A superplastic molded side wall panel for a rail passenger vehicle and its manufacturing method

Abstract

This invention relates to the field of interior wall panel technology for rail passenger vehicles, specifically a superplastic-molded side wall panel and its manufacturing method. It solves the problems of existing wall panels' inability to further optimize weight, flame retardancy, and recyclability. The wall panel body is manufactured using superplastic molding; the wall panel body, U-shaped lower air outlet, water guide channel, coat hook mounting base, roller blind mounting base, and coat hook are all made of aluminum; the air duct is a phenolic foam air duct. The method includes: preparing the aluminum wall panel body using superplastic molding; placing the wall panel on an bonding fixture; installing the U-shaped lower air outlet, water guide channel, coat hook mounting base, roller blind mounting base, Z-shaped pressure strip, and air duct onto the wall panel body to obtain a semi-finished wall panel assembly; painting the semi-finished wall panel assembly; and installing the roller blind, coat hook, roller blind cover, and window sill cover. This invention provides a recyclable, highly flame-retardant, and relatively lightweight side wall panel for rail passenger vehicles.

Description

Technical Field

[0001] This invention relates to the field of interior wall panel technology for rail passenger vehicles, specifically to a superplastic molding side wall panel for rail passenger vehicles and its manufacturing method. Background Technology

[0002] With the rapid development of high-speed railway passenger cars in China, rail transit passenger cars are being recognized by more and more people as a means of transportation. At the same time, people's requirements for the comfort of riding in the car are also getting higher and higher. The passenger compartment wall panels, which account for about 40% of the passenger compartment area, are not only the main decorative components of the interior products, but also a scenic line and an important component.

[0003] Currently, many sections of the passenger compartment wall panels in rail passenger cars utilize thermoplastic composites, thermosetting composites, and thick metals. For composite materials, mass production often relies on SMC (semi-cured fiberglass) molding, a process combining unsaturated polyester resin and chopped glass fiber. This molding process is costly, and meeting environmental and flame-retardant standards is difficult, as is recycling. Metal materials, on the other hand, rely on traditional technologies, limiting their ability to achieve desired shapes and weight reduction. Currently, high-speed rail passenger car side wall panels are primarily made of fiberglass, which struggles to meet existing fire resistance and recyclability standards, and weight optimization has reached its limits. To further optimize flame retardancy, recyclability, and weight, it is necessary to develop a recyclable, high-flame-retardant, and relatively lighter rail passenger car side wall panel. Summary of the Invention

[0004] In view of the above-mentioned problems existing in the prior art, the present invention provides a superplastic molding side wall panel for a rail passenger vehicle and a method for manufacturing the same.

[0005] The technical solution adopted by this invention to solve the technical problem is as follows:

[0006] A superplastic-molded side wall panel for a rail passenger vehicle includes a wall panel body, coat hooks and roller blinds, and also includes an air duct, a U-shaped lower air outlet, a water guide channel, coat hook mounting seats, roller blind mounting seats, Z-shaped pressure strips, roller blind covers, and window sill covers installed on the wall panel body. The coat hooks are installed on the coat hook mounting seats, and the roller blinds are installed on the roller blind mounting seats. The wall panel body is made of superplastic molding. The wall panel body, U-shaped lower air outlet, water guide channel, coat hook mounting seats, roller blind mounting seats, and coat hooks are all made of aluminum. The air duct is a phenolic foam air duct.

[0007] A method for manufacturing a superplastic molded side wall panel for a rail passenger vehicle includes the following steps:

[0008] S1. The wall panel body is prepared using a superplastic forming process, and the wall panel body is made of aluminum material;

[0009] S2. Place the wall panel on the bonding fixture, and install the U-shaped lower air outlet, water guide groove, coat hook mounting base, roller shutter mounting base, Z-shaped pressure strip and air duct on the wall panel body to obtain a semi-finished wall panel assembly; the U-shaped lower air outlet, water guide groove, coat hook mounting base and roller shutter mounting base are all made of aluminum material, and the air duct is a phenolic foam air duct;

[0010] S3. Spray paint on the semi-finished wall panel assembly;

[0011] S4. Install the roller blind on the roller blind mounting base, install the coat hook on the coat hook mounting base, the coat hook is made of aluminum material, install the roller blind cover plate and the window sill cover plate on the wall panel body, and a superplastic molded side wall panel of a rail passenger car is completed.

[0012] The beneficial effects of this invention are:

[0013] The present invention provides a superplastic molding side wall panel for rail passenger vehicles that meets existing standard requirements, especially in terms of flame retardancy, recyclability, and light weight. It provides a rail passenger vehicle side wall panel that is recyclable, has a high flame retardancy rating, and is relatively lighter in weight. Attached Figure Description

[0014] Figure 1 This is a split structural diagram of a superplastic molded side wall panel for a rail passenger vehicle according to the present invention.

[0015] Figure 2 This is a structural diagram of a superplastic molded side wall panel for a rail passenger vehicle according to the present invention.

[0016] Figure 3 This is a flowchart illustrating a method for manufacturing a superplastic molded side wall panel for a rail passenger vehicle according to the present invention.

[0017] In the diagram: 1. Air duct, 2. U-shaped lower air outlet, 3. Water guide groove, 4. Coat hook mounting base, 5. Roller blind mounting base, 6. Z-shaped pressure strip, 7. Main wall panel, 8. Roller blind cover, 9. Coat hook, 10. Window sill cover, 11. Roller blind. Detailed Implementation

[0018] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0019] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0020] A superplastic molded side wall panel for a rail passenger vehicle, such as Figure 1 and Figure 2 The wall panel includes an air duct 1, a U-shaped lower air outlet 2, a water guide trough 3, a coat hook mounting base 4, a roller blind mounting base 5, a Z-shaped pressure strip 6, a wall panel body 7, a roller blind cover plate 8, a window sill cover plate 10, coat hooks 9, and a roller blind 11. The air duct 1, U-shaped lower air outlet 2, water guide trough 3, coat hook mounting base 4, roller blind mounting base 5, Z-shaped pressure strip 6, roller blind cover plate 8, and window sill cover plate 10 are all installed on the wall panel body 7. The coat hook 9 is installed on the coat hook mounting base 4, the roller blind 11 is installed on the roller blind mounting base 5, the roller blind cover plate 8 serves as the cover plate for the roller blind 11, and the wall panel body 7 has a window sill, with the window sill cover plate 10 serving as the window sill cover plate. The wall panel body 7 is made of superplastic molding; the wall panel body 7, the U-shaped lower air outlet 2, the water guide groove 3, the coat hook mounting base 4, the roller blind mounting base 5, and the coat hook 9 are all made of aluminum; the air duct 1 is a phenolic foam air duct 1.

[0021] The air duct 1 is a phenolic foam air duct 1; the U-shaped lower air outlet 2 is an aluminum U-shaped lower air outlet 2; the water guide channel 3 is a composite material water guide channel 3; the coat hook mounting base 4 is an aluminum coat hook mounting base 4; the roller blind mounting base 5 is an aluminum roller blind mounting base 5; the Z-shaped pressure strip 6 is a composite material Z-shaped pressure strip 6; the wall panel body 7 is an aluminum superplastic wall panel body 7, that is, the wall panel body 7 is made of aluminum and is made by superplastic molding. The roller blind cover 8 is a composite material roller blind cover 8; the coat hook 9 is an aluminum coat hook 9; the window sill cover 10 is a composite material window sill cover 10; and the roller blind 11 is made of PA66 material, and is again referred to as PA66 roller blind 11. The following components are installed on the aluminum superplastic wall panel body 7: 1. Phenolic foam air duct; 2. Aluminum U-shaped lower air outlet; 3. Composite material water guide channel; 4. Aluminum coat hook mounting base; 5. Aluminum roller blind mounting base; 6. Composite material Z-shaped pressure strip; 7. Aluminum superplastic wall panel body; 8. Composite material roller blind cover plate; and 10. Composite material window sill cover plate.

[0022] The composite material of the water guide channel 3 is carbon fiber. As one embodiment, the composite materials of the Z-shaped pressure strip 6, the window sill cover 10, and the roller shutter cover 8 are also all carbon fiber.

[0023] The phenolic foamed air duct 1, composite material water guide channel 3, aluminum coat hook mounting base 4, aluminum roller shutter mounting base 5, and composite material Z-shaped pressure strip 6 are all bonded and fixed to the main body of aluminum superplastic wall panel 7 with structural adhesive and sealed with sealant.

[0024] The aluminum superplastic wall panel body 7 has a window sill and roller blind installation position. The aluminum roller blind mounting base 5 is adhered to the roller blind installation position. The composite material roller blind cover plate 8 is set corresponding to the roller blind 11. The composite material roller blind cover plate 8 is installed on the aluminum superplastic wall panel body 7 and / or PA66 roller blind 11 by plugging in. For example, the composite material roller blind cover plate 8 is plugged into the outside of the installed roller blind 11. The composite material window sill cover plate 10 is installed on the aluminum superplastic wall panel body 7 by plugging in. The window sill cover plate 10 is installed corresponding to the window sill. For example, the window sill cover plate 10 is plugged into the upper insertion port of the water guide trough 3.

[0025] The roller blind 11 is fixed to the aluminum roller blind mounting base 5 with bolts, and the aluminum coat hook 9 is fixed to the aluminum coat hook mounting base 4 with bolts.

[0026] As a preferred embodiment, the forming material parameters of the above-mentioned aluminum superplastic wall panel body 7 are as follows: aluminum plate material 5083, temper H111, thickness 2.5mm, width 1700mm, and length 2800mm. The equipment parameters for the aluminum superplastic wall panel body 7 are as follows: the equipment used is a 1250-ton press, the press table width is greater than 2000mm, the table length is greater than 3000mm, and the effective stroke is approximately 1500mm, typically greater than 1500mm.

[0027] Parameters for the molding die of the aluminum superplastic wall panel body 7: The material is ductile iron, formed using metal casting technology, and then CNC machined (computer numerical control machining) according to a 3D digital model using a five-axis gantry milling machine. Gas parameters for molding the aluminum superplastic wall panel body 7: Helium (He) is used for blow molding, with a blowing pressure of 4-6 kgf or 0.4-0.6 MPa. Heating parameters for molding the aluminum superplastic wall panel body 7: The wall panel mold is placed on the press, connected, fixed, and heated to between 400-500℃. Molding parameters for the aluminum superplastic wall panel body 7: The aluminum plate is placed on the preheated mold, connected, fixed, and heated. Simultaneously, the press and slide descend at a speed of 600 mm / min, with a slow descent speed of 20 mm / min when the upper and lower molds are in contact. Pressure is applied to the aluminum plate and the lower mold, while helium is blown onto the wall panel being formed for 3-5 minutes. After superplastic molding, the wall panel is cooled to below 350℃ and then removed from the mold. The wall panel body 7 is obtained by using laser blanking and template marking, followed by CNC machining and cutting.

[0028] After the aluminum superplastic wall panel body 7 is formed, the accessories are installed: After the wall panel is superplastic formed, it is placed on the bonding fixture; the U-shaped aluminum lower air outlet 2 is bonded to the lower part of the wall panel 7, and the carbon fiber water guide channel 3 is bonded to the lower part of the window sill; then the aluminum coat hook mounting base 4 and the aluminum roller blind mounting base 5 are bonded to the roller blind installation position, and the Z-shaped pressure strip 6 is bonded to both sides of the wall panel body 7; the density is 270kg / m³. 3The phenolic air duct 1 is adhered to the back of the wall panel, and all joints are sealed with sealant.

[0029] Spraying after installation of superplastic wall panel molding accessories: After the wall panel accessories are bonded, use environmentally friendly water-based paint, and spray according to the coating structure of two coats of primer and two coats of topcoat, with a color difference δE < 1.5 and a gloss N = 5-15.

[0030] Installation of accessories after spraying the superplastic wall panel: After the wall panel is sprayed, install the roller blind 11 onto the roller blind mounting base 5 using M8 hex bolts, install the coat hook 9 onto the coat hook mounting base 4 using M4 hex bolts, and then insert the composite material roller blind cover plate 8 onto the outside of the installed roller blind 11 and the window sill cover plate 10 into the upper insertion port of the water guide channel 3.

[0031] Installation of accessories after spraying the superplastic wall panel: After the wall panel is sprayed, the roller shutter 11 is installed onto the roller shutter mounting base 5 using M8 hex bolts. The coat hook 9 is installed onto the coat hook mounting base 4 using M4 hex bolts. Then, the composite material roller shutter cover plate 8 is inserted and installed onto the outside of the installed roller shutter 11, and the window sill cover plate 10 is inserted and installed onto the upper insertion port of the water guide channel 3. The front and back of the wall panel body 7 are wiped clean, finally resulting in a lightweight and environmentally friendly wall panel composed mainly of the wall panel body 7, composite materials, and aluminum accessories.

[0032] This invention provides a method for manufacturing a superplastic molded side wall panel for a rail passenger vehicle, such as... Figure 3 Specifically, it includes the following steps:

[0033] S1. The wall panel body 7 is prepared using a superplastic forming process, and the wall panel body 7 is made of aluminum material.

[0034] Material parameters for the main body of the wall panel 7: It uses aluminum material, aluminum plate material 5083, temper H111, thickness 2.5mm, width 1700mm, length 2800mm.

[0035] Equipment parameters for forming the main body of the wall panel: The equipment and specifications used are a 1250-ton press with a table width greater than 2000mm, a table length greater than 3000mm, and an effective stroke of approximately 1500mm.

[0036] The mold parameters for forming the main body of the wall panel 7 are as follows: the material is ductile iron, formed by metal casting process, and then CNC machined according to the three-dimensional digital model using a five-axis gantry milling machine.

[0037] Gas parameters for forming the main body of the wall panel 7: Helium (He) is used for blow molding, and the blowing pressure is 4-6 kgf or 0.4-0.6 MPa.

[0038] Heating parameters for forming the main body of the wall panel: Place the wall panel mold on the press, connect and fix it, and heat it to between 400 and 500 degrees Celsius.

[0039] Forming parameters for wall panel body 7: Place the aluminum plate on the preheated mold, fix the aluminum plate on the preheated mold and heat it. At the same time, the press and slide descend at a speed of 600 mm / min until the upper mold contacts the lower mold, at which point the speed decreases to 20 mm / min. Pressurize the aluminum plate and the lower mold, and simultaneously blow helium gas onto the forming wall panel for 3-5 minutes. After the wall panel is formed, a film is removed, resulting in the formed wall panel. Laser blanking is used on the formed wall panel. After blanking, a template is drawn on the wall panel using a laser. Then, CNC machining is used to cut according to the template drawing results to obtain the wall panel body 7.

[0040] S2. Place the wall panel on the bonding fixture, and install the U-shaped lower air outlet 2, water guide groove 3, coat hook mounting base 4, roller shutter mounting base 5, Z-shaped pressure strip 6, and air duct 1 onto the wall panel body 7 to obtain a semi-finished wall panel assembly. The U-shaped lower air outlet 2, water guide groove 3, coat hook mounting base 4, and roller shutter mounting base 5 are all made of aluminum, and the air duct 1 is a phenolic foam air duct 1.

[0041] After the main body of the wall panel 7 is formed, the accessories are installed: After the wall panel is superplastically formed, it is placed on the bonding fixture; the U-shaped aluminum lower air outlet is bonded to the lower part of the wall panel, and the water guide channel 3 is bonded to the lower part of the windowsill; then the aluminum coat hook mounting base 4 and the aluminum roller blind mounting base 5 are bonded to the coat hook 9 installation position, and at the same time, the Z-shaped pressure strip 6 is bonded to both sides of the wall panel, with a density of 270kg / m³. 3 The phenolic foamed air duct 1 is adhered to the back of the wall panel. Finally, all joints are sealed with sealant.

[0042] S3. Spray paint on the semi-finished wall panels.

[0043] Composed of metal superplastic composite wall panels, the superplastic wall panel molding accessories are sprayed after installation: after the wall panel accessories are bonded, environmentally friendly water-based paint is used, with two coats of primer and two coats of topcoat according to the coating structure, and the spraying standard is that the color difference δE < 1.5 and the gloss N = 5~15.

[0044] S3. Install the roller blind 11 on the roller blind mounting base 5, install the coat hook 9 on the coat hook mounting base 4. The coat hook 9 is made of aluminum. Install the roller blind cover plate 8 on the wall panel body 7, and install the window sill cover plate 10 on the wall panel body 7. The superplastic molding side wall panel of a rail passenger car is completed.

[0045] Installation of accessories after superplastic wall panel assembly and spraying: After the wall panel is sprayed, the roller shutter 11 is installed onto the roller shutter mounting base 5 using M8 hex bolts, and the coat hook 9 is installed onto the coat hook mounting base 4 using M4 hex bolts. Then, the composite material roller shutter cover plate 8 is inserted and installed onto the outside of the installed roller shutter 11, and the window sill cover plate 10 is inserted and installed onto the upper insertion port of the water guide channel 3. The front and back of the wall panel are wiped clean, and finally, a composite wall panel mainly based on metal superplastic molding is obtained. The superplastic molding side wall panel of a rail passenger car is completed.

[0046] Experimental testing shows that the weight of the superplastic composite wall panel obtained by this invention is <23kg. The main body of the wall panel is made of aluminum plate 5083-H111, which is recyclable and reusable. Its fire resistance can reach EN45545-HL3 and it is non-combustible. Its tensile strength can reach 270mpa.

[0047] The present invention provides a superplastic molding side wall panel for rail passenger vehicles that meets the current requirements for wall panels, especially in terms of flame retardancy, recyclability, and light weight. It provides a rail passenger vehicle side wall panel that is recyclable, has a high flame retardancy rating, and is relatively lighter in weight.

[0048] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for manufacturing a superplastic molded side wall panel for a rail passenger vehicle, characterized in that, Includes the following steps: S1. The wall panel body (7) is prepared by superplastic forming process, and the wall panel body (7) is made of aluminum material; S2. Place the wall panel on the bonding fixture and install the U-shaped lower air outlet (2), water guide groove (3), coat hook mounting base (4), roller shutter mounting base (5), Z-shaped pressure strip (6) and air duct (1) on the wall panel body (7) to obtain a semi-finished wall panel assembly; the U-shaped lower air outlet (2), water guide groove (3), coat hook mounting base (4), and roller shutter mounting base (5) are all made of aluminum material, and the air duct (1) is a phenolic foam air duct (1); S3. Spray paint on the semi-finished wall panel assembly; S4. Install the roller blind (11) on the roller blind mounting base (5), install the coat hook (9) on the coat hook mounting base (4), the coat hook (9) is made of aluminum material, install the roller blind cover plate (8) and the window sill cover plate (10) on the wall panel body (7), and a superplastic molding side wall panel of a rail passenger car is completed. S1 specifically involves: fixing an aluminum plate onto a preheating mold of the wall panel body (7), heating the preheating mold while the press and slide descend, applying pressure to the aluminum plate and the lower mold, and blowing helium gas onto the wall panel being formed. After the wall panel is formed, a film is formed, resulting in a formed wall panel. The formed wall panel is then laser-cut, patterned, and cut to obtain the wall panel body (7). The aluminum plate is 5083 aluminum plate in H111 condition. The preheating mold is made of ductile iron. The blowing pressure is 4-6 kgf or 0.4-0.6 MPa. The preheating mold is heated to 400-500℃. The press is a 1250-ton press. When the upper mold and lower mold are not in contact, the press descends at a speed of 600 mm / min. When the upper mold and lower mold are in contact, the press descends at a speed of 20 mm / min.

2. A superplastic molded side wall panel for a rail passenger vehicle, comprising a wall panel body (7), coat hooks (9), and a roller blind (11), and further comprising an air duct (1), a U-shaped lower air outlet (2), a water guide groove (3), a coat hook mounting base (4), a roller blind mounting base (5), a Z-shaped pressure strip (6), a roller blind cover plate (8), and a window sill cover plate (10) installed on the wall panel body (7), wherein the coat hooks (9) are installed on the coat hook mounting base (4), and the roller blind (11) is installed on the roller blind mounting base (5), characterized in that, The superplastic molded side wall panel is prepared by the manufacturing method of the superplastic molded side wall panel of a rail passenger car as described in claim 1. The wall panel body (7) is made by superplastic molding. The wall panel body (7), U-shaped lower air outlet (2), water guide groove (3), coat hook mounting base (4), roller shutter mounting base (5), and coat hook (9) are all made of aluminum. The air duct (1) is a phenolic foam air duct (1).

3. The superplastic molding side wall panel of a rail passenger vehicle as described in claim 2, characterized in that, The water guide groove (3), Z-shaped pressure strip (6), window sill cover (10) and roller shutter cover (8) are all made of composite materials.

4. The superplastic molding side wall panel of a rail passenger vehicle as described in claim 2, characterized in that, The roller shutter (11) is made of PA66 material.

5. The superplastic molding side wall panel of a rail passenger vehicle as described in claim 2, characterized in that, The air duct (1), water guide groove (3), coat hook mounting base (4), roller shutter mounting base (5), and Z-shaped pressure strip (6) are all bonded to the wall panel body (7).

6. The superplastic molding side wall panel of a rail passenger vehicle as described in claim 2, characterized in that, The roller blind (11) is bolted to the roller blind mounting base (5), and the coat hook (9) is bolted to the coat hook mounting base (4).

7. The superplastic molding side wall panel of a rail passenger vehicle as described in claim 2, characterized in that, The roller shutter cover plate (8) is inserted into the wall panel body (7) or the roller shutter (11), and the window sill cover plate (10) is inserted into the wall panel body (7).

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