Integrally formed structure and manufacturing method of composite material window frame in driver's cab

Abstract

The present invention discloses an integrally formed structure of a composite material window frame for a driver's cab and a manufacturing method. The integrally formed structure of the composite material window frame for a driver's cab comprises an upper window frame and a lower window frame; the upper window frame comprises a first upper continuous ply, a plurality of first preforms, and a first lower continuous ply; the lower window frame comprises a second upper continuous ply, a plurality of second preforms, and a second lower continuous ply; the upper window frame and the lower window frame are matched in shape, and the first preform and the second preform correspond one to one, the first preform section is provided with a threaded hole, the second preform section is provided with a threaded hole, and the two threaded holes are connected by a latch screw sleeve; the present invention effectively avoids possible connection welds in traditional metal window frames, eliminates the influence of welding heat affected zones and residual stresses, and effectively improves the overall rigidity and strength of the window frame structure; the use of preforms for segmented filling effectively reduces the risks of internal quality defects and the like.

Description

Technical Field

[0001] The invention relates to the technical field of composite materials, and in particular to an integrally formed structure of a composite material window frame in a driver's cab and a manufacturing method thereof. Background Art

[0002] As the speed of rail vehicles continues to increase, the wind resistance of high-speed trains increases significantly, so there is a more urgent need for the driver's cab to have a low drag coefficient. The windward side of the driver's cab of existing high-speed trains is a streamlined shape with complex three-dimensional curves. The front window position is the key position of the driver's cab shape, and its structural outline is more complex. At the same time, the front window frame needs to be installed with a streamlined front windshield assembly, which has strict requirements on the structural strength, shape accuracy, and installation and maintenance of the window frame.

[0003] At present, the front window frames of the driver's cab of high-speed trains are generally formed by integral CNC processing of aluminum alloy profiles, which are difficult to manufacture, have high processing costs, and have a low product qualification rate. Summary of the invention

[0004] The purpose of the present invention is to provide a composite material window frame integrally formed structure and a manufacturing method for a driver's cab in view of the deficiencies in the prior art.

[0005] The technical solution of the present invention to solve the above problem is: the composite material window frame integrally formed structure of the driver's cab comprises an upper window frame and a lower window frame;

[0006] The upper window frame includes a first upper continuous ply, a plurality of first preforms, and a first lower continuous ply;

[0007] The lower window frame includes a second upper continuous ply, a plurality of second preforms, and a second lower continuous ply;

[0008] The upper window frame and the lower window frame are matched in shape, and the first preformed body and the second preformed body correspond to each other one by one. The first preformed body segment is provided with a threaded hole, and the second preformed body segment is provided with a threaded hole, and the two threaded holes are connected by a bolt sleeve;

[0009] A sealing strip installation groove is provided in the cross section of the lower window frame, the sealing strip installation groove is arranged at the connection between the upper window frame and the lower window frame, and a sealing strip is installed in the sealing strip installation groove;

[0010] The first upper continuous ply, the first lower continuous ply, the second upper continuous ply, and the second lower continuous ply respectively include a plurality of composite material layers.

[0011] Furthermore, a cross section of the upper window frame is provided with a mounting position for the front windshield of the driver's cab.

[0012] Furthermore, the composite material layer is selected from one of carbon fiber / epoxy composite materials, glass fiber / epoxy composite materials, carbon fiber + glass fiber hybrid / epoxy composite materials, chopped carbon fiber / epoxy composite materials, and chopped glass fiber / epoxy composite materials.

[0013] Furthermore, the first preform and the second preform are made of fiber-reinforced composite material or chopped fiber composite material.

[0014] The manufacturing method of the composite material window frame integrally formed structure of the driver's cab is characterized by comprising the following steps:

[0015] The first step is to prepare the upper window frame;

[0016] The second step is to prepare the lower window frame;

[0017] The third step is to install the sealing strip in the sealing strip installation groove of the lower window frame, assemble the upper window frame and the lower window frame accordingly, correspond each first preform to the second preform one by one, drill threaded holes on the first preform and the second preform, and thread the pin screw sleeves in the threaded holes to connect the upper window frame and the lower window frame.

[0018] Furthermore, the preparation method of the upper window frame specifically includes the following steps:

[0019] In the first step, a plurality of composite material layers are laid in the window frame mold in order to form a first upper continuous layer, and a heat setting agent is evenly sprayed on each composite material layer after laying;

[0020] The second step is to place the prepared multiple first preforms on the corresponding positions of the window frame mold, fill the gaps between the first preforms, and connect the vacuum system to vacuum and pre-compact;

[0021] The third step is to lay a plurality of composite material layers on the first preform in sequence to form a first lower continuous layer, spray a heat setting agent evenly on each composite material layer after laying, and perform pre-compaction every 5-10 layers to obtain a semi-finished product;

[0022] The fourth step is to pre-mold the semi-finished product, check for possible mold clearance or interference, adjust possible problems with the layering in the mold cavity, and ensure that the cavity is fully filled;

[0023] The fifth step is to use the vacuum introduction process to introduce the resin into the mold cavity after the pre-molding is completed, and then solidify the part after the introduction is completed;

[0024] Step 6. After curing is completed, release the pressure and demould, clean and deal with the burrs on the edge of the window frame to obtain the upper window frame.

[0025] Before preparing the upper window frame, a first preform is added to the complex curvature section according to the structural contour of the window frame. Different molds can be designed for the first preform according to different positions, shapes and sizes of the first preform. The mold is used to prepare the first preform using a fiber-reinforced composite material or a chopped fiber composite material. The preparation can also be completed by 3D printing of a fiber-reinforced composite material or a chopped fiber composite material.

[0026] The preparation method of the lower window frame is the same as that of the upper window frame.

[0027] The present invention has the beneficial effects:

[0028] (1) The present invention effectively avoids the connection welds that may exist in traditional metal window frames, eliminates the influence of welding heat-affected zones and residual stress, and effectively improves the overall rigidity and strength of the window frame structure; the upper window frame and the lower window frame are installed with latch screw sleeves, which can realize flexible adjustment of the window frame connection relationship;

[0029] (2) The composite material layer used in the present invention can effectively improve the corrosion resistance and fatigue resistance of the window frame, significantly increase the service life of the window frame, and significantly reduce the weight of the structure, thereby achieving the purpose of lightweight rail transit; the composite material layer is heat-set by a heat setting agent, which effectively improves the production efficiency of continuous laying and eliminates the residual stress problem caused by uneven resin dispersion that may occur during the resin injection process;

[0030] (3) The present invention uses a preform segmented filling technology, which effectively reduces the risk of large deformation and internal quality defects during the curing of ultra-thick and complex cross-section composite parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a structural schematic diagram of the integrally formed structure of the composite material window frame of the driver's cab.

[0032] Figure 2 It is a cross-sectional view of the integrally formed structure of the composite material window frame of the driver's cab.

[0033] Figure 3 It is a schematic diagram of the structure of the upper window frame and the lower window frame.

[0034] In the figure: 1-upper window frame, 2-lower window frame, 3-first upper continuous ply, 4-first preform, 5-first lower continuous ply, 6-second upper continuous ply, 7-second preform, 8-second lower continuous ply, 9-latch screw sleeve, 10-driver's cab front windshield mounting position, 11-sealing strip mounting groove. DETAILED DESCRIPTION

[0035] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood by specific circumstances.

[0036] like Figure 1-3 As shown, the integrally formed structure of the composite material window frame of the driver's cab includes an upper window frame and a lower window frame.

[0037] The upper window frame includes a first upper continuous ply, a plurality of first preforms, and a first lower continuous ply.

[0038] The lower window frame includes a second upper continuous ply, a plurality of second preforms, and a second lower continuous ply.

[0039] Before preparing the upper window frame, a first preform is added to the complex curvature section according to the structural contour of the upper window frame. Different molds can be designed for the first preform according to different positions, shapes and sizes of the first preform. These molds are used to prepare the first preform using fiber-reinforced composite materials or chopped fiber composite materials. The preparation can also be completed by 3D printing of fiber-reinforced composite materials or chopped fiber composite materials.

[0040] The preparation of the upper window frame includes the following steps:

[0041] The first step is to lay 2-10 layers of composite materials in the window frame mold in order to form the first upper continuous layer. After each layer of composite materials is laid, a heat setting agent is evenly sprayed. The heat setting agent uses thermoplastic nylon powder, the dosage is 0.5g-2g per square meter, and the temperature is heated to 60℃-80℃, and the heat setting is completed in 30 minutes;

[0042] In the second step, the prepared multiple first preforms are placed at corresponding positions of the window frame mold, the gaps between the first preforms are filled, and the vacuum system is connected for vacuum pre-compaction, the vacuum degree is not less than 900 mbar, and the time is not less than 15 minutes. Pre-compaction requires laying peelable cloth, porous isolation film, breathable felt, and vacuum bag on the open surface of the mold in sequence, or a flexible silicone layer can be directly used on the open surface of the mold;

[0043] The third step is to lay 2 to 10 layers of composite material on the first preform in sequence to form a first lower continuous layer, and evenly spray a heat setting agent on each layer of composite material after laying, and pre-compact to obtain a semi-finished product;

[0044] The fourth step is to pre-mold the semi-finished product, check for possible mold clearance or interference, adjust possible problems with the layering in the mold cavity, and ensure that the cavity is fully filled;

[0045] The fifth step is to use the vacuum introduction process to introduce the resin into the mold cavity after the pre-molding is completed. After the introduction is completed, the part is cured. The curing process is heated to 80°C at a rate of 1-3°C per minute, kept warm for 0.5 hours, then heated to 120°C at a rate of 1-3°C per minute, kept warm and pressurized for 2 hours, and then cooled to below 60°C at a rate of 1-3°C per minute to complete the curing of the part;

[0046] Step 6: After curing is completed, release the pressure and demould, clean and deal with the burrs on the edge of the window frame to obtain the upper window frame;

[0047] Before preparing the lower window frame, a second preform is added in the complex curvature section according to the structural profile of the lower window frame, and the position of the second preform corresponds to that of the first preform.

[0048] The process for preparing the lower window frame is the same as the process for preparing the upper window frame.

[0049] The composite material layers used in the first upper continuous ply, the first lower continuous ply, the second upper continuous ply and the second lower continuous ply can be selected from: one of carbon fiber / epoxy composite materials, glass fiber / epoxy composite materials, carbon fiber + glass fiber hybrid / epoxy composite materials, chopped carbon fiber / epoxy composite materials and chopped glass fiber / epoxy composite materials.

[0050] The first preform and the second preform are 200 mm to 800 mm long and 10 mm to 15 mm thick.

[0051] The upper window frame and the lower window frame are correspondingly assembled, each first preform and the second preform correspond to each other, threaded holes are drilled on the first preform and the second preform, and the latch screw sleeves are threadedly connected in the threaded holes to connect the upper window frame and the lower window frame. The latch screw sleeve can achieve a design adjustment range of 10-20N·m for the bolt tightening torque.

[0052] The cross section of the upper window frame is provided with a driver's cab front windshield installation position, and the cross section of the lower window frame is provided with a sealing strip installation groove, which is arranged at the connection between the upper window frame and the lower window frame, and the sealing strip is installed in the sealing strip installation groove.

[0053] The above description is only a preferred embodiment of the present invention and does not limit the present invention in other forms. Any technician familiar with the profession may use the technical content disclosed above to change or modify it into an equivalent embodiment with equivalent changes and apply it to other fields. However, any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the content of the technical solution of the present invention still falls within the protection scope of the technical solution of the present invention.

Claims

1. The composite window frame integrally formed structure of the driver's cab is characterized by: Including upper window frame and lower window frame; The upper window frame includes a first upper continuous ply, a plurality of first preforms, and a first lower continuous ply; The lower window frame includes a second upper continuous ply, a plurality of second preforms, and a second lower continuous ply; The upper window frame and the lower window frame are matched in shape, and the first preformed body and the second preformed body correspond to each other one by one. The first preformed body segment is provided with a threaded hole, and the second preformed body segment is provided with a threaded hole, and the two threaded holes are connected by a bolt sleeve; A sealing strip installation groove is provided in the cross section of the lower window frame, the sealing strip installation groove is arranged at the connection between the upper window frame and the lower window frame, and a sealing strip is installed in the sealing strip installation groove; The first upper continuous layer, the first lower continuous layer, the second upper continuous layer, and the second lower continuous layer respectively include a plurality of composite material layers; The cross section of the upper window frame is provided with a mounting position for the front windshield of the driver's cab; The first preform and the second preform are made of fiber-reinforced composite material or chopped fiber composite material.

2. The method for manufacturing the integrally formed structure of the composite material window frame of the driver's cab according to claim 1, characterized in that: The specific steps include: The first step is to prepare the upper window frame; The second step is to prepare the lower window frame; The third step is to install the sealing strip in the sealing strip installation groove of the lower window frame, assemble the upper window frame and the lower window frame accordingly, correspond each first preform to the second preform one by one, drill threaded holes on the first preform and the second preform, and thread the pin screw sleeves in the threaded holes to connect the upper window frame and the lower window frame.

3. The manufacturing method according to claim 2, characterized in that: The preparation method of the upper window frame is specific The following steps are involved: In the first step, a plurality of composite material layers are laid in the window frame mold in order to form a first upper continuous layer, and a heat setting agent is evenly sprayed on each composite material layer after laying; The second step is to place the prepared multiple first preforms on the corresponding positions of the window frame mold, fill the gaps between the first preforms, and connect the vacuum system to vacuum and pre-compact; The third step is to lay a plurality of composite material layers on the first preform in sequence to form a first lower continuous layer, and evenly spray a heat setting agent on each composite material layer after laying, and pre-compact, so as to obtain a semi-finished product; The fourth step is to pre-mold the semi-finished product, check for possible mold clearance or interference, adjust possible problems with the layering in the mold cavity, and ensure that the cavity is fully filled; The fifth step is to use the vacuum introduction process to introduce the resin into the mold cavity after the pre-molding is completed, and then solidify the part after the introduction is completed; Step 6. After curing is completed, release the pressure and demould, clean and deal with the burrs on the edge of the window frame to obtain the upper window frame.

4. The manufacturing method according to claim 3, characterized in that: Before preparing the upper window frame, a first preform is added to the complex curvature section according to the structural contour of the window frame. Different molds can be designed for the first preform according to different positions, shapes and sizes of the first preform. The mold is used to prepare the first preform using a fiber-reinforced composite material or a chopped fiber composite material. The preparation can also be completed by 3D printing of a fiber-reinforced composite material or a chopped fiber composite material.

5. The manufacturing method according to claim 3 or 4, characterized in that: The preparation method of the lower window frame is the same as that of the upper window frame.

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