Forming die for manufacturing middle roof of rail vehicle with air vent and middle roof

Abstract

The utility model discloses a rail vehicle middle roof manufacturing using forming die with air vent belongs to the rail technical field. Including upper die, lower die and workpiece, and upper die and lower die all have the cavity surface corresponding to workpiece, and the cavity surface of lower die is equipped with a plurality of hole forming pieces, and hole forming piece has the regular arrangement according to the demand, workpiece includes first layer fiber felt, second layer fiber felt, third layer fiber felt and fourth layer fiber felt that lay in the cavity in proper order, and there is polyurethane between the adjacent layer and sprays, the utility model discloses a forming die, and the heat pressure is carried out to workpiece through upper die and lower die, makes the polyurethane flow filling multilayer fiber felt's internal cavity, and then forms the lightweight, the good structure middle roof, makes the through -hole also along with the forming of middle roof simultaneously while making the forming, not only has saved the subsequent mechanical processing through -hole's step, also effectively reduced the waste of raw material, improved production efficiency and product consistency.

Description

Technical Field

[0001] This utility model relates to the field of track technology, and in particular to a molding die for manufacturing the top plate of a track vehicle with ventilation holes and the top plate itself. Background Technology

[0002] Currently, the interior of rail passenger cars mostly uses aluminum plates, thermosetting composite material plates, or thermosetting composite material sandwich panels to make non-load-bearing decorative components such as the top panel, side top panel, and wall panels.

[0003] While aluminum sheet stamping offers good rigidity, it results in poor vehicle weight reduction. Thermosetting composite sheet molding, to maintain structural rigidity, also doesn't offer a significant weight reduction advantage compared to aluminum. Furthermore, thermosetting composite parts with through holes often cannot be formed in a single process; the holes must be formed after the part has cured through machining (drilling, punching). This forming method is inefficient and wasteful of raw materials for parts with numerous small-diameter through holes. Utility Model Content

[0004] The technical problem to be solved by this utility model is: in order to solve the problem of low production efficiency caused by using other methods to form through holes after the existing composite material is formed, this utility model provides a forming mold for the production of the top plate of a rail vehicle with ventilation holes, so that the through holes are formed at the same time as the top plate is formed, which effectively reduces the production cost and improves the production efficiency.

[0005] The technical solution adopted by this utility model to solve its technical problem is: a forming mold for making the top plate of a rail vehicle with ventilation holes, including an upper mold, a lower mold and a part, wherein the upper mold and the lower mold have cavity surfaces corresponding to the part, the upper mold and the lower mold fit together so that the cavity surfaces are combined to form a cavity, and the cavity surface of the lower mold is provided with a plurality of hole forming parts, the hole forming parts are arranged in a regular manner according to requirements; The component comprises a first layer of fiber felt, a second layer of fiber felt, a third layer of fiber felt, and a fourth layer of fiber felt, wherein the first, second, third, and fourth layers of fiber felt are sequentially laid within the cavity, and polyurethane is sprayed between adjacent layers. Thus, during the hot pressing of the component by the upper and lower molds, the polyurethane flows and fills the internal cavities of the multiple layers of fiber felt, thereby forming a lightweight, structurally sound top plate. Simultaneously, during the hot pressing process, the perforated part is formed synchronously with the component, ensuring that the ventilation holes on the top plate are precisely positioned and regularly shaped. This mold design not only eliminates the need for subsequent machining of the through holes but also effectively reduces raw material waste and improves production efficiency and product consistency.

[0006] Furthermore, both the upper and lower molds are double-sided metal, and the cavity surfaces are mirror-polished to ensure that the surface of the part is smooth and easy to demold.

[0007] Furthermore, the upper mold is provided with a positioning pin, and the lower mold is provided with a guide groove. The positioning pin and the guide groove are a mating structure to ensure accurate alignment when the mold is closed and to avoid product defects caused by misalignment.

[0008] Furthermore, the hole-forming part has a cylindrical structure, and its diameter matches the design dimensions of the ventilation hole.

[0009] Furthermore, the bottom of the hole-forming part is integrally formed with the lower mold to ensure that it is not easy to shift during the pressing process, thereby ensuring the accuracy and consistency of the ventilation hole forming.

[0010] Furthermore, the bottom of the hole forming part is connected to the lower mold by a thread, so as to facilitate disassembly and replacement when needed, thereby improving the service life and maintenance convenience of the mold.

[0011] Furthermore, the end of the hole-forming part away from the lower mold is provided with a cone; thus, the cone design improves the penetration of the hole-forming part into the layup, while ensuring the forming quality of the ventilation hole and the ease of demolding.

[0012] Furthermore, the surface of the cone is also polished; thereby enhancing demolding performance and reducing frictional damage between the molded part and the workpiece.

[0013] Furthermore, the cone angle α of the cone head is inversely proportional to the thickness of the part, which can ensure stable penetration of the fiber layer during the molding process and avoid local stress concentration caused by excessively steep angle, thus affecting the overall strength of the top plate.

[0014] Furthermore, the upper mold cavity surface is provided with several grooves that match the shape of the cone. The design of the grooves ensures that the cone is accurately positioned and stably supported during the pressing process, thereby effectively improving the forming accuracy and consistency of the ventilation holes.

[0015] Furthermore, the depth of the groove is matched with the height of the cone, ensuring that the cone is fully embedded in the groove during the pressing process, avoiding interference and collision between the molded part and the upper mold, thereby ensuring the molding quality of the part and the safety of the mold.

[0016] Furthermore, the first, second, third, and fourth layers of fiber felt are all chopped strand mats. The first and fourth layers of fiber felt have the same density, the second and third layers have the same density, and the first layer has a lower density than the third layer. By layering fiber felts of different densities, the weight of the top plate is further reduced while still meeting strength requirements.

[0017] Furthermore, the amount of polyurethane sprayed between the second and third fiber felt layers, and between the third and fourth fiber felt layers, is less than that sprayed between the first and second fiber felt layers. Specifically, the amount of polyurethane sprayed between the first and second fiber felt layers is 650 g / m², between the second and third layers is 550 g / m², and between the third and fourth layers is 450 g / m². By controlling the amount of polyurethane sprayed in layers, the bonding strength between each layer is ensured, while avoiding the problem of increased overall weight due to excessive polyurethane usage. This spraying distribution method not only improves material utilization but also enhances the overall rigidity and durability of the top plate, achieving lightweighting while ensuring structural performance, thus meeting the dual requirements of energy conservation, environmental protection, and efficient manufacturing for rail vehicles.

[0018] Furthermore, a rigid component, such as a honeycomb panel or a tubular beam, is provided between the second and third fiber felt layers. By setting a rigid component such as a honeycomb panel or a tubular beam between the second and third fiber felt layers, the structural stiffness and bending resistance of the top plate are effectively improved without significantly increasing the overall weight; a good balance is achieved between lightweight and high strength, which is suitable for the requirements of rail vehicles for lightweight and high-strength structural components.

[0019] Furthermore, the rigid components are made of paper or aluminum. This not only effectively reduces the overall weight of the top plate but also provides excellent processing performance and cost advantages, meeting the needs of mass production of rail vehicles. Specifically, paper-based rigid components are environmentally friendly and recyclable, while aluminum-based rigid components offer higher strength and durability; both can be flexibly selected based on actual working conditions and performance requirements.

[0020] A type of top plate is made by forming a part in a molding die for making the top plate of a rail vehicle with ventilation holes.

[0021] The beneficial effect of this utility model is that the molding mold for the production of the top plate of the rail vehicle with ventilation holes of this utility model, by uniformly spraying polyurethane between each layer of fiber felt, makes the part lightweight and structurally sound top plate after hot pressing.

[0022] This utility model discloses a molding die for manufacturing a roof panel with ventilation holes in a rail vehicle. The die includes a hole-forming component, allowing the ventilation holes to be integrally formed with the roof panel, eliminating the need for secondary processing. This not only improves production efficiency but also ensures the precise positioning and structural integrity of the ventilation holes. The roof panel produced using this molding die features evenly distributed ventilation holes and smooth edges, effectively enhancing the product's appearance and functionality, and meeting the high-performance and high-precision requirements of rail vehicle interior components.

[0023] This utility model discloses a molding die for manufacturing the top plate of a rail vehicle with ventilation holes. The end of the hole-forming part is designed as a cone shape, which effectively improves the penetration efficiency during the pressing process while avoiding damage to the fiber layer due to excessive impact, thus ensuring the stability of the ventilation hole forming quality. The precise fit between the cone and the groove not only improves the positioning accuracy of the die but also further ensures the smoothness of the top plate during demolding, thereby reducing the surface defect rate of the part. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0025] Figure 1 This is an assembly drawing of the molding die used to manufacture the top plate of the rail vehicle with ventilation holes in Embodiment 1.

[0026] Figure 2 It is a cross-sectional schematic diagram of the assembly of the molding die and the part.

[0027] Figure 3 This is a cross-sectional schematic diagram of the lower mold and the hole forming part in Embodiment 1.

[0028] Figure 4 This is a cross-sectional schematic diagram of the lower mold and the hole forming part in Embodiment 2.

[0029] In the figure: 1. Part; 21. Lower mold; 211. Guide groove; 212. Hole forming part; 22. Upper mold; 221. Positioning pin; 222. Groove. Detailed Implementation

[0030] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the present invention, and therefore only show the components relevant to the present invention.

[0031] Example 1: like Figure 1 As shown, a molding die for manufacturing the top plate of a rail vehicle with ventilation holes includes an upper die 22, a lower die 21 and a part 1. Both the upper die 22 and the lower die 21 have cavity surfaces corresponding to the part 1. The upper die 22 and the lower die 21 fit together so that the cavity surfaces are combined to form a cavity. A plurality of hole forming parts 212 are provided on the cavity surface of the lower die 21. The hole forming parts 212 are arranged regularly according to requirements. Part 1 comprises a first layer of fiber felt, a second layer of fiber felt, a third layer of fiber felt, and a fourth layer of fiber felt, with polyurethane sprayed between adjacent fiber felt layers. Part 1 is formed into a roof panel through a hot-pressing process, while the layer structure of the roof panel remains unchanged. Simultaneously, a perforated part 212 passes through part 1 to form several regularly arranged ventilation holes. Thus, during the hot-pressing process, polyurethane flows and fills the internal cavities of the multi-layered fiber felt, thereby forming a lightweight composite material that can significantly reduce the overall vehicle weight. The uniform spraying of polyurethane between each layer of fiber felt, combined with the hot-pressing process, not only enhances the bonding strength between the layers but also improves the overall structural rigidity, allowing the roof panel to maintain good mechanical properties while reducing weight.

[0032] in: The first, second, third, and fourth layers of fiber felt are all chopped strand mats. The first and fourth layers have the same density, the second and third layers have the same density, and the first layer has a lower density than the third layer. By layering fiber felts of different densities, the weight of the top slab can be further reduced while still meeting strength requirements.

[0033] The amount of polyurethane sprayed between the second and third fiber felt layers, and between the third and fourth fiber felt layers, is less than that sprayed between the first and second fiber felt layers. In this embodiment, the amount of polyurethane sprayed between the first and second fiber felt layers is 650 g / m², between the second and third layers is 550 g / m², and between the third and fourth layers is 450 g / m². By controlling the amount of polyurethane sprayed in layers, the bonding strength between each layer is ensured, while avoiding the problem of increased overall weight due to excessive polyurethane usage. This spraying distribution method not only improves material utilization but also enhances the overall rigidity and durability of the top plate, further achieving the goal of lightweighting while ensuring structural performance, thus meeting the dual requirements of energy conservation, environmental protection, and efficient manufacturing for rail vehicles.

[0034] A rigid component, such as a honeycomb panel or a tubular beam, is installed between the second and third fiber felt layers. By incorporating rigid components like honeycomb panels or tubular beams between these layers, the structural stiffness and bending resistance of the top plate are effectively improved without significantly increasing the overall weight. This achieves a good balance between lightweight and high strength, making it suitable for the requirements of rail vehicles for lightweight and high-strength structural components.

[0035] The rigid components are made of either paper or aluminum. This not only effectively reduces the overall weight of the top plate but also provides excellent processing performance and cost advantages, meeting the needs of mass production of rail vehicles. Paper-based rigid components are environmentally friendly and recyclable, while aluminum-based rigid components offer higher strength and durability. Both can be flexibly selected based on actual working conditions and performance requirements.

[0036] Secondly: Both the upper mold 22 and the lower mold 21 are double-sided metal, and the cavity surfaces are mirror-polished to ensure that the surface of the part 1 is smooth and easy to demold.

[0037] Reference Figure 2 The upper mold 22 is provided with a positioning pin 221, and the lower mold 21 is provided with a guide groove 211. The positioning pin 221 and the guide groove 211 are a mating structure to ensure accurate alignment when the mold is closed and to avoid product defects caused by misalignment. The hole forming part 212 is a cylindrical structure, and its diameter matches the design size of the ventilation hole. The end of the hole forming part 212 away from the lower mold 21 is provided with a cone head to improve the penetration of the hole forming part 212 into the layup, while ensuring the forming quality of the ventilation hole and the convenience of demolding. The surface of the cone head is also polished to enhance the demolding performance and reduce frictional damage between the forming part and the workpiece 1. The cone angle α of the cone head is inversely proportional to the thickness of the workpiece 1, which can ensure stable penetration of the fiber layer during the forming process and avoid local stress concentration caused by excessively steep angle, which would affect the overall strength of the top plate.

[0038] Reference Figure 3 The bottom of the hole forming part 212 is integrally formed with the lower mold 21 to ensure that it is not easy to shift during the pressing process, thereby ensuring the accuracy and consistency of the ventilation hole forming.

[0039] The hot pressing process for manufacturing the top plate using the above-mentioned molding die is as follows: After the upper mold 22 and the lower mold 21 are preheated to 100-130°C, the pre-made uncured part 1 is placed in the cavity, and a downward pressure of 8-12 MPa is applied to the upper mold 22 for 300-350 seconds, thereby pressing the part 1 into a central top plate with ventilation holes. Then, the pressed and cured central top plate is cooled and shaped, and the excess material and burrs around it are removed.

[0040] Because the lower mold 21 has a hole forming part 212, the ventilation holes are integrally formed with the top plate, eliminating the need for secondary processing. This not only improves production efficiency but also ensures the precise positioning and structural integrity of the ventilation holes. The top plate produced by this forming mold has evenly distributed ventilation holes and smooth edges, effectively improving the product's appearance quality and functionality, and meeting the high-performance and high-precision requirements of rail vehicles for interior parts.

[0041] Example 2: The difference from Example 1 is: Reference Figure 4 The bottom of the hole forming part 212 is connected to the lower mold 21 by a thread, so as to facilitate disassembly and replacement when needed, thereby improving the service life and maintenance convenience of the mold.

[0042] Example 3: Based on Example 1 or Example 2, the following is added: Reference Figure 2 The upper mold 22 has several grooves 222 on its cavity surface that match the shape of the cone. The design of the grooves 222 ensures that the cone is accurately positioned and stably supported during the pressing process, thereby effectively improving the forming accuracy and consistency of the ventilation holes.

[0043] Wherein: the depth of the groove 222 is matched with the height of the cone, ensuring that the cone is fully embedded in the groove 222 during the pressing process, avoiding interference and collision between the molded part and the upper mold 22, thereby ensuring the molding quality of the part 1 and the safety of the mold.

[0044] Based on the above-described preferred embodiments of this utility model, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A molding die for manufacturing the top plate of a rail vehicle with ventilation holes, characterized in that: The system includes an upper mold (22), a lower mold (21), and a workpiece (1). Both the upper mold (22) and the lower mold (21) have cavity surfaces corresponding to the workpiece (1). The upper mold (22) and the lower mold (21) fit together to form a cavity, and the workpiece (1) is placed in the cavity. The cavity surface of the lower mold (21) is provided with a plurality of hole forming parts (212), which are arranged in a regular pattern. The component (1) includes a first layer of fiber felt, a second layer of fiber felt, a third layer of fiber felt and a fourth layer of fiber felt. The adjacent layers of the first layer of fiber felt, the second layer of fiber felt, the third layer of fiber felt and the fourth layer of fiber felt are coated with polyurethane. The component (1) is formed into a top plate by hot pressing with an upper mold (22) and a lower mold (21). At the same time, a number of ventilation holes are formed by a hole forming part (212). The ventilation holes are arranged in a regular pattern.

2. The forming mold for manufacturing the top plate of a rail vehicle with ventilation holes as described in claim 1, characterized in that: Both the upper mold (22) and the lower mold (21) are double-sided metal, and the cavity surfaces are mirror-polished. The upper mold (22) is provided with a positioning pin (221), and the lower mold (21) is provided with a guide groove (211). The positioning pin (221) and the guide groove (211) are a mating structure.

3. The forming mold for manufacturing the top plate of a rail vehicle with ventilation holes as described in claim 1, characterized in that: The bottom of the hole forming part (212) is integrally formed with the lower mold (21) or connected by threads.

4. The forming mold for manufacturing the top plate of a rail vehicle with ventilation holes as described in claim 3, characterized in that: The hole forming part (212) has a cone head at one end away from the lower mold (21), and the surface of the cone head is polished; the cone angle α of the cone head is inversely proportional to the thickness of the part (1).

5. The forming mold for manufacturing the top plate of a rail vehicle with ventilation holes as described in claim 4, characterized in that: The upper mold (22) has a plurality of grooves (222) on its cavity surface that match the shape of the cone, and the depth of the grooves (222) is adapted to the height of the cone.

6. The forming mold for manufacturing the top plate of a rail vehicle with ventilation holes as described in claim 1, characterized in that: The first, second, third, and fourth fiber felts are all chopped strand mats. The first and fourth fiber felts have the same density, the second and third fiber felts have the same density, and the density of the first fiber felt is less than that of the third fiber felt.

7. The forming mold for manufacturing the top plate of a rail vehicle with ventilation holes as described in claim 6, characterized in that: A rigid element is provided between the second layer of fiber felt and the third layer of fiber felt.

8. The forming mold for manufacturing the top plate of a rail vehicle with ventilation holes as described in claim 7, characterized in that: The rigid component is made of paper or aluminum.

9. A central top plate, characterized in that: The part (1) is made in the molding die according to any one of claims 1-8.

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