A door post cover and a method of manufacturing the same

Abstract

The application provides a door post cover and a preparation method thereof. The door post cover comprises a door post cover plate body, a handrail mounting area is arranged on the door post cover plate body, a transition area one is arranged between the lower part of the handrail mounting area and the door post cover plate body, the door post cover plate body comprises a cover plate common area one and a cover plate common area two, the handrail mounting area comprises a transition area two, a handrail common area and a transition area three, the transition area three extends to the cover plate common area one and the cover plate common area two respectively, the innermost side and the outermost side of the cover plate common area one, the cover plate common area two, the handrail common area, the transition area one, the transition area two and the transition area three are respectively an inner glass fiber layer and an outer glass fiber layer, and a carbon fiber layer is arranged between the inner glass fiber layer and the outer glass fiber layer. The preparation method is realized by die forming or hot press tank forming. The application solves the problems of large density, easy deformation and complex process of the current door post cover, and has the advantages of low cost, high efficiency and batch production.

Description

Technical Field

[0001] This invention relates to the field of transportation equipment technology, specifically to a door pillar cover and its manufacturing method. Background Technology

[0002] Currently, the door pillar covers of rail transit vehicles are generally made of aluminum profile welded structure or fiberglass material. The aluminum profile welding process is complicated and the welding heat deformation is large, which can easily cause surface quality problems. Fiberglass material has a low elastic modulus, and in order to maintain the shape and increase rigidity, it is necessary to increase the thickness, which will increase the weight. Moreover, the increase in thickness is prone to internal defects and interlayer cracking.

[0003] The applicant, after conducting a search, found the following prior art:

[0004] Prior art 1: Application No. CN202223365666.6 discloses a subway door post handrail, which includes a door post cover and a handrail. The handrail passes through the door post cover. A first connecting plate and a second connecting plate are threaded to both sides of the door post cover. An L-shaped plate is provided on the second connecting plate. During installation, the two ends of the handrail are first inserted into the through holes opened on the outside of the door post cover, so that the boss fixedly connected on the left side of the handrail is close to the position of the first connecting plate. The first connecting plate is threaded into the door post cover. The first connecting plate is threaded to the boss on the left side of the handrail. A connecting post is fixedly connected to the other side of the handrail. The connecting post is bolted to the L-shaped plate on the second connecting plate to fix the right side of the handrail. This solves the problems of inconvenient installation and disassembly and unstable fixation of the current subway door post handrail. However, this application only carries out modal matching design from the perspective of structural form and fails to fundamentally solve the above-mentioned technical problems.

[0005] Prior Art 2: A doorpost cover panel with application number CN202110693594.9 provides a technical solution, including a cover panel body. An emergency unlocking port is provided at the top of one side of the cover panel body, and an inspection port is provided at the bottom of one side of the cover panel body. The diagonal reinforcing ribs are composed of eight layers of composite material, with the innermost layer of the diagonal reinforcing ribs consisting of two 0.2mm thick inner glass fiber layers tightly bonded together. This invention uses eight layers of composite material, connected by inner and outer glass fiber layers, and internally supported by four layers of fiberglass carbon fiber composite layer. Under the same usage requirements, the total thickness of this material is [not specified]. With a thickness of 1.5mm, only one-quarter the thickness of fiberglass sheets, the weight of the sheet is greatly reduced while ensuring strength and stability. Furthermore, the multi-layered composite method of glass-carbon blending improves the fire resistance and safety of the sheet. The sheet is also non-volatile and pollution-free, reducing production costs while maintaining strength. Although this application changes the material, it only improves the diagonal reinforcing ribs. Since the doorpost cover is a monolithic structure, the stress on each part is different. Without scientifically improving the entire doorpost cover, optimal impact resistance cannot be achieved. Secondly, this application involves composite materials, which are expensive to manufacture.

[0006] In summary, a new technical solution is needed to address the aforementioned technical problems. Summary of the Invention

[0007] The purpose of this invention is to provide a doorpost cover, including a doorpost cover panel body, a handrail mounting area on the doorpost cover panel body, a transition area I between the lower part of the handrail mounting area and the doorpost cover panel body, the doorpost cover panel body including a cover panel ordinary area I and a cover panel ordinary area II, the handrail mounting area including a transition area II connected to the transition area I, the transition area II connected to the handrail ordinary area, a transition area III connected to the upper and lower ends of the handrail ordinary area, the transition area III extending to the cover panel ordinary area I and the cover panel ordinary area II respectively, wherein the innermost and outermost sides of the cover panel ordinary area I, cover panel ordinary area II, handrail ordinary area, transition area I, transition area II, and transition area III are respectively an inner glass fiber layer and an outer glass fiber layer, and a carbon fiber layer is disposed between the inner glass fiber layer and the outer glass fiber layer.

[0008] As a preferred embodiment, the inner glass fiber layer of the ordinary area of ​​the cover plate comprises two layers, the outer glass fiber layer comprises two layers, and the carbon fiber layer between the inner and outer glass fiber layers comprises 5-7 layers.

[0009] As a preferred embodiment, the inner glass fiber layer of the ordinary zone two of the cover plate comprises two layers, the outer glass fiber layer comprises two layers, and the carbon fiber layer between the inner and outer glass fiber layers comprises 5-7 layers.

[0010] As a preferred embodiment, the inner glass fiber layer of the transition zone one comprises two layers, the outer glass fiber layer comprises two layers, and the carbon fiber layer between the inner and outer glass fiber layers comprises 7-9 layers.

[0011] As a preferred embodiment, the inner glass fiber layer of the transition zone two comprises two layers, the outer glass fiber layer comprises two layers, and the carbon fiber layer between the inner and outer glass fiber layers comprises 9-11 layers.

[0012] As a preferred embodiment, the inner glass fiber layer of the ordinary area of ​​the handrail comprises two layers, the outer glass fiber layer comprises two layers, and the carbon fiber layer between the inner and outer glass fiber layers comprises 7-9 layers.

[0013] As a preferred embodiment, the inner glass fiber layer of the transition zone comprises two layers, the outer glass fiber layer comprises two layers, and the carbon fiber layer between the inner and outer glass fiber layers comprises 7-9 layers.

[0014] As a preferred embodiment, the lower part of the door pillar cover body is also provided with a reserved maintenance area cover.

[0015] As a preferred embodiment, the lower part of the reserved maintenance area cover is provided with a mounting base, and the mounting base has mounting holes.

[0016] As a preferred embodiment, a boss-shaped gasket is provided inside the mounting hole.

[0017] A method for preparing a door pillar cover includes the following steps:

[0018] A1: Cut the material pieces according to the shape of each section of the door pillar cover, and make the blanks according to the layering design of each section;

[0019] A2: Clean the mold and then apply release agent thoroughly;

[0020] A3: Mold closing;

[0021] A4: Heat to 80-90℃ at a heating rate of 100-240℃ / h, open the mold and add the blanks prepared in step one for each zone;

[0022] A5: After the material is added, close the mold;

[0023] A6: Increase temperature and pressure, increase temperature at a rate of 60℃-120℃ / h and maintain pressure at 10-30MPa, increase temperature to 150-190℃, heat preservation to allow the product to continue to solidify for 5-10 minutes, cool to 50-60℃, and release pressure;

[0024] A7: Mold opening, demolding and part removal.

[0025] As a preferred embodiment, in step A5, after the mold is closed, the pressure is increased to 3-6 MPa, the temperature is maintained for 4-7 minutes, and the air is released 2-3 times, each time for 4-15 seconds.

[0026] As a preferred embodiment, the sheet comprises carbon fiber woven fabric and glass fiber woven fabric, which are impregnated to form a prepreg.

[0027] As a preferred embodiment, the door pillar enclosure includes the following zones: ordinary zone 1, ordinary zone 2, transition zone 1, transition zone 2, transition zone 3, and handrail ordinary zone. The ply design of ordinary zone 1 and ordinary zone 2 includes two inner fiberglass layers and two outer fiberglass layers, with 5-7 carbon fiber layers between the inner and outer fiberglass layers. The ply design of transition zone 1, handrail ordinary zone, and transition zone 3 includes two inner fiberglass layers and two outer fiberglass layers, with 7-9 carbon fiber layers between the inner and outer fiberglass layers. The ply design of transition zone 2 includes two inner fiberglass layers and two outer fiberglass layers, with 9-11 carbon fiber layers between the inner and outer fiberglass layers.

[0028] A method for preparing a door pillar cover, characterized by comprising the following steps:

[0029] B1: Cut the carbon fiber layer and glass fiber layer according to the shape of each area of ​​the door pillar cover, and apply resin glue to the carbon fiber layer and glass fiber layer of each area;

[0030] B2: According to the layering method of each zone, the carbon fiber layer and glass fiber layer are laid on the mold of the door pillar cover;

[0031] B3: Wrap the mold of the door pillar cover with absorbent felt, and then wrap the outside of the absorbent felt with a release film and a vacuum bag in sequence, and seal it with tape.

[0032] B4: Place the mold processed in step B3 into the autoclave and close the autoclave;

[0033] B5: Start the autoclave, first heat up to 80°C, which takes 20 minutes, and maintain the temperature at 80°C for 50 minutes; then heat up to 120°C, which takes 20 minutes, and maintain the temperature at 120°C for 150 minutes; finally cool down to room temperature, which takes 30 minutes.

[0034] B6: Open the can, remove the mold, and demold.

[0035] As a preferred embodiment, the door pillar enclosure includes the following zones: ordinary zone 1, ordinary zone 2, transition zone 1, transition zone 2, transition zone 3, and handrail ordinary zone. The ply design of ordinary zone 1 and ordinary zone 2 includes two inner fiberglass layers and two outer fiberglass layers, with 5-7 carbon fiber layers between the inner and outer fiberglass layers. The ply design of transition zone 1, handrail ordinary zone, and transition zone 3 includes two inner fiberglass layers and two outer fiberglass layers, with 7-9 carbon fiber layers between the inner and outer fiberglass layers. The ply design of transition zone 2 includes two inner fiberglass layers and two outer fiberglass layers, with 9-11 carbon fiber layers between the inner and outer fiberglass layers.

[0036] This invention employs a combined carbon fiber and fiberglass layer integrated design for the door pillar cover, eliminating the need for composite materials. This solves the problems of complex welding processes and susceptibility to thermal deformation associated with aluminum profiles used in rail transit vehicle door pillar covers, while also addressing the increased thickness and weight issues associated with fiberglass manufacturing. This application utilizes different layering designs for different locations within the door pillar cover, ensuring that the original structural rigidity remains unchanged. This results in a weight reduction of over 50% compared to traditional aluminum alloy structures and over 66% compared to traditional fiberglass structures, achieving the lowest economic cost. Furthermore, the manufacturing method of this application is twice as efficient as traditional processes. This invention can be applied not only to the rail transit field but also to aerospace, aircraft, and other related fields.

[0037] The door pillar cover of this application solves the problems of high density, easy deformation and complex process of current door pillar covers; the preparation method of the door pillar cover of this application has the advantages of low cost, high efficiency and mass production capability, and has good innovation in reducing weight, reducing cost and improving production efficiency and quality of door pillar covers. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0039] Figure 1 This is a structural schematic diagram of the door pillar cover of the present invention at angle one;

[0040] Figure 2 This is a schematic diagram of the structure of the door pillar cover at angle two of the present invention;

[0041] Figure 3 This is a structural schematic diagram of angle three of the door pillar cover of the present invention;

[0042] Figure 4 This is a structural schematic diagram of angle four of the door pillar cover of the present invention;

[0043] Figure 5 This is a schematic diagram of the structure of the ordinary area of ​​the cover plate of the present invention;

[0044] Figure 6 This is a schematic diagram of the structure of the ordinary section two of the cover plate of the present invention;

[0045] Figure 7 This is a schematic diagram of the structure of the transition region one of the present invention;

[0046] Figure 8 This is a schematic diagram of the structure of the second transition region of the present invention;

[0047] Figure 9 This is a schematic diagram of the structure of the transition region three of the present invention;

[0048] Figure 10 This is a schematic diagram of the structure of the ordinary area of ​​the handrail in this invention;

[0049] Figure 11 This is a schematic diagram of the structure of the boss-type gasket and the mounting hole of the present invention;

[0050] Figure 12 This is a cross-sectional view of the compression molding process described in this application;

[0051] Figure 13 This is a schematic diagram of the compression molding and curing process of this application;

[0052] Figure 14 This is a schematic diagram of the autoclave molding and curing process of this application;

[0053] Figure label:

[0054] 1. Door post cover body; 2. Handrail installation area; 3. Handrail mounting base; 4. Transition area one.

[0055] 5. Standard Area 1 of the Exterior Panel 6. Standard Area 2 of the Exterior Panel 7. Transition Area 2 8. Standard Area of ​​the Handrail

[0056] 9. Transition Zone 3; 10. Reserved Maintenance Area Cover; 11. Mounting Base; 12. Mounting Holes

[0057] 13. Boss-shaped pad 14. Upper mold 15. Lower mold 16. Release agent

[0058] 17. Raw material blank. Detailed Implementation

[0059] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to specific examples and the accompanying drawings.

[0060] It should be noted that all uses of "a" and "b" in the embodiments of the present invention are for the purpose of distinguishing two entities or parameters with the same name but different names. It is clear that "a" and "b" are only for the convenience of expression and should not be construed as limiting the embodiments of the present invention. Subsequent embodiments will not explain this in detail.

[0061] Example 1:

[0062] This embodiment provides a doorpost cover, including a doorpost cover body 1. The doorpost cover body 1 has a handrail mounting area 2. One end of the handrail mounting area 2 is a handrail mounting seat 3, and the other end of the handrail mounting area 2 is a transition area 4 between it and the doorpost cover body 1. The doorpost cover body 1 includes a cover plate ordinary area 5 and a cover plate ordinary area 6. The handrail mounting area 2 includes a transition area 7 connected to the transition area 4. The transition area 7 is connected to the handrail ordinary area 8. The upper and lower ends of the handrail ordinary area 8 are connected to a transition area 3 9, which extends to the cover plate ordinary area 5 and the cover plate ordinary area 6, respectively. Ordinary Zone 2 6, wherein the innermost and outermost layers of Ordinary Zone 1 5, Ordinary Zone 2 6, Ordinary Zone 8, Transition Zone 1 4, Transition Zone 2 7, and Transition Zone 3 9 are respectively an inner glass fiber layer and an outer glass fiber layer. The inner and outer glass fiber layers can be made of existing glass fiber layers. The descriptions of "inner" and "outer" are for better distinction of positional relationship. A carbon fiber layer is provided between the inner and outer glass fiber layers, effectively utilizing the impact resistance of the glass fiber layer and increasing the structural stiffness and strength through the carbon fiber layer, fully leveraging the superior mechanical properties of the glass fiber layer and carbon fiber layer. It has advantages, and its cost is lower than that of composite materials while meeting the required stiffness and strength conditions; the above-mentioned ordinary area 5 of the cover plate, ordinary area 6 of the cover plate, ordinary area 8 of the handrail, transition area 4 of transition area 1, transition area 7 of transition area 2, and transition area 3 of transition area 9 are integrally formed; the inner and outer glass fiber layers effectively utilize the impact resistance and economy of glass fiber, and the carbon fiber between the inner and outer glass fiber layers plays a role in increasing high strength; preferably, the layup range of the entire door pillar cover plate body 1 is 9-15 layers, and the layup design of the entire door pillar cover plate body 1 adopts a symmetrical and balanced design concept to reduce deformation during the forming process. To address the issue and reduce interlayer stress, this embodiment adopts an integrated design of carbon fiber layer and glass fiber layer. Compared with the case of profile welding or fiberglass fabrication, the stiffness is improved. Due to the superior strength and lower density of carbon fiber layer and glass fiber layer, this embodiment achieves a weight reduction of more than 50% compared with traditional aluminum alloy structure and more than 66% compared with traditional fiberglass structure. Preferably, the glass fiber layer is made of glass fiber woven fabric, the carbon fiber layer is made of carbon fiber woven fabric, and the glass fiber woven fabric and carbon fiber woven fabric are impregnated to make prepreg. More preferably, T300 UD carbon fiber woven fabric and LY5566 glass fiber woven fabric are used.

[0063] Example 2:

[0064] This embodiment conducts a load-bearing analysis based on the actual service conditions of the doorpost cover. Each part has an independent layer design, specifically:

[0065] like Figure 5 The dotted-line outline of the cover plate's ordinary area 5 is shown. The layup range of the ordinary area 5 is 9-11 layers, including two inner glass fiber layers, two outer glass fiber layers, and 5-7 carbon fiber layers between the inner and outer glass fiber layers. This design fully utilizes the impact resistance and economy of glass fiber while increasing strength with carbon fiber. The symmetrical and balanced design concept reduces deformation during the forming process and minimizes interlayer stress.

[0066] like Figure 6 The dotted-line frame indicates the second ordinary area 6 of the cover plate. The layup range of the second ordinary area 6 of the cover plate is 9-11 layers, of which the inner glass fiber layer includes two layers, the outer glass fiber layer includes two layers, and the carbon fiber layer between the inner and outer glass fiber layers includes 5-7 layers. The symmetrical and balanced design concept is adopted to reduce deformation problems during the forming process and reduce interlayer stress.

[0067] like Figure 10 The handrail ordinary area 8 shown is the part highlighted by the dashed line. The layup range of the handrail ordinary area 8 is 11-13 layers, of which the inner glass fiber layer includes two layers, the outer glass fiber layer includes two layers, and the carbon fiber layer between the inner and outer glass fiber layers includes 7-9 layers. The symmetrical and balanced design concept is adopted to reduce deformation problems during the forming process and reduce interlayer stress.

[0068] like Figure 7 The transition zone 4 shown is defined by the dashed box. The transition zone 4 has 11-13 layers, including two inner glass fiber layers, two outer glass fiber layers, and 7-9 carbon fiber layers between the inner and outer glass fiber layers. The design adopts a symmetrical and balanced approach to reduce deformation during the forming process and decrease interlayer stress.

[0069] like Figure 8 The transition zone 2 7 shown is defined by the dashed box. The layup range of the transition zone 2 7 is 13-15 layers. The inner glass fiber layer includes two layers, the outer glass fiber layer includes two layers, and the carbon fiber layer between the inner and outer glass fiber layers includes 9-11 layers. A symmetrical and balanced design concept is adopted to reduce deformation problems during the forming process and reduce interlayer stress.

[0070] like Figure 9 The transition zone 3.9 shown is defined by the dashed box. The layup range of the transition zone 3.9 is 11-13 layers, including two inner glass fiber layers, two outer glass fiber layers, and 7-9 carbon fiber layers between the inner and outer glass fiber layers. The symmetrical and balanced design concept is adopted to reduce deformation problems during the forming process and reduce interlayer stress.

[0071] Table 1 shows the number of layers and the layer sequence for 9, 11, 13, and 15-layer door pillar cover designs, using a layer-dropping design;

[0072] When laying 9 layers, the laying angle between the outer and inner glass fiber layers of the outer layer is 45 degrees (laying angle refers to the fiber laying angle; 0 degrees is the fiber direction, which has the highest strength, and 90 degrees is perpendicular to this direction, which has the lowest strength). The laying angle between the outer and inner glass fiber layers of the inner layer is -45 degrees. Five carbon fiber layers are laid between the outer and inner glass fiber layers of the inner layer, and the laying angle of all five carbon fiber layers is 0 degrees. The carbon fiber layer in the middle of the five carbon fiber layers is a symmetrical plane. As shown in Table 1, the laying angle of the glass fiber layers of the 1st and 15th layers is 45 degrees, the laying angle of the glass fiber layers of the 2nd and 14th layers is -45 degrees, the carbon fiber layer of the 8th layer is a symmetrical plane, and the laying angle of the carbon fiber layers of the 3rd, 4th, 12th, and 13th layers is 0 degrees. The remaining layers adopt a layer-dropping design.

[0073] When laying 11 layers, the laying angle between the outer and inner glass fiber layers of the outer layer is 45 degrees, and the laying angle between the outer and inner glass fiber layers of the inner layer is -45 degrees. Seven carbon fiber layers are laid between the outer and inner glass fiber layers of the inner layer. The carbon fiber layer in the middle of the seven carbon fiber layers is a symmetrical plane, and the laying angle of the carbon fiber layer on the symmetrical plane is 0 degrees. The laying angle of the two carbon fiber layers adjacent to the symmetrical plane is 45 degrees, and the laying angle of the remaining four carbon fiber layers is 0 degrees. As shown in Table 1, the laying angle of the glass fiber layers of the 1st and 15th layers is 45 degrees, the laying angle of the glass fiber layers of the 2nd and 14th layers is -45 degrees, the carbon fiber layer of the 8th layer is a symmetrical plane, the laying angle of the 6th and 10th layers is 45 degrees, and the laying angle of the carbon fiber layers of the 3rd, 4th, 12th, and 13th layers is 0 degrees. The remaining layers adopt a layer-dropping design.

[0074] When laying 13 layers, the outermost and innermost glass fiber layers are laid at a 45-degree angle, while the outermost and innermost glass fiber layers are laid at a -45-degree angle. Nine carbon fiber layers are laid between the outermost and innermost glass fiber layers. The carbon fiber layers in the middle of these nine layers form a symmetrical plane. The laying angle between two adjacent carbon fiber layers on this symmetrical plane is -45 degrees. The laying angle between two adjacent carbon fiber layers laid at a -45 degree angle is... The fiberglass layers are laid at 45 degrees, while the remaining four layers are laid at 0 degrees. As shown in Table 1, the fiberglass layers of the 1st and 15th layers are laid at 45 degrees, the fiberglass layers of the 2nd and 14th layers are laid at -45 degrees, the carbon fiber layer of the 8th layer is symmetrical, the layers of the 7th and 9th layers are laid at -45 degrees, the layers of the 6th and 10th layers are laid at 45 degrees, and the carbon fiber layers of the 3rd, 4th, 12th and 13th layers are laid at 0 degrees. The remaining layers adopt a layer-dropping design.

[0075] When laying 15 layers, the laying angle between the outer and inner glass fiber layers of the outer layer is 45 degrees, that is, the laying angle between the 1st and 15th layers is 45 degrees. The laying angle between the outer and inner glass fiber layers of the inner layer is -45 degrees, that is, the laying angle between the 2nd and 14th layers is -45 degrees. There are 11 carbon fiber layers between the outer and inner glass fiber layers of the inner layer. The carbon fiber layer in the middle of the 11 carbon fiber layers is a symmetrical plane, that is, the 8th layer is a symmetrical plane. The laying angle of the carbon fiber layers on both sides adjacent to the symmetrical plane is -45 degrees, that is, the laying angle of the 7th and 9th layers is -45 degrees. The laying angle of the carbon fiber layers of the 6th and 10th layers is 45 degrees. The laying angle of the carbon fiber layers of the 5th and 11th layers is 90 degrees. The laying angle of the carbon fiber layers of the 3rd, 4th, 12th and 13th layers is 0 degrees.

[0076] By designing the laying angles of each layer as described above, the doorpost cover in this application is guaranteed to have optimal strength, rigidity, and impact resistance.

[0077] The design adopts a symmetrical and balanced concept, which can also be achieved when setting 10, 12, or 14 layers. For example, when setting 10 layers, you can delete the symmetrical layer of layer 11; when setting 12 layers, you can delete the symmetrical layer of layer 13; and when setting 14 layers, you can delete the symmetrical layer of layer 15.

[0078]

[0079]

[0080] Table 1

[0081] The different areas mentioned above are separated by clear boundaries or cross sections. The corners are stress concentration areas, and the maximum number of ply layers in the stress concentration areas is 15, that is, the maximum number of ply layers in transition zone 2 is 15, which increases the strength. The innermost and outermost layers are made of glass fiber to increase the impact resistance at the corners. Carbon fiber is used between the glass fiber layers to increase the mechanical properties.

[0082] In this embodiment, transition zone 3 9 is a corner with high stress concentration, while ordinary cover zone 1 5 and ordinary cover zone 2 6 are areas with low stress. The entire layup design is based on the specific structural stress, achieving the minimum cost to meet strength, stiffness, and design requirements. Compared to the aluminum profile structure of the prior art, it reduces weight by more than 50%, and compared to the fiberglass structure of the prior art, it reduces weight by more than 66%. The symmetrical and balanced design of the layer structure in this embodiment reduces deformation problems during the forming process and reduces interlayer stress. The carbon fiber layer at the very center of each zone is a symmetrical layer.

[0083] Example 3

[0084] This embodiment facilitates the inspection and maintenance of the circuits and components inside the door pillar cover. Specifically:

[0085] The lower part of the door pillar cover body 1 is provided with a reserved maintenance area cover 10. More specifically, the door pillar cover body 1 has a maintenance cover mounting hole, and a reserved maintenance area cover 10 is provided on the maintenance cover mounting hole. The reserved maintenance area cover 10 is connected to the door pillar cover body 1 by a detachable method such as snap-fit ​​or screw connection, so as to facilitate the opening of the reserved maintenance area cover 10 for maintenance of the circuit and components inside the pillar cover. The reserved maintenance area cover 10 can be made of materials such as aluminum profiles and fiberglass in the prior art.

[0086] Example 4

[0087] This embodiment facilitates the installation of doorpost covers, specifically:

[0088] The lower part of the reserved maintenance area cover 10 is provided with a mounting base 11, and the mounting base 11 has mounting holes 12; in order to improve strength and service life, the mounting base 11 is preferably integrally formed with the door post cover body 1 and the handrail mounting area 2; Figure 11 As shown, in order to avoid local stress concentration, a boss-type gasket 13 is provided in the mounting hole 12. The boss-type gasket 13 is preferably a boss-type metal gasket. When fixing, the bolt tightening pressure is transmitted through the boss-type metal gasket 13, avoiding direct pressure on the column cover plate body 1.

[0089] Example 5:

[0090] This embodiment provides a method for integral molding using compression molding, specifically:

[0091] A method for preparing a door pillar cover includes the following steps:

[0092] A1: Cut the material sheets according to the shape of each area of ​​the door pillar cover, and make the blank 17 according to the layering design of each area; the material sheets include carbon fiber woven fabric and glass fiber woven fabric, and the carbon fiber woven fabric and glass fiber woven fabric are impregnated to make prepreg, the carbon fiber woven fabric is T300, and the glass fiber woven fabric is LY5566.

[0093] The door pillar enclosure includes several sections: ordinary section 1 (5), ordinary section 2 (6), transition section 1 (4), transition section 2 (7), transition section 3 (9), and handrail ordinary section 8. The ply design of ordinary section 1 (5) and ordinary section 2 (6) includes two inner fiberglass layers and two outer fiberglass layers, with 5-7 layers of carbon fiber between the inner and outer fiberglass layers. The ply design of transition section 1 (4), handrail ordinary section 8, and transition section 3 (9) includes two inner fiberglass layers and two outer fiberglass layers, with 7-9 layers of carbon fiber between the inner and outer fiberglass layers. The ply design of transition section 2 (7) includes two inner fiberglass layers and two outer fiberglass layers, with 9-11 layers of carbon fiber between the inner and outer fiberglass layers.

[0094] A2: Clean the mold and then apply release agent 16 thoroughly to the upper mold 14 and lower mold 15; to ensure smooth demolding;

[0095] A3: The mold is closed, and the pressure is 0MPa at this time;

[0096] A4: Heat to 80-90℃ at a rate of 100-240℃ / h, open the mold and add the blanks 17 prepared in step one for each zone; when adding material, ensure that the material is evenly placed in the center and predetermined positions of the mold cavity so that the material can reach the predetermined positions of the mold during molding and avoid the press and mold from bearing eccentric loads; the cross-section of the molding is viewed from the perspective of... Figure 12 As shown;

[0097] A5: After the material is added, the mold is closed to allow for a curing reaction. The mold should be closed as quickly as possible to achieve heat preservation and to remove air, moisture, and volatiles remaining in the mold material to ensure product quality.

[0098] A6: Increase temperature and pressure at a rate of 60℃-120℃ / h, maintaining a pressure of 10-30MPa. When the temperature reaches 150-190℃, hold the product at this temperature for 5-10 minutes to allow it to cool naturally or be forced to cool to 50-60℃, then release the pressure. The molding and curing process is as follows: Figure 13 As shown;

[0099] A7: Mold opening, demolding and part removal; Further, in order to prevent the door pillar cover product from deforming during cooling, the door pillar cover product needs to be placed on a professional cooling and fixing bracket and allowed to cool for more than 10 minutes. According to the installation requirements and shape requirements of the door pillar cover product, the door pillar cover product is inspected for matching dimensions, surface quality, etc. If the inspection is qualified, the standard part is obtained. Compared with fiberglass door pillar covers, the weight reduction can reach 66%, and compared with aluminum profile door pillar covers, the weight reduction can reach more than 50%.

[0100] Preferably, in step A5, after the mold is closed, the pressure is increased to 3-6 MPa and the temperature is maintained for 4-7 minutes. During this period, in order to ensure the density of the door pillar cover product and prevent air bubbles and delamination, the pressure is appropriately released after the mold is closed according to the characteristics of the carbon fiber woven fabric prepreg and the glass fiber woven fabric prepreg. In this embodiment, the pressure is released 2-3 times, each time for 4-15 seconds. The pressure release is carried out after the molding material is melted. The molding material is carbon fiber woven fabric prepreg and glass fiber woven fabric prepreg.

[0101] Table 2 compares the thickness and weight of the door pillar cover obtained in this embodiment with those of traditional aluminum profile structures and fiberglass structures:

[0102]

[0103] Table 2

[0104] Example 6:

[0105] This embodiment provides a method for integral molding of an autoclave, specifically:

[0106] A method for preparing a door pillar cover, characterized by comprising the following steps:

[0107] B1: The carbon fiber and fiberglass layers are cut according to the shape of each section of the doorpost enclosure, and resin is applied to the carbon fiber and fiberglass layers of each section using a hand lay-up method. The carbon fiber layer uses carbon fiber woven fabric, and the fiberglass layer uses fiberglass woven fabric. The carbon fiber woven fabric and fiberglass woven fabric are impregnated to form a prepreg. The carbon fiber woven fabric uses T300, and the fiberglass woven fabric uses LY5566. Each section of the doorpost enclosure includes: Common Section 1 (5), Common Section 2 (6), Transition Section 1 (4), Transition Section 2 (7), Transition Section 3 (9), and Handrail Common Section 8. 5. The layup design of the ordinary area 26 of the cover panel includes two inner glass fiber layers and two outer glass fiber layers, with 5-7 layers of carbon fiber layers between the inner and outer glass fiber layers; the layup design of the ordinary area 8 and the transition area 39 of the transition area 1 includes two inner glass fiber layers and two outer glass fiber layers, with 7-9 layers of carbon fiber layers between the inner and outer glass fiber layers; the layup design of the transition area 27 includes two inner glass fiber layers and two outer glass fiber layers, with 9-11 layers of carbon fiber layers between the inner and outer glass fiber layers.

[0108] B2: According to the layering method of each zone, the carbon fiber layer and glass fiber layer are laid on the mold of the door pillar cover;

[0109] B3: Wrap the mold of the door pillar cover with absorbent felt, and then wrap the outside of the absorbent felt with a release film and a vacuum bag in sequence, and seal it with tape.

[0110] B4: Place the mold processed in step B3 into the autoclave and close the autoclave; connect the autoclave to the autoclave extraction valve.

[0111] B5: Start the autoclave, first heat to 80℃ for 20 minutes, then maintain a constant temperature of 80℃ for 50 minutes; then heat to 120℃ for 20 minutes, then maintain a constant temperature of 120℃ for 150 minutes; finally cool to room temperature for 30 minutes; maintain a constant pressure of one atmosphere throughout the entire process; the autoclave curing process is as follows. Figure 14 As shown;

[0112] B6: Open the can, remove the mold, and demold. After demolding, perform post-processing, specifically: inspect the door pillar cover products for matching dimensions and surface quality according to the installation and shape requirements of the product. Once the inspection is qualified, standard parts are obtained. Compared with fiberglass door pillar covers, the weight reduction can reach 66%, and compared with aluminum profile door pillar covers, the weight reduction can reach more than 50%.

[0113] Compared with Example 6 and Example 5, compression molding has a shorter molding time, higher automation efficiency, double-sided molding, and higher product dimensional accuracy and surface finish. Compression molding has advantages such as low density, high strength, wide range of design performance, strong heat resistance, corrosion resistance, good conductivity, no pollution, and short production time. Technicians can choose different processes according to the actual situation.

[0114] In summary, due to the adoption of the above technical solution, this application has the following advantages:

[0115] 1. The rail transit vehicle door pillar cover structure based on carbon fiber and glass fiber layers adopts an integrated structural design. First, both the carbon fiber and glass fiber layers are single-layer structures, not composite materials, resulting in low material costs. Second, its structural form and layup design are based on the actual service conditions of the structure. The door pillar cover structural design, impact-resistant layup design, and stiffness zone design increase stiffness while reducing product weight, increasing the natural frequency of the inner door cover, and reducing product cracking caused by modal resonance.

[0116] 2. Boss-type gasket design: The boss-type gasket design at the mounting hole avoids stress concentration;

[0117] 3. The molding process adopts compression molding, which has the advantages of low cost, high efficiency and mass production capability. It has certain innovations in reducing weight, lowering costs and improving production efficiency of door pillar covers.

[0118] 4. The molding process adopts pressure can molding, which has the advantages of low density, high strength, wide range of design performance, strong heat resistance, corrosion resistance, good conductivity, no pollution, and short production time.

[0119] 5. This invention meets the current trend of weight reduction and efficiency improvement in the rail transit field, conforms to the demand for lightweight design of key components of urban rail vehicles, and has certain market application prospects and applicability; it can be installed on urban rail vehicles and has certain market value; it can also be installed on urban rail vehicles and has certain production value; this application can be applied not only to the rail transit field, but also to the aerospace, aircraft and other fields.

[0120] It should be noted that the components or steps in the above embodiments can be interchanged, substituted, added, or deleted. Therefore, the combinations formed by these reasonable permutations and transformations should also fall within the protection scope of this invention, and the protection scope of this invention should not be limited to the above embodiments.

[0121] The above are exemplary embodiments disclosed in this invention. The order of the disclosed embodiments is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. However, it should be noted that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the disclosed embodiments of this invention (including the claims) is limited to these examples. Various changes and modifications can be made without departing from the scope defined by the claims. The functions, steps, and / or actions of the methods according to the disclosed embodiments described herein do not need to be performed in any particular order. Furthermore, although the elements disclosed in the embodiments of this invention may be described or claimed individually, they may be understood as multiple unless explicitly limited to a singular.

[0122] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention (including the claims) is limited to these examples. Within the framework of the invention, technical features of the above embodiments or different embodiments can be combined, and many other variations of the different aspects of the invention as described above exist, which are not provided in the details for the sake of brevity. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the protection scope of the invention.

Claims

1. A doorpost cover, comprising a doorpost cover body (1), wherein the doorpost cover body (1) is provided with a handrail mounting area (2), one end of the handrail mounting area (2) is a handrail mounting seat (3), and a transition area (4) is provided between the other end of the handrail mounting area (2) and the doorpost cover body (1), characterized in that, The doorpost cover body (1) includes a cover general area one (5) and a cover general area two (6). The handrail installation area (2) includes a transition area two (7) connected to transition area one (4). The transition area two (7) is connected to the handrail general area (8). The upper and lower ends of the handrail general area (8) are respectively connected to transition area three (9). The two transition areas three (9) extend to cover general area one (5) and cover general area two (6) respectively. The innermost and outermost sides of cover general area one (5), cover general area two (6), handrail general area (8), transition area one (4), transition area two (7), and transition area three (9) are respectively an inner glass fiber layer and an outer glass fiber layer. A carbon fiber layer is provided between the inner glass fiber layer and the outer glass fiber layer. Cover general area one (5) and cover general area two (6) The handrail ordinary area (8), transition area one (4), transition area two (7), and transition area three (9) are integrally formed, and the entire door pillar cover body (1) has a layer range of 9-15 layers; the layer design of the cover plate ordinary area one (5) and the cover plate ordinary area two (6) includes two inner glass fiber layers and two outer glass fiber layers, with 5-7 carbon fiber layers between the inner and outer glass fiber layers; the layer design of the transition area one (4), handrail ordinary area (8), and transition area three (9) includes two inner glass fiber layers and two outer glass fiber layers, with 7-9 carbon fiber layers between the inner and outer glass fiber layers; the layer design of the transition area two (7) includes two inner glass fiber layers and two outer glass fiber layers, with 9-11 carbon fiber layers between the inner and outer glass fiber layers.

2. A method for preparing a door pillar cover, characterized in that, Includes the following steps: A1: Cut the material pieces according to the shape of each section of the door pillar cover, and make the blanks according to the layering design of each section; A2: Clean the mold and then apply release agent thoroughly; A3: Mold closing; A4: Heat to 80-90℃ at a heating rate of 100-240℃ / h, open the mold and add the blanks prepared in step A1 for each zone; A5: After the material is added, close the mold; A6: Increase temperature and pressure, increase temperature at a rate of 60℃-120℃ / h and maintain pressure at 10-30MPa, increase temperature to 150-190℃, heat preservation to allow the product to continue to solidify for 5-10 minutes, cool to 50-60℃, and release pressure; A7: Mold opening, demolding and part removal; The door pillar cover includes the following areas: ordinary area 1 (5), ordinary area 2 (6), transition area 1 (4), transition area 2 (7), transition area 3 (9), and handrail ordinary area (8). The ply design of ordinary area 1 (5) and ordinary area 2 (6) includes two inner glass fiber layers and two outer glass fiber layers, with 5-7 carbon fiber layers between the inner and outer glass fiber layers. The ply design of transition area 1 (4), handrail ordinary area (8), and transition area 3 (9) includes two inner glass fiber layers and two outer glass fiber layers, with 7-9 carbon fiber layers between the inner and outer glass fiber layers. The ply design of transition area 2 (7) includes two inner glass fiber layers and two outer glass fiber layers, with 9-11 carbon fiber layers between the inner and outer glass fiber layers.

3. A method for preparing a door pillar cover, characterized in that, Includes the following steps: B1: Cut the carbon fiber layer and glass fiber layer according to the shape of each area of ​​the door pillar cover, and apply resin glue to the carbon fiber layer and glass fiber layer of each area; B2: According to the layering method of each zone, the carbon fiber layer and glass fiber layer are laid on the mold of the door pillar cover; B3: Wrap the mold of the door pillar cover with absorbent felt, and then wrap the outside of the absorbent felt with a release film and a vacuum bag in sequence, and seal it with tape. B4: Place the mold processed in step B3 into the autoclave and close the autoclave; B5: Start the autoclave, first heat up to 80°C, which takes 20 minutes, and maintain the temperature at 80°C for 50 minutes; then heat up to 120°C, which takes 20 minutes, and maintain the temperature at 120°C for 150 minutes; finally cool down to room temperature, which takes 30 minutes. B6: Open the can, remove the mold, and perform demolding. The door pillar cover includes the following areas: ordinary area 1 (5), ordinary area 2 (6), transition area 1 (4), transition area 2 (7), transition area 3 (9), and handrail ordinary area (8). The ply design of ordinary area 1 (5) and ordinary area 2 (6) includes two inner glass fiber layers and two outer glass fiber layers, with 5-7 carbon fiber layers between the inner and outer glass fiber layers. The ply design of transition area 1 (4), handrail ordinary area (8), and transition area 3 (9) includes two inner glass fiber layers and two outer glass fiber layers, with 7-9 carbon fiber layers between the inner and outer glass fiber layers. The ply design of transition area 2 (7) includes two inner glass fiber layers and two outer glass fiber layers, with 9-11 carbon fiber layers between the inner and outer glass fiber layers.

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