Laying structure of and laying implementation method for thick-walled multi-cavity pultruded beam in shape of chinese character "目" for vehicle body

Abstract

A laying structure of and a laying implementation method for a thick-walled multi-cavity pultruded beam in the shape of a Chinese character "目" for a vehicle body, relating to the technical field of rail transit. The laying structure comprises a first cavity region (1), a second cavity region (2), a third cavity region (3), and an outer skin region (4) that are all formed by laying multi-axial fabrics. The second cavity region (2) is located between the first cavity region (1) and the third cavity region (3), and the first, second and third cavity regions are collectively wrapped by the outer skin region (4) to form a rectangular structure in the shape of the Chinese character "目". In the laying structure of a thick-walled multi-cavity pultruded beam in the shape of the Chinese character "目" for a vehicle body, quasi-isotropic mechanical properties of the thick-walled multi-cavity pultruded beam in the shape of the Chinese character "目" for a vehicle body are achieved by laying multi-axial fabrics; moreover, the laying structure is adapted to a pultrusion process, and optimizes the structural design, improving the overall rigidity and strength.

Description

Ply structure and ply implementation method of thick-walled eye-shaped multi-cavity pultruded beam of vehicle body

[0001] The present application claims priority to the Chinese patent application No. 202410895550.8, filed on July 4, 2024, and entitled "Ply structure and ply implementation method of thick-walled eye-shaped multi-cavity pultruded beam of vehicle body", the content of which is incorporated herein by reference in its entirety. TECHNICAL FIELD

[0002] The present application relates to the field of rail transit technology, and in particular to a ply structure and ply implementation method of thick-walled eye-shaped multi-cavity pultruded beam of vehicle body. BACKGROUND

[0003] Rail transit vehicles pursue higher operating efficiency and safety, and at the same time, higher requirements are put forward for the lightweight and strength of the vehicle body structure. Carbon fiber reinforced composite materials (CFRP) become an ideal choice for vehicle body structure materials due to their lightweight and high strength characteristics. The pultrusion process provides the possibility for the application of CFRP materials in thick-walled structures of vehicle bodies due to its high efficiency and cost-effectiveness, but how to achieve high-performance plies to meet the complex mechanical performance requirements is still a key challenge in technology development.

[0004] Currently, an important problem faced by the ply technology of thick-walled multi-cavity structure of vehicle body is the anisotropy of mechanical properties, which limits the performance of the structure under multi-directional stress. The existing ply method is difficult to achieve uniform and efficient mechanical load capacity while maintaining the lightweight of the structure. This limitation directly affects the operating efficiency and safety of rail vehicles, highlighting the urgency of developing new ply structures and processes. SUMMARY

[0005] The purpose of the present application is to provide a ply structure of thick-walled eye-shaped multi-cavity pultruded beam of vehicle body, which realizes quasi-isotropic mechanical properties of the thick-walled eye-shaped multi-cavity pultruded beam of vehicle body by using multi-axial fabric plies, adapts to the pultrusion process, optimizes the structure design, and improves the overall stiffness and strength. Another purpose of the present application is to provide a ply implementation method of thick-walled eye-shaped multi-cavity pultruded beam of vehicle body.

[0006] To achieve the above-mentioned purposes, the present application provides a ply structure of thick-walled eye-shaped multi-cavity pultruded beam of vehicle body, which comprises a first cavity area, a second cavity area, a third cavity area and an outer skin area, all of which are laid with multi-axial fabric, the second cavity area is located between the first cavity area and the third cavity area, and the three are collectively wrapped by the outer skin area to form a rectangular structure in the shape of an eye.

[0007] In some embodiments, further comprising two stringer regions laid with multi-axial fabric, the first stringer region is located between the first cavity region and the second cavity region, and the second stringer region is located between the second cavity region and the third cavity region.

[0008] In some embodiments, further comprising four corner regions laid with fiber yarn, the first and second corner regions are located between the two ends of the first stringer region and the skin region, and the third and fourth corner regions are located between the two ends of the second stringer region and the skin region.

[0009] In some embodiments, the first cavity region comprises, from inside to outside, a cavity first multi-axial fabric layer, a cavity unidirectional fabric layer, and a cavity second multi-axial fabric layer; and / or,

[0010] the second cavity region comprises, from inside to outside, a cavity first multi-axial fabric layer, a cavity unidirectional fabric layer, and a cavity second multi-axial fabric layer; and / or,

[0011] the third cavity region comprises, from inside to outside, a cavity first multi-axial fabric layer, a cavity unidirectional fabric layer, and a cavity second multi-axial fabric layer;

[0012] wherein any multi-axial fabric layer comprises at least two layers of multi-axial fabric, and the area density of a single layer of multi-axial fabric is not less than 200 g / m 2 .

[0013] In some embodiments, the cavity first multi-axial fabric layer and the cavity second multi-axial fabric layer each comprise two layers of four-axial warp-knitted fabric, and the cavity unidirectional fabric layer comprises a layer of unidirectional fiber cloth.

[0014] In some embodiments, the outer skin region comprises, from inside to outside, a skin first multi-axial fabric layer and a skin second multi-axial fabric layer;

[0015] the skin first multi-axial fabric layer comprises multiple layers of four-axial warp-knitted fabric, and the skin second multi-axial fabric layer comprises a layer of two-axial warp-knitted fabric.

[0016] In some embodiments, the stringer region comprises a stringer first multi-axial fabric layer and a stringer unidirectional fabric layer;

[0017] the stringer first multi-axial fabric layer comprises a layer of four-axial warp-knitted fabric, and the stringer unidirectional fabric layer comprises a layer of unidirectional fiber cloth.

[0018] The application also provides a method for implementing the layering of a thick-walled monocoque multi-cavity pultrusion beam of a vehicle body, for manufacturing the above-mentioned layering structure, comprising:

[0019] sequentially laying the first cavity area, the second cavity area and the third cavity area by using multi-axial fabric;

[0020] laying the outer skin area by using multi-axial fabric, the outer skin area simultaneously wrapping the first cavity area, the second cavity area and the third cavity area and forming a rectangular structure in the shape of an eye.

[0021] In some embodiments, before the laying of the outer skin area by using multi-axial fabric, the method further comprises:

[0022] laying the stringer area by using multi-axial fabric, the number of the stringer area being two, the first stringer area being located between the first cavity area and the second cavity area, and the second stringer area being located between the second cavity area and the third cavity area;

[0023] laying the corner area by using fiber yarn, the number of the corner area being four, the first and second corner areas being located between the two ends of the first stringer area and the skin area, and the third and fourth corner areas being located between the two ends of the second stringer area and the skin area.

[0024] In some embodiments, the first cavity area, the second cavity area and the third cavity area are laid by using cavity layering, the number of the layers being no less than two, and the cavity layering comprises:

[0025] the first layer layering gradual change process: the layering is made by straight cloth in the shape of a line, then is bent into a circular arc structure, then is bent into an open trapezoidal structure, then is bent into a U-shaped structure, and finally is made into an inner cavity trapezoidal layering structure;

[0026] the second layer layering gradual change process: the layering is made by straight cloth in the shape of a line, then is bent into a circular arc structure, then is bent into an open trapezoidal structure, then is bent into a U-shaped structure, and finally is made into an outer cavity port layering structure;

[0027] the outer skin area is laid by using skin layering, and the skin layering comprises:

[0028] the skin layering deformation process: the layering is made by straight cloth in the shape of a line, then is bent into a circular arc structure, then is bent into an open trapezoidal structure, then is bent into a U-shaped structure, and finally is made into a skin rectangular layering structure.

[0029] With respect to the above background technology, the layering structure provided by the present application mainly comprises a first cavity area, a second cavity area, a third cavity area and an outer skin area, the first cavity area, the second cavity area, the third cavity area and the outer skin area are all laid by using multi-axial fabric, the second cavity area is located between the first cavity area and the third cavity area, and the three areas are collectively wrapped by the outer skin area to form a rectangular structure in the shape of an eye.

[0030] In the design of the car body structure of rail transit vehicles, isotropy of mechanical properties is a key technical problem. Traditional materials and structural design often struggle to provide uniform mechanical properties in all directions, which can lead to uneven performance of the vehicle under multi-directional stress, affecting the stability and safety of the vehicle. To address this technical problem, the provided layup structure uses an innovative design method, which uses multi-axial fabric for laying in the first cavity area, the second cavity area, the third cavity area, and the outer skin area, forming a rectangular structure in the shape of an eye, achieving optimization of the structure. Multi-axial fabric, due to the distribution of its fibers in multiple directions, can provide more uniform mechanical properties, thereby improving the load-carrying capacity of the car body structure in different directions. In addition, the use of multi-axial fabric also enables the layup structure to be adapted to the pultrusion process, which is a high-efficiency, low-cost production method suitable for mass production. The pultrusion process can ensure the uniform distribution and accuracy of the direction of the fibers during the laying process, further improving the mechanical properties of the car body thick-wall eye-shaped multi-cavity pultruded beam.

[0031] In combination with the above structure and process description, it can be seen that the layup structure of the car body thick-wall eye-shaped multi-cavity pultruded beam has at least the following beneficial effects: the layup structure of the car body thick-wall eye-shaped multi-cavity pultruded beam uses multi-axial fabric layup to achieve quasi-isotropic mechanical properties of the car body thick-wall eye-shaped multi-cavity pultruded beam, while adapting to the pultrusion process, optimizing the structural design, and improving the overall stiffness and strength. BRIEF DESCRIPTION OF DRAWINGS

[0032] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed in the embodiment or prior art description will be briefly introduced below. Obviously, the drawings in the following description are only embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor on the basis of the provided drawings.

[0033] Figure 1 is a schematic diagram of the layup structure of the car body thick-wall eye-shaped multi-cavity pultruded beam provided by the present application;

[0034] Figure 2 is a size diagram of the layup structure of the car body thick-wall eye-shaped multi-cavity pultruded beam provided by the present application;

[0035] Figure 3 is a layup diagram of the layup structure of the car body thick-wall eye-shaped multi-cavity pultruded beam provided by the present application;

[0036] Figure 4 is a schematic diagram of the layup process provided by the present application.

[0037] Among them:

[0038] First cavity area 1, first cavity first ply 101, first cavity second ply 102, first cavity third ply 103, first cavity fourth ply 104, first cavity fifth ply 105,

[0039] Second cavity area 2, second cavity first ply 201, second cavity second ply 202, second cavity third ply 203, second cavity fourth ply 204, second cavity fifth ply 205,

[0040] Third cavity area 3, third cavity first ply 301, third cavity second ply 302, third cavity third ply 303, third cavity fourth ply 304, third cavity fifth ply 305,

[0041] Outer skin area 4, skin first ply 401, skin second ply 402, skin third ply 403, skin fourth ply 404, skin fifth ply 405, skin sixth ply 406, skin seventh ply 407, skin eighth ply 408,

[0042] Standoff area 5, standoff first ply 501, standoff second ply 502, standoff third ply 503, standoff fourth ply 504,

[0043] Corner area 6, corner first ply 601, corner second ply 602, corner third ply 603, corner fourth ply 604. DETAILED DESCRIPTION

[0044] Carbon fiber material has higher strength than conventional steel material, and its density is lower than aluminum. Carbon fiber composite material after compounding with resin material has higher tensile strength and mechanical properties, and also has advantages of anti-deformation, anti-magnetization, high temperature resistance, corrosion resistance, etc. On the basis of wide successful application in sports products, wind power, aerospace, with the continuous progress of carbon fiber composite material manufacturing process, its application in rail transit vehicles is also increasing, which effectively widens the designable range and application field of rail vehicles. The composite material main load-bearing beam body of rail vehicle is an equal cross-section, long and large section material, so the pultrusion process with high efficiency, low cost and high quality becomes the most suitable solution for its forming.

[0045] The technical solutions in the embodiments of the present application will be described clearly and completely in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the protection scope of the present application.

[0046] In order to make the technical personnel in the technical field better understand the present application, the present application will be further described in detail below in combination with the drawings and specific embodiments.

[0047] Please refer to FIG. 1, which is a schematic diagram of the layer structure of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body provided by the present application. The different divisions between the zones can be more easily understood through the dashed lines in the figure. Therefore, in order to facilitate the distinction, the distance between the dashed lines is not the actual distance between the zones. The position of the dashed lines in FIG. 1 is specially treated. In fact, the zones are in close contact with each other, so the dashed lines separating the different zones in the figure are actually coincident. In addition to this explanation, this actual situation can also be understood from the subsequent drawings.

[0048] As shown in FIG. 1, in the first specific embodiment, the layer structure provided by the present application mainly includes a first cavity zone 1, a second cavity zone 2, a third cavity zone 3, and an outer skin zone 4. The first cavity zone 1, the second cavity zone 2, the third cavity zone 3, and the outer skin zone 4 are all laid with multi-axial fabric. The second cavity zone 2 is located between the first cavity zone 1 and the third cavity zone 3, and the three are collectively wrapped by the outer skin zone 4 to form a rectangular structure in the shape of an eye.

[0049] In the design of the vehicle body structure of the rail transit vehicle, isotropy of mechanical properties is a key technical problem. Traditional materials and structural designs often have difficulty in providing uniform mechanical properties in all directions, which can lead to uneven performance of the vehicle under multi-directional stress, affecting the stability and safety of the vehicle. To solve this technical problem, the layer structure provided by the present application uses an innovative design method. By laying the first cavity zone 1, the second cavity zone 2, the third cavity zone 3, and the outer skin zone 4 with multi-axial fabric, a rectangular structure in the shape of an eye is formed, realizing the optimization of the structure. Due to the distribution of fibers in multiple directions, multi-axial fabric can provide more uniform mechanical properties, thereby improving the load-carrying capacity of the vehicle body structure in different directions. In addition, the use of multi-axial fabric also makes the layer structure suitable for pultrusion forming, which is a high-efficiency and low-cost production method suitable for mass production. The pultrusion process can ensure the uniform distribution and accuracy of the direction of the fibers during the laying process, further improving the mechanical properties of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body.

[0050] In combination with the above structure and process description, it can be seen that the layer structure of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body has at least the following beneficial effects: the layer structure of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body realizes quasi-isotropic mechanical properties of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body by using multi-axial fabric layering, while adapting to the pultrusion process, optimizing the structural design, and improving the overall stiffness and strength.

[0051] It should be noted that the multi-axial fabric referred to in the present application includes but is not limited to four-axial warp-knitted fabric, two-axial warp-knitted fabric, etc.; the use of multi-axial fabric layers in the layer structure is not limited to only using multi-axial fabric as the only fabric layer, but means that the fabric used includes multi-axial fabric, so it can also be a combination of multi-axial fabric and uniaxial fabric such as unidirectional fiber fabric layer, which also belongs to the scope of the present application.

[0052] Further, the layer structure of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body further includes a standing rib area 5 laid with multi-axial fabric, the number of standing rib areas 5 is two, the first standing rib area 5 is located between the first cavity area 1 and the second cavity area 2, and the second standing rib area 5 is located between the second cavity area 2 and the third cavity area 3.

[0053] In the present embodiment, in addition to the improvement of the stiffness and load-carrying capacity of the overall structure by the eye-shaped rectangular structure, in order to further strengthen the stability and mechanical properties of the structure, the technical solution further includes the design of the standing rib area 5. The setting of the standing rib area 5 not only enhances the connection strength between the cavities, but also helps to disperse and transfer loads, thereby improving the bending and torsional resistance of the entire thick-walled beam of the vehicle body.

[0054] At the same time, the use of multi-axial fabric ensures that the standing rib area 5 has balanced mechanical properties in multiple directions, which is crucial for the structural integrity under complex load conditions. Through this design, the standing rib area 5 works together with the cavity area and the outer skin area to form a high-efficiency and reliable structural system, meeting the strict requirements of rail transit vehicles for vehicle body structural performance.

[0055] Further, the layer structure of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body further includes an angle area 6 laid with fiber yarn, the number of angle areas 6 is four, the first and second angle areas 6 are located between the two ends of the first standing rib area 5 and the skin area, and the third and fourth angle areas 6 are located between the two ends of the second standing rib area 5 and the skin area.

[0056] In the present embodiment, in addition to the cavity area and the standing rib area laid with multi-axial fabric, a specially designed angle area 6 is also included. The setting of the angle area 6 is mainly to enhance the local stability and load-carrying capacity of the structure, especially at the junction of the standing rib area and the skin area, which is also the intersection of the standing rib area, the skin area and the cavity area. These areas are often stress concentration areas in mechanics. By setting the angle area 6 at these key points, stress can be effectively dispersed and stress concentration can be reduced, thereby improving the durability and reliability of the entire structure.

[0057] Meanwhile, the use of fiber yarns provides the necessary tensile strength while maintaining the lightweight of the structure. The fiber yarns laid in the corner regions, through synergistic effects with the stand-off region and the skin region, form a more balanced and stable structural system. Such a design not only improves the overall mechanical properties of the thick-walled beam of the vehicle body, but also helps to improve its adaptability and durability in practical applications.

[0058] In summary, the present application provides a layer structure of a thick-walled beam of a rail vehicle body, which has the characteristics of a thick-walled beam of a rail vehicle body, and is a three-cavity, rectangular design with a stand-off, forming a unique eye-shaped structure.

[0059] In order to make the pultruded beam approach isotropic mechanical properties, the layer structure of the present application particularly uses multi-axial fabric for laying and auxiliary use of fiber yarns at necessary parts. Such multi-axial fabric is laid in five main layer regions, and fiber yarns are laid in the adjacent corners of these regions to enhance the overall stability and local carrying capacity of the structure.

[0060] The layer structure not only realizes the quasi-isotropic mechanical properties of the composite beam by using multi-axial fabric, but also perfectly adapts to the requirements of the pultrusion forming process. Such a structural design enables the beam to be continuously produced by the pultrusion forming process, meeting the engineering requirements of lightweight and high strength, and maintaining the efficiency and economy of the production process.

[0061] In some embodiments, the first cavity region 1 comprises, from inside to outside, a cavity first multi-axial fabric layer, a cavity unidirectional fabric layer, and a cavity second multi-axial fabric layer.

[0062] In some embodiments, the second cavity region 2 comprises, from inside to outside, a cavity first multi-axial fabric layer, a cavity unidirectional fabric layer, and a cavity second multi-axial fabric layer.

[0063] In some embodiments, the third cavity region 3 comprises, from inside to outside, a cavity first multi-axial fabric layer, a cavity unidirectional fabric layer, and a cavity second multi-axial fabric layer.

[0064] Any multi-axial fabric layer comprises at least two layers of multi-axial fabric, and the area density of a single layer of multi-axial fabric is not less than 200 g / m 2 .

[0065] Optionally, the first cavity region 1, the second cavity region 2, and the third cavity region 3 use the same cavity layer structure, and the cavity layer structures formed are similar.

[0066] For example, the first cavity region 1 includes three different fabric layers from inside to outside. First, the first multi-axial fabric layer of the cavity, which uses the multi-directional fibers of the multi-axial fabric to provide initial mechanical properties to the structure. Then, the unidirectional fabric layer of the cavity, which uses unidirectional fibers to provide higher load-carrying capacity in a specific direction. Finally, the second multi-axial fabric layer of the cavity, which again uses the properties of multi-axial fabric to enhance the overall stability and mechanical properties of the structure. This inside-out layering design aims to achieve more balanced and optimized mechanical load-carrying capacity through the combination of different fabric layers.

[0067] It should be noted that any multi-axial fabric layer is composed of at least two layers of multi-axial fabric, ensuring the strength and stiffness of the structure. Crucially, each layer of multi-axial fabric has a high area density of no less than 200 grams per square meter. This high-density design standard allows each layer of fabric to withstand a large load while maintaining the overall lightweight of the structure. This design not only improves the mechanical efficiency of the material, but also meets the strict requirements of rail transit vehicles for lightweight and high-strength vehicle body structures.

[0068] In some embodiments, the first multi-axial fabric layer of the cavity and the second multi-axial fabric layer of the cavity each include two layers of four-axial warp-knitted fabric, and the unidirectional fabric layer of the cavity includes one layer of unidirectional fiber cloth.

[0069] In this embodiment, the four-axial warp-knitted fabric can provide more uniform mechanical properties and enhance load-carrying capacity in all directions. The four-axial warp-knitted fabric has high strength and stability in multiple directions due to its special knitting method, which is crucial for improving the overall performance of the cavity. Meanwhile, the unidirectional fabric layer in the cavity is composed of one layer of unidirectional fiber cloth, which provides concentrated reinforcement in a specific direction, helping to improve the longitudinal strength of the structure. Through this design, the combination of unidirectional fiber cloth and multi-axial fabric layers allows the entire cavity region to maintain lightweight while also exhibiting excellent mechanical properties.

[0070] In some embodiments, the outer skin region 4 includes, from inside to outside, a first multi-axial fabric layer of the skin and a second multi-axial fabric layer of the skin;

[0071] The first multi-axial fabric layer of the skin includes multiple layers of four-axial warp-knitted fabric, and the second multi-axial fabric layer of the skin includes one layer of two-axial warp-knitted fabric.

[0072] In this embodiment, the design of the outer skin area adopts a layer-by-layer structure from inside to outside, which includes two different multi-axial fabric layers. First is the skin first multi-axial fabric layer, which is composed of multiple layers of four-axial warp-knitted fabric. Such a structure design enables the outer skin area to have balanced mechanical properties in multiple directions, thereby enhancing the overall load-carrying capacity and anti-deformation characteristics. Then comes the skin second multi-axial fabric layer, which is composed of double-axial warp-knitted fabric, further enhancing the structural performance of the outer skin area, especially in the warp-knitted direction. The double-axial fabric provides additional stability and strength, enabling the outer skin area to better withstand external loads and stresses under various working conditions.

[0073] In some embodiments, the stand area 5 includes a stand first multi-axial fabric layer and a stand unidirectional fabric layer;

[0074] The stand first multi-axial fabric layer includes a layer of four-axial warp-knitted fabric, and the stand unidirectional fabric layer includes a layer of unidirectional fiber cloth.

[0075] In this embodiment, the stand first multi-axial fabric layer is composed of a layer of four-axial warp-knitted fabric, which can provide reinforcement in multiple directions, thereby bringing higher structural stability and mechanical properties to the stand area. The stand unidirectional fabric layer is composed of unidirectional fiber cloth, which provides concentrated strength in a specific direction, helping to improve the longitudinal load-carrying capacity of the stand area. The use of such unidirectional fabric ensures that the stand area has sufficient mechanical properties in the key direction, while also helping to achieve lightweight structure. The combination of multi-axial and unidirectional fabrics in the stand area 5 achieves structural optimization, not only enhancing the overall stiffness and strength, but also helping to disperse and transfer loads, improving the bending and torsional resistance of the entire vehicle body thick-walled pultruded beam. This design meets the strict requirements of rail transit vehicles for vehicle body structural performance, ensuring the stability and safety of vehicle operation.

[0076] Please refer to FIG. 2 and FIG. 3, FIG. 2 is a size diagram of the layer structure of the vehicle body thick-walled pultruded beam provided by the embodiment of the present application, and FIG. 3 is a layer diagram of the layer structure of the vehicle body thick-walled pultruded beam provided by the embodiment of the present application.

[0077] As shown in FIG. 3, the first cavity area 1 is sequentially composed of a first cavity first layer 101, a first cavity second layer 102, a first cavity third layer 103, a first cavity fourth layer 104, and a first cavity fifth layer 105 from inside to outside.

[0078] Among them, the first cavity first layer 101 and the first cavity second layer 102 are the cavity first multi-axial fabric layer of the first cavity area 1, the first cavity third layer 103 is the cavity unidirectional fabric layer of the first cavity area 1, and the first cavity fourth layer 104 and the first cavity fifth layer 105 are the cavity second multi-axial fabric layer of the first cavity area 1.

[0079] The fabric used in the first cavity first ply 101 is a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m 2 .

[0080] The fabric used in the first cavity second ply 102 is a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m 2 .

[0081] The fabric used in the first cavity third ply 103 is a unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m 2 .

[0082] The fabric used in the first cavity fourth ply 104 is a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m 2 .

[0083] The fabric used in the first cavity fifth ply 105 is a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m 2 .

[0084] As shown in FIG. 3, the second cavity area 2 comprises, from inside to outside, a second cavity first ply 201, a second cavity second ply 202, a second cavity third ply 203, a second cavity fourth ply 204, and a second cavity fifth ply 205.

[0085] The second cavity first ply 201 and the second cavity second ply 202 are the first multi-axial fabric layer of the second cavity area 2, the second cavity third ply 203 is the unidirectional fabric layer of the second cavity area 2, and the second cavity fourth ply 204 and the second cavity fifth ply 205 are the second multi-axial fabric layer of the second cavity area 2.

[0086] The fabric used in the second cavity first ply 201 is a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m 2 .

[0087] The fabric used in the second cavity second ply 202 is a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m 2 .

[0088] The fabric used in the second cavity third ply 203 is a unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m2 .

[0089] The fourth layer 204 of the second cavity adopts a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m 2 .

[0090] The fifth layer 205 of the second cavity adopts a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m 2 .

[0091] As shown in FIG. 3, the third cavity area 3 sequentially comprises a first layer 301, a second layer 302, a third layer 303, a fourth layer 304, and a fifth layer 305 of the third cavity from inside to outside.

[0092] The first layer 301 and the second layer 302 of the third cavity are the first multi-axial fabric layer of the third cavity area 3, the third layer 303 of the third cavity is the unidirectional fabric layer of the third cavity area 3, and the fourth layer 304 and the fifth layer 305 of the third cavity are the second multi-axial fabric layer of the third cavity area 3.

[0093] The first layer 301 of the third cavity adopts a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m 2 .

[0094] The second layer 302 of the third cavity adopts a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m 2 .

[0095] The third layer 303 of the third cavity adopts a unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m 2 .

[0096] The fourth layer 304 of the third cavity adopts a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m2.

[0097] The fifth layer 305 of the third cavity adopts a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m 2 .

[0098] As shown in FIG. 3, the outer skin area 4 is sequentially provided with a first skin layer 401, a second skin layer 402, a third skin layer 403, a fourth skin layer 404, a fifth skin layer 405, a sixth skin layer 406, a seventh skin layer 407 and an eighth skin layer 408 from inside to outside.

[0099] The first skin layer 401, the second skin layer 402, the third skin layer 403, the fourth skin layer 404, the fifth skin layer 405, the sixth skin layer 406 and the seventh skin layer 407 are first multi-axial fabric layers of the outer skin area 4, and the eighth skin layer 408 is a second multi-axial fabric layer of the outer skin area 4.

[0100] The first skin layer 401 is made of a four-axial warp-knitted fabric (0°, +45°, 90°, -45°) with T700 material and 800g / m 2 .

[0101] The second skin layer 402 is made of a four-axial warp-knitted fabric (0°, +45°, 90°, -45°) with T700 material and 800g / m 2 .

[0102] The third skin layer 403 is made of a four-axial warp-knitted fabric (0°, +45°, 90°, -45°) with T700 material and 800g / m 2 .

[0103] The fourth skin layer 404 is made of a four-axial warp-knitted fabric (0°, +45°, 90°, -45°) with T700 material and 800g / m 2 .

[0104] The fifth skin layer 405 is made of a four-axial warp-knitted fabric (0°, +45°, 90°, -45°) with T700 material and 800g / m 2 .

[0105] The sixth skin layer 406 is made of a four-axial warp-knitted fabric (0°, +45°, 90°, -45°) with T700 material and 800g / m 2 .

[0106] The seventh skin layer 407 is made of a four-axial warp-knitted fabric (0°, +45°, 90°, -45°) with T700 material and 800g / m 2 .

[0107] The fabric used in the eighth skin layer 408 is a biaxial warp-knitted fabric (+45°, -45°), the material is T700, and the specification is 200g / m 2 .

[0108] As shown in FIG. 3, the first standing rib area 5 is located between the first cavity area 1 and the second cavity area 2, and includes a standing rib first layer 501 and a standing rib second layer 502; the second standing rib area 5 is located between the second cavity area 2 and the third cavity area 3, and includes a standing rib third layer 503 and a standing rib fourth layer 504.

[0109] The standing rib first layer 501 is a standing rib unidirectional fabric layer of the first standing rib area 5, the standing rib second layer 502 is a standing rib first multi-axial fabric layer of the first standing rib area 5, the standing rib third layer 503 is a standing rib unidirectional fabric layer of the second standing rib area 5, and the standing rib fourth layer 504 is a standing rib first multi-axial fabric layer of the second standing rib area 5.

[0110] The fabric used in the standing rib first layer 501 is a unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m 2 .

[0111] The fabric used in the standing rib second layer 502 is a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m 2 .

[0112] The fabric used in the standing rib third layer 503 is a unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m 2 .

[0113] The fabric used in the standing rib fourth layer 504 is a four-axial warp-knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m 2 .

[0114] As shown in FIG. 3, the four corner areas 6 include a corner first layer 601, a corner second layer 602, a corner third layer 603, and a corner fourth layer 604.

[0115] The corner first layer 601 and the corner second layer 602 are corner areas 6 at both ends of the first standing rib area 5, and the corner third layer 603 and the corner fourth layer 604 are corner areas 6 at both ends of the second standing rib area 5.

[0116] The fabrics used in the corner first layer 601, the corner second layer 602, the corner third layer 603, and the corner fourth layer 604 are all 12K carbon fiber filaments, and the material is T700.

[0117] The application also provides a layer implementation method of a thick-walled multi-cavity pultrusion beam of a vehicle body, which is used to manufacture the layer structure and comprises the following steps:

[0118] The first cavity area 1, the second cavity area 2 and the third cavity area 3 are sequentially laid by using multi-axial fabric;

[0119] The outer skin area 4 is laid by using multi-axial fabric, and the outer skin area 4 simultaneously wraps the first cavity area 1, the second cavity area 2 and the third cavity area 3 and forms a rectangular structure in the shape of an eye.

[0120] In some embodiments, before the outer skin area 4 is laid by using multi-axial fabric, the following steps are further included:

[0121] The stud area 5 is laid by using multi-axial fabric, and the number of the stud area 5 is two, the first stud area 5 is located between the first cavity area 1 and the second cavity area 2, and the second stud area 5 is located between the second cavity area 2 and the third cavity area 3;

[0122] The corner area 6 is laid by using fiber yarn, and the number of the corner area 6 is four, the first and second corner areas 6 are located between the two ends of the first stud area 5 and the skin area, and the third and fourth corner areas 6 are located between the two ends of the second stud area 5 and the skin area.

[0123] In summary, by using the layer implementation method of the thick-walled multi-cavity pultrusion beam of the vehicle body, the layer structure of the thick-walled multi-cavity pultrusion beam of the vehicle body suitable for the pultrusion process and meeting the mechanical requirements can be manufactured.

[0124] For example, according to the layer structure, the overall layer structure sequence is laid according to the following process: the first cavity area 1→the second cavity area 2→the third cavity area 3→the stud area 5→the outer skin area 4.

[0125] Please refer to FIG. 4, which is a schematic diagram of a layer process provided by an embodiment of the application.

[0126] In some embodiments, the first cavity area 1, the second cavity area 2 and the third cavity area 3 are laid by using a cavity layer method, and the number of layers is not less than two, and the cavity layer method comprises the following steps:

[0127] The first layer of the layer gradually changes according to the following process: the layer is laid by using a straight fabric in the shape of a one, is bent to form a circular arc structure, is bent again to form an open trapezoidal structure, is bent again to form a U-shaped structure, and finally forms an inner cavity trapezoidal layer structure;

[0128] The second layer of the layer gradually changes according to the following process: the layer is laid by using a straight fabric in the shape of a one, is bent to form a circular arc structure, is bent again to form an open trapezoidal structure, is bent again to form a U-shaped structure, and finally forms an outer cavity trapezoidal layer structure.

[0129] In the embodiment, the first cavity area 1, the second cavity area 2 and the third cavity area 3 adopt no less than two layers of laying, and the single layer is no less than 200g / m 2 For example, the first cavity multi-axial fabric layer is no less than two layers, and the second cavity multi-axial fabric layer is no less than two layers.

[0130] Taking the first cavity area 1 as an example, as shown in FIG. 3, the two layers of the first cavity area 1 are sequentially deformed according to the following gradient method, the first layer of laying gradient process: one-dimensional (flat cloth) → circular arc type → open trapezoidal structure → U-shaped structure → the final inner cavity trapezoidal layer structure, the second layer of laying gradient process: one-dimensional (flat cloth) → circular arc type → open trapezoidal structure → U-shaped structure → the final outer cavity port layer structure.

[0131] The second cavity area 2 and the third cavity area 3 are sequentially deformed according to the same gradient process as the first cavity area 1.

[0132] In some embodiments, the outer skin area 4 adopts a skin laying method, and the skin laying method includes:

[0133] The skin layer deformation process: the laying is made into a circular arc structure by bending from a one-dimensional flat cloth, then made into an open trapezoidal structure by bending, then made into a U-shaped structure by bending, and finally made into a skin rectangular layer structure.

[0134] It should be noted that many components mentioned in the present application are general standard components or components known to those skilled in the art, and their structure and principle can be known by the technical personnel through technical manual or through conventional experimental method.

[0135] It should be noted that in the present application, the relationship terms such as first and second are only used to distinguish one entity from another entity, and do not necessarily require or imply any such actual relationship or order between the entities.

[0136] The above describes in detail the laying structure and laying implementation method of the thick-walled multi-cavity pultrusion beam of the vehicle body provided by the present application. The principles and implementation methods of the present application are described by using specific examples in the present application. The above description of the embodiments is only used to help understand the method and its core idea of the present application. It should be pointed out that for ordinary skilled in the art, some improvements and modifications can be made to the present application without departing from the principles of the present application, and these improvements and modifications also fall within the protection scope of the claims of the present application.

Claims

1. A layup structure for a thick-walled, tubular, multi-cavity pultruded beam for a vehicle body, characterized by, The first cavity area, the second cavity area, the third cavity area and the outer skin area are all laid by multi-axial fabric, the second cavity area is located between the first cavity area and the third cavity area, and the three are collectively wrapped by the outer skin area to form a rectangular structure in the shape of an eye.

2. The laminate structure of thick-walled profiled multi-cavity pultruded beam for vehicle body according to claim 1, characterized in that, The stringer area is laid by multi-axial fabric, the number of the stringer area is two, the first stringer area is located between the first cavity area and the second cavity area, and the second stringer area is located between the second cavity area and the third cavity area.

3. The ply structure of a thick-walled profiled multi-cavity pultruded beam of a vehicle body according to claim 2, characterized in that, The corner area is laid by fiber yarn, the number of the corner area is four, the first and second corner areas are located between the two ends of the first stringer area and the skin area, and the third and fourth corner areas are located between the two ends of the second stringer area and the skin area.

4. The laminate structure of thick-walled profiled multi-cavity pultruded beam for vehicle body according to claim 1, characterized in that, The first cavity area comprises, from inside to outside, a cavity first multi-axial fabric layer, a cavity unidirectional fabric layer and a cavity second multi-axial fabric layer; and / or, The second cavity area comprises, from inside to outside, a cavity first multi-axial fabric layer, a cavity unidirectional fabric layer and a cavity second multi-axial fabric layer; And / or, The third cavity area comprises, from inside to outside, a cavity first multi-axial fabric layer, a cavity unidirectional fabric layer and a cavity second multi-axial fabric layer; Any one of the multi-axial fabric layers comprises at least two layers of multi-axial fabric, and the area density of the single layer of multi-axial fabric is not less than 200 g / m 2 .

5. The laminate structure of thick-walled profile multicell pultruded beam for vehicle body according to claim 4, characterized in that, The cavity first multi-axial fabric layer and the cavity second multi-axial fabric layer each comprise two layers of four-axial warp-knitted fabric, and the cavity unidirectional fabric layer comprises one layer of unidirectional fiber cloth.

6. The laminate structure of thick-walled profiled multi-cavity pultruded beam for vehicle body according to claim 1, characterized in that, The outer skin area comprises, from inside to outside, a skin first multi-axial fabric layer and a skin second multi-axial fabric layer; The skin first multi-axial fabric layer comprises multiple layers of four-axial warp-knitted fabric, and the skin second multi-axial fabric layer comprises one layer of two-axial warp-knitted fabric.

7. The laminate structure of thick-walled profiled multi-cavity pultruded beam for vehicle body according to claim 2, characterized in that, The stringer area comprises a stringer first multi-axial fabric layer and a stringer unidirectional fabric layer; The stringer first multi-axial fabric layer comprises one layer of four-axial warp-knitted fabric, and the stringer unidirectional fabric layer comprises one layer of unidirectional fiber cloth.

8. A method for implementing the plies of a thick-walled profile multicellular pultruded beam of a vehicle body, characterized in that, The method for manufacturing the layup structure as claimed in any one of claims 1 to 7 comprises: laying, in sequence, a first cavity area, a second cavity area and a third cavity area by multi-axial fabric; laying an outer skin area by multi-axial fabric, the outer skin area wrapping the first cavity area, the second cavity area and the third cavity area and forming a rectangular structure in the shape of an eye.

9. The method of claim 8, wherein the method further comprises: providing a plurality of layers of the fiber reinforced polymer material; and arranging the plurality of layers of the fiber reinforced polymer material in a predetermined pattern to form the vehicle body thick-walled profiled multi-cavity pultruded beam. Before laying the outer skin area by multi-axial fabric, the method further comprises: laying a stringer area by multi-axial fabric, the number of the stringer area being two, the first stringer area being located between the first cavity area and the second cavity area, and the second stringer area being located between the second cavity area and the third cavity area; laying a corner area by fiber yarn, the number of the corner area being four, the first and second corner areas being located between the two ends of the first stringer area and the skin area, and the third and fourth corner areas being located between the two ends of the second stringer area and the skin area.

10. The method of claim 8, wherein the method further comprises: providing a plurality of layers of the fiber reinforced polymer material; and arranging the plurality of layers of the fiber reinforced polymer material in a predetermined pattern to form the vehicle body thick-walled profiled multi-cavity pultruded beam. The first cavity area, the second cavity area and the third cavity area are laid by cavity layup, the number of the layers being no less than two, and the cavity layup comprises: The first layer of the gradual change process of the laying layer is as follows: the laying layer is made of a straight strip, is bent into a circular arc structure, is bent into an open trapezoidal structure, is bent into a U-shaped structure, and finally is made into an inner cavity trapezoidal laying layer structure; The second layer of the gradual change process of the laying layer is as follows: the laying layer is made of a straight strip, is bent into a circular arc structure, is bent into an open trapezoidal structure, is bent into a U-shaped structure, and finally is made into an outer cavity mouth-shaped laying layer structure; The outer skin area adopts a skin laying manner, and the skin laying manner comprises: The skin laying deformation process is as follows: the laying layer is made of a straight strip, is bent into a circular arc structure, is bent into an open trapezoidal structure, is bent into a U-shaped structure, and finally is made into a skin rectangular laying structure.

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