staggered.
(4)复合材料盒子铺层完成后，在130℃条件下固化2小时，得固化后的复合材料盒子。(4) After the laminate of the composite material box is completed, it is cured at 130° C. for 2 hours to obtain a cured composite material box.
(5)按照设计部分在复合材料盒子侧壁打孔。(5) Punch holes in the side wall of the composite material box according to the design part.
(6)不同复合材料盒子按照一定的位置采用胶膜粘接，形成复合材料骨架层预制体。(6) Different composite material boxes are bonded with adhesive film according to a certain position to form a composite material skeleton layer prefabricated body.
(7)在骨架预制体外采用碳纤维无卤阻燃环氧树脂单向预浸料进行缠绕成型，形成缠绕补强层，与骨架预制体形成缠绕骨架预制体。(7) The carbon fiber halogen-free flame-retardant epoxy resin unidirectional prepreg is used for winding molding outside the skeleton prefabricated body to form a winding reinforcement layer, which forms a wound skeleton prefabricated body with the skeleton prefabricated body.
(8)在产品模具上铺放预浸料，形成下壁板层，并进行抽空压实。(8) Lay the prepreg on the product mold to form the lower wall layer, and carry out vacuum compaction.
(9)在未固化的下壁板层上面铺放中温固化预浸料，在胶膜上放置缠绕骨架预制体。(9) Lay medium-temperature curing prepreg on the uncured lower wall layer, and place the winding skeleton prefabricated body on the adhesive film.
(10)再预制体上铺放中温固化胶膜，然后铺放中温无卤阻燃预浸料。形成上壁板。(10) Lay a medium-temperature curing adhesive film on the prefabricated body, and then lay a medium-temperature halogen-free flame-retardant prepreg. Form the upper siding.
(11)包覆后进热压罐固化成型。(11) After coating, enter the autoclave for curing and molding.
在一可选实施例中，复合材料的联系枕梁的中空结构通过先制备方盒子，然后将方盒子粘接练成一个内部连通的容器来实现。In an optional embodiment, the hollow structure of the composite material connected to the corbel is realized by first preparing a square box, and then bonding the square box to form an internally connected container.
在一可选实施例中，所述中空部位的垂直连接部位的补强是通过一体固化成型实现的。In an optional embodiment, the reinforcement of the vertical connection portion of the hollow portion is realized through integral solidification molding.
在一可选实施例中，所述成型过程，单元气室盒子的成型过程中第一层需铺放表面膜，然后再铺预浸料。有利提高气室的气密性。In an optional embodiment, in the forming process, the surface film needs to be laid on the first layer during the forming process of the unit air chamber box, and then the prepreg is laid. It is beneficial to improve the airtightness of the air chamber.
在一可选实施例中，所述成型过程所用预浸料为碳纤维增强无卤阻燃环氧预浸料。固化需采用热压罐固化，固化压力为0.5MPa以上，可从成型、固化等工序中保证产品的强度及气密性。In an optional embodiment, the prepreg used in the molding process is a carbon fiber reinforced halogen-free flame-retardant epoxy prepreg. Curing needs to be cured in an autoclave, and the curing pressure is above 0.5MPa, which can ensure the strength and airtightness of the product from the molding and curing processes.
实施例1Example 1
一种轨道交通车辆用复合材料联系枕梁，该联系枕梁包括上壁板、下壁板和气室，气室包括27个结构单元排列组成的主结构和包覆层，主结构为三层，如图1-3所示，包覆层缠绕在在主结构外，气室位于上壁板和下壁板之间；结构单元为带有顶端通孔、底端通孔和中间通孔的棱柱(单元气室)，棱柱(单元气室)的顶端通孔的内径小于中间通孔，棱柱(单元气室)的底端通孔的内径小于中间通孔，棱柱(单元气室)的顶端通孔的内径与棱柱的底端通孔的内径相同，如图4-5所示；A composite material connecting corbel for a rail transit vehicle, the connecting corbel includes an upper wall plate, a lower wall plate and an air chamber, the air chamber includes a main structure and a cladding layer composed of 27 structural units arranged, the main structure is three layers, As shown in Figure 1-3, the cladding layer is wound outside the main structure, and the air chamber is located between the upper wall plate and the lower wall plate; the structural unit is a prism with a top through hole, a bottom through hole and a middle through hole (unit air chamber), the inner diameter of the top through hole of the prism (unit air chamber) is smaller than the middle through hole, the inner diameter of the bottom through hole of the prism (unit air chamber) is smaller than the middle through hole, the top of the prism (unit air chamber) is through The inner diameter of the hole is the same as that of the through hole at the bottom of the prism, as shown in Figure 4-5;
相邻的结构单元之间通过环氧胶黏剂粘接而成；Adjacent structural units are bonded by epoxy adhesive;
相邻的结构单元共用的侧壁上带有通孔，该通孔用于连同相邻的结构单元，通孔的形状为圆形，通孔的直径为30mm；There is a through hole on the side wall shared by adjacent structural units, the through hole is used to connect with adjacent structural units, the shape of the through hole is circular, and the diameter of the through hole is 30mm;
结构单元外轮廓的横截面为正方形The cross-section of the outer contour of the structural unit is square
所述上壁板的厚度为6mm；The thickness of the upper wall plate is 6mm;
所述下壁板的厚度为6mm；The thickness of the lower wall plate is 6mm;
结构单元带有中间通孔部分的壁厚为3mm；The wall thickness of the structural unit with the middle through hole is 3mm;
包覆层的厚度为5mm；The thickness of the cladding layer is 5mm;
结构单元外轮廓的边长为230mm，结构单元的高度150mmThe side length of the outer contour of the structural unit is 230mm, and the height of the structural unit is 150mm
联系枕梁的材料为碳纤维复合材料；碳纤维复合材料的树脂体系采用无卤阻燃热固性树脂体系，优选无卤阻燃环氧树脂体系，碳纤维采用T700级碳纤维，复合材料阻燃性能满足EN45545-2标准的要求；The material used to contact the corbel is carbon fiber composite material; the resin system of the carbon fiber composite material adopts a halogen-free flame-retardant thermosetting resin system, preferably a halogen-free flame-retardant epoxy resin system, and the carbon fiber adopts T700 carbon fiber, and the flame retardancy of the composite material meets EN45545-2 standard requirements;
包覆层采用单向碳纤维预浸料；The cladding layer is made of unidirectional carbon fiber prepreg;
一种轨道交通车辆用复合材料联系枕梁的成型方法的步骤包括：The steps of a molding method for connecting corbels with composite materials for rail transit vehicles include:
(1)制备结构单元的模具，结构单元的模具的外形面与结构单元的内形面一致，制备联系枕梁的模具，联系枕梁的模具的内形面与联系枕梁的外形面一致；(1) prepare the mold of structural unit, the profile surface of the mold of structural unit is consistent with the internal profile surface of structural unit, prepare the mold of contact corbel, the internal profile surface of the mold of contact corbel is consistent with the profile surface of contact corbel;
(2)使用步骤(1)制备的结构单元的模具成型六个结构单元，成型时选用无卤阻燃热固性树脂预浸料，采用610B无卤阻燃环氧树脂预浸料，面密度200g/m2，优选采用单向碳纤维预浸料，不同预浸料铺层间搭接部位相对错开，成型完成后进行固化，固化温度为130℃，固化时间为2h，固化完成后得到结构单元；使用结构单元的模具成型结构单元，先在结构单元的模具上铺放面密度为300g/m2无卤阻燃环氧树脂膜，然后再铺放碳纤维无卤阻燃环氧树脂单向预浸料。(2) Use the mold of the structural unit prepared in step (1) to form six structural units. When molding, select a halogen-free flame-retardant thermosetting resin prepreg, use 610B halogen-free flame-retardant epoxy resin prepreg, and the surface density is 200g/ m2 , it is preferable to use unidirectional carbon fiber prepregs, and the overlapping parts between different prepregs are relatively staggered. After the molding is completed, it is cured. The curing temperature is 130 ° C, and the curing time is 2 hours. After the curing is completed, the structural unit is obtained; use The mold of the structural unit is used to form the structural unit. First, lay a halogen-free flame-retardant epoxy resin film with an area density of 300g/m2 on the mold of the structural unit, and then lay a carbon fiber halogen-free flame-retardant epoxy resin unidirectional prepreg .
(3)在步骤(2)得到的结构单元需要与其他结构单元连接的侧壁打孔；(3) The structural unit obtained in step (2) needs to be perforated with the side wall connected with other structural units;
(4)将步骤(3)打孔后的结构单元采用环氧胶黏剂进行粘接，得到主结构；(4) bonding the structural units after punching in step (3) with an epoxy adhesive to obtain the main structure;
(5)在步骤(4)得到的主结构外采用碳纤维无卤阻燃环氧树脂单向预浸料进行缠绕成型，形成包覆层，得到气室；(5) outside the main structure obtained in step (4), the carbon fiber halogen-free flame-retardant epoxy resin unidirectional prepreg is used for winding molding to form a cladding layer to obtain an air chamber;
(6)在步骤(1)制备的联系枕梁的模具上铺放碳纤维无卤阻燃环氧树脂预浸料，形成下壁板层，并进行抽空压实。(6) Lay the carbon fiber halogen-free flame-retardant epoxy resin prepreg on the mold for contacting the corbel prepared in step (1) to form the lower wall layer, and carry out vacuum compaction.
(7)在步骤(6)得到的未固化的下壁板层上面铺放可在130℃条件下2小时内固化的胶膜，胶膜面密度为300g/m2，在中温固化胶膜上放置步骤(5)得到的气室；(7) Lay an adhesive film that can be cured within 2 hours at 130°C on the uncured lower wall layer obtained in step (6). The surface density of the adhesive film is 300g/m2 . Place the air chamber that step (5) obtains;
(8)在步骤(7)的气室上上面铺放中温固化胶膜，在中温固化胶膜上铺放碳纤维无卤阻燃环氧树脂预浸料，形成上壁板层，得到组合体；(8) laying a medium-temperature curing adhesive film on the air chamber of step (7), and laying a carbon fiber halogen-free flame-retardant epoxy resin prepreg on the medium-temperature curing adhesive film to form an upper wall layer to obtain an assembly;
(9)对步骤(8)得到组合体进行热压罐固化成型，得到复合材料联系枕梁，固化温度130℃，固化压力为0.6MPa，固化时间为2h。(9) Perform autoclave curing molding on the assembly obtained in step (8) to obtain a composite material contact corbel. The curing temperature is 130° C., the curing pressure is 0.6 MPa, and the curing time is 2 hours.
得到的复合材料联系枕梁进行静力试验测试及打压试验测试，结果表面枕梁可满足轨道交通用的静力要求，具有较好的气密性，可承受6bar的工作压力。采用单元格组合的设计，可以提高整体的刚度，提高枕梁的承载能力和承压能力。枕梁的重量相比金属材料降低35％。满足轨道交通车辆的轻量化的要求。The obtained composite material was contacted with the corbel for static test and pressure test. The results showed that the surface corbel can meet the static requirements of rail transit, has good air tightness, and can withstand the working pressure of 6bar. The design of unit combination can increase the overall rigidity and improve the bearing capacity and pressure bearing capacity of the corbel. The weight of the corbel is 35% lower than that of metal materials. Meet the lightweight requirements of rail transit vehicles.
实施例2Example 2
一种轨道交通车辆用复合材料联系枕梁，该联系枕梁包括上壁板、下壁板和气室，气室包括30个结构单元排列组成的主结构和包覆层，包覆层缠绕在在主结构外，气室位于上壁板和下壁板之间；结构单元为带有顶端通孔、底端通孔和中间通孔的棱柱(单元气室)，棱柱(单元气室)的顶端通孔的内径小于中间通孔，棱柱(单元气室)的底端通孔的内径小于中间通孔，棱柱(单元气室)的顶端通孔的内径与棱柱的底端通孔的内径相同；A composite material connecting corbel for a rail transit vehicle, the connecting corbel includes an upper wall plate, a lower wall plate and an air chamber, the air chamber includes a main structure composed of 30 structural units and a cladding layer, and the cladding layer is wound on the Outside the main structure, the air chamber is located between the upper wall plate and the lower wall plate; the structural unit is a prism (unit air chamber) with a top through hole, a bottom end through hole and a middle through hole, and the top of the prism (unit air chamber) The inner diameter of the through hole is less than the middle through hole, the inner diameter of the bottom through hole of the prism (unit air chamber) is smaller than the middle through hole, and the inner diameter of the top through hole of the prism (unit air chamber) is the same as the inner diameter of the bottom through hole of the prism;
相邻的结构单元之间通过环氧胶黏剂粘接而成；Adjacent structural units are bonded by epoxy adhesive;
相邻的结构单元共用的侧壁上带有通孔，该通孔用于连同相邻的结构单元，通孔的形状为圆形，通孔的直径为25mm；There is a through hole on the side wall shared by adjacent structural units, the through hole is used to connect with adjacent structural units, the shape of the through hole is circular, and the diameter of the through hole is 25mm;
结构单元外轮廓的横截面为正方形The cross-section of the outer contour of the structural unit is square
所述上壁板的厚度为5mm；The thickness of the upper wall plate is 5mm;
所述下壁板的厚度为5mm；The thickness of the lower wall plate is 5mm;
结构单元带有中间通孔部分的壁厚为2.5mm；The wall thickness of the structural unit with the middle through hole is 2.5mm;
包覆层的厚度为6mm；The thickness of the cladding layer is 6mm;
结构单元外轮廓的边长为250mm，宽为200mm，为避开连接件，适当调整边长，结构单元的高度150mmThe side length of the outer contour of the structural unit is 250mm, and the width is 200mm. In order to avoid the connectors, adjust the side length appropriately, and the height of the structural unit is 150mm
联系枕梁的材料为碳纤维复合材料；碳纤维复合材料的树脂体系采用无卤阻燃热固性树脂体系，优选无卤阻燃环氧树脂体系，碳纤维采用T700级碳纤维，复合材料阻燃性能可以满足EN45545-2标准的要求；The material used to contact the corbel is carbon fiber composite material; the resin system of the carbon fiber composite material adopts a halogen-free flame-retardant thermosetting resin system, preferably a halogen-free flame-retardant epoxy resin system, and the carbon fiber adopts T700 grade carbon fiber. 2 standard requirements;
包覆层采用单向碳纤维预浸料；The cladding layer is made of unidirectional carbon fiber prepreg;
一种轨道交通车辆用复合材料联系枕梁的成型方法的步骤包括：The steps of a molding method for connecting corbels with composite materials for rail transit vehicles include:
(1)制备结构单元的模具，结构单元的模具的外形面与结构单元的内形面一致，制备联系枕梁的模具，联系枕梁的模具的内形面与联系枕梁的外形面一致；(1) prepare the mold of structural unit, the profile surface of the mold of structural unit is consistent with the internal profile surface of structural unit, prepare the mold of contact corbel, the internal profile surface of the mold of contact corbel is consistent with the profile surface of contact corbel;
(2)使用步骤(1)制备的结构单元的模具成型六个结构单元，成型时选用无卤阻燃热固性树脂预浸料，采用610B无卤阻燃环氧树脂预浸料，面密度165g/m2，优选采用单向碳纤维预浸料，不同预浸料铺层间搭接部位相对错开，成型完成后进行固化，固化温度为130℃，固化时间为2h，固化完成后得到结构单元；使用结构单元的模具成型结构单元，先在结构单元的模具上铺放面密度为280g/m2无卤阻燃环氧树脂膜，然后再铺放碳纤维无卤阻燃环氧树脂单向预浸料。(2) Use the mold of the structural unit prepared in step (1) to form six structural units. When molding, select a halogen-free flame-retardant thermosetting resin prepreg, using a 610B halogen-free flame-retardant epoxy resin prepreg, with an area density of 165g/ m2 , it is preferable to use unidirectional carbon fiber prepregs, and the overlapping parts between different prepregs are relatively staggered. After the molding is completed, it is cured. The curing temperature is 130 ° C, and the curing time is 2 hours. After the curing is completed, the structural unit is obtained; use The mold of the structural unit forms the structural unit, first laying a halogen-free flame-retardant epoxy resin film with an area density of 280g/m2 on the mold of the structural unit, and then laying a carbon fiber halogen-free flame-retardant epoxy resin unidirectional prepreg .
(3)在步骤(2)得到的结构单元需要与其他结构单元连接的侧壁打孔；(3) The structural unit obtained in step (2) needs to be perforated with the side wall connected with other structural units;
(4)将步骤(3)打孔后的结构单元采用环氧胶黏剂进行粘接，得到主结构；(4) bonding the structural units after punching in step (3) with an epoxy adhesive to obtain the main structure;
(5)在步骤(4)得到的主结构外采用碳纤维无卤阻燃环氧树脂单向预浸料进行缠绕成型，形成包覆层，得到气室；(5) outside the main structure obtained in step (4), the carbon fiber halogen-free flame-retardant epoxy resin unidirectional prepreg is used for winding molding to form a cladding layer to obtain an air chamber;
(6)在步骤(1)制备的联系枕梁的模具上铺放碳纤维无卤阻燃环氧树脂预浸料，形成下壁板层，并进行抽空压实。(6) Lay the carbon fiber halogen-free flame-retardant epoxy resin prepreg on the mold for contacting the corbel prepared in step (1) to form the lower wall layer, and carry out vacuum compaction.
(7)在步骤(6)得到的未固化的下壁板层上面铺放可在130℃条件下2小时内固化的胶膜，胶膜面密度为280g/m2，在中温固化胶膜上放置步骤(5)得到的气室；(7) Lay an adhesive film that can be cured within 2 hours at 130°C on the uncured lower wall layer obtained in step (6). The surface density of the adhesive film is 280g/m2 . Place the air chamber that step (5) obtains;
(8)在步骤(7)的气室上上面铺放中温固化胶膜，在中温固化胶膜上铺放碳纤维无卤阻燃环氧树脂预浸料，形成上壁板层，得到组合体；(8) laying a medium-temperature curing adhesive film on the air chamber of step (7), and laying a carbon fiber halogen-free flame-retardant epoxy resin prepreg on the medium-temperature curing adhesive film to form an upper wall layer to obtain an assembly;
(9)对步骤(8)得到组合体进行热压罐固化成型，得到复合材料联系枕梁，固化温度150℃，固化压力为0.6MPa，固化时间为1h。(9) Perform autoclave curing molding on the assembly obtained in step (8) to obtain a composite material contact bolster. The curing temperature is 150° C., the curing pressure is 0.6 MPa, and the curing time is 1 h.
得到的复合材料联系枕梁进行静力试验测试及打压试验测试，结果表面枕梁可满足轨道交通用的静力要求，具有较好的气密性，可承受16bar的水压试验。采用单元格组合的设计，可以提高整体的刚度，提高枕梁的承载能力和承压能力。枕梁的重量相比金属材料降低30％。满足轨道交通车辆的轻量化的要求。The obtained composite material was contacted with the corbel for static test and compression test. The results showed that the surface corbel can meet the static requirements of rail transit, has good air tightness, and can withstand 16bar water pressure test. The design of unit combination can increase the overall rigidity and improve the bearing capacity and pressure bearing capacity of the corbel. The weight of the corbel is 30% lower than that of metal materials. Meet the lightweight requirements of rail transit vehicles.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910754714.4ACN110435701B (en) | 2019-08-15 | 2019-08-15 | A composite material connecting corbel for rail transit vehicle and its forming method |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910754714.4ACN110435701B (en) | 2019-08-15 | 2019-08-15 | A composite material connecting corbel for rail transit vehicle and its forming method |
| Publication Number | Publication Date |
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| CN110435701Atrue CN110435701A (en) | 2019-11-12 |
| CN110435701B CN110435701B (en) | 2020-08-14 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201910754714.4AActiveCN110435701B (en) | 2019-08-15 | 2019-08-15 | A composite material connecting corbel for rail transit vehicle and its forming method |
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| CN (1) | CN110435701B (en) |
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