Rail vehicle, layer structure of special-shaped double-cavity pultrusion beam and layer implementation method

Abstract

The present application relates to the technical field of rail vehicles, and particularly discloses a layer structure of a special-shaped double-cavity pultrusion beam, which comprises a first cavity layer area, a second cavity layer area, an upper skin layer area and a lower skin layer area. The second cavity layer area is arranged adjacent to one side of the first cavity layer area; the upper skin layer area is arranged above the first cavity layer area and the second cavity layer area, and the two sides of the upper skin layer area extend to the outer sides of the first cavity layer area and the second cavity layer area respectively; and the lower skin layer area is arranged below the first cavity layer area and the second cavity layer area, and the two sides of the lower skin layer area extend to the outer sides of the first cavity layer area and the second cavity layer area respectively. The layer structure is suitable for pultrusion process forming, so that the pultrusion forming of the structure beam body is possible. The present application also discloses a rail vehicle and a layer implementation method of the special-shaped double-cavity pultrusion beam, which also has the above technical effects.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of rail vehicle technology, and more particularly to a rail vehicle, a special-shaped double-cavity pultrusion beam, and a layering structure and layering implementation method thereof. BACKGROUND

[0002] To promote the green and low-carbon development of rail transit, follow the national energy-saving and emission-reducing strategy, and further improve the energy utilization rate, lightweight has become one of the important concerns in the design and manufacturing requirements of the next generation of train bodies.

[0003] Compared with metal materials, carbon fiber composite materials have higher specific stiffness and specific strength. Currently, the main load-bearing beams of rail vehicles are mainly made of aluminum alloy, stainless steel and other metal materials. Therefore, developing lightweight carbon fiber composite material main load-bearing beams can be one of the solutions for lightweight rail vehicle bodies. The main load-bearing beam of a rail vehicle is an equal cross-section and large profile. Therefore, how to provide a layering structure and layering implementation method that meets the mechanical performance requirements and is suitable for pultrusion process to realize the molding of a composite material special-shaped double-cavity pultrusion beam is a problem that needs to be solved by those skilled in the art. SUMMARY

[0004] Therefore, the purpose of the present application is to provide a rail vehicle, a special-shaped double-cavity pultrusion beam, and a layering structure and layering implementation method thereof, which can effectively solve the molding problem of a composite material special-shaped double-cavity pultrusion beam.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical solutions:

[0006] A layering structure of a special-shaped double-cavity pultrusion beam comprises:

[0007] a first cavity layering area;

[0008] a second cavity layering area, which is adjacent to one side of the first cavity layering area;

[0009] an upper skin layering area, which is laid above the first cavity layering area and the second cavity layering area, and the two sides of the upper skin layering area extend to the outside of the first cavity layering area and the second cavity layering area, respectively;

[0010] a lower skin layering area, which is laid below the first cavity layering area and the second cavity layering area, and the two sides of the lower skin layering area extend to the outside of the first cavity layering area and the second cavity layering area, respectively;

[0011] The first cavity layering area, the second cavity layering area, the upper skin layering area and the lower skin layering area are all covered with multi-axial fabric.

[0012] Optionally, in the above-mentioned ply structure of the irregular double-cavity pultruded beam, the upper skin ply area located on the side of the first cavity ply area away from the second cavity ply area is straight and adjacent to the lower skin ply area;

[0013] And / or, the upper skin ply region located on the side of the second cavity ply region away from the first cavity ply region is disposed opposite to the lower skin ply region, and the ply structure further includes a U-shaped flange ply region, which is disposed in the U-shaped cavity formed by the upper skin ply region, the lower skin ply region and the second cavity ply region and is adjacent to the three.

[0014] Optionally, in the above-mentioned ply structure of the irregular double-cavity pultruded beam, the upper skin ply area includes an upper arc-shaped section, an inner concave section and an upper straight section in the direction from the second cavity ply area to the first cavity ply area. The inner concave section is adjacent to the top surface of the first cavity ply area to the side wall of the first cavity ply area away from the second cavity ply area.

[0015] And / or, the lower skin ply region, from the second cavity ply region to the first cavity ply region, sequentially includes a lower arc-shaped segment and a lower straight segment, wherein the lower arc-shaped segment and the lower straight segment form a preset angle.

[0016] Optionally, in the above-mentioned ply structure of the irregular double-cavity pultruded beam, the first cavity ply region includes at least two first cavity ply layers, and the interface of the inner first cavity ply layer and the interface of the outer first cavity ply layer are respectively located at the middle of opposite ends of the first cavity ply region.

[0017] And / or, the second cavity layup region includes at least two second cavity layups, and the interface of the inner second cavity layup and the interface of the outer second cavity layup are respectively located at the middle of opposite ends of the second cavity layup region.

[0018] Optionally, in the above-mentioned ply structure of the irregular double-cavity pultruded beam, the multiaxial fabric includes a four-axis carbon fiber warp-knitted fabric.

[0019] Optionally, in the above-mentioned ply structure of the irregular double-cavity pultruded beam, the uppermost layer of the four-axis carbon fiber warp-knitted fabric in the upper skin ply region has carbon fiber yarn bundles arranged in a 0-degree angle direction; the lowermost layer of the four-axis carbon fiber warp-knitted fabric in the lower skin ply region has carbon fiber yarn bundles arranged in a 0-degree angle direction.

[0020] Optionally, in the above-mentioned ply structure of the irregular double-cavity pultruded beam, fiber yarn is laid at the corner positions where the first cavity ply area, the second cavity ply area, the upper skin ply area and the lower skin ply area are respectively connected.

[0021] The ply structure of the irregularly shaped double-cavity pultruded beam provided by the present invention includes a first cavity ply region, a second cavity ply region, an upper skin ply region, and a lower skin ply region. The second cavity ply region is adjacent to one side of the first cavity ply region; the upper skin ply region is laid above the first and second cavity ply regions, and both sides of the upper skin ply region extend outwards from the first and second cavity ply regions respectively; the lower skin ply region is laid below the first and second cavity ply regions, and both sides of the lower skin ply region extend outwards from the first and second cavity ply regions respectively; the first cavity ply region, the second cavity ply region, the upper skin ply region, and the lower skin ply region are all covered with multiaxial fabric.

[0022] The ply structure of the irregular double-cavity pultruded beam provided by this invention features a first-cavity ply region and a second-cavity ply region that work together to provide good rigidity. The upper and lower skin ply regions are respectively laid on the upper and lower ends of the first and second cavity ply regions, providing reinforcement. The portions of the upper and lower skin ply regions extending beyond the first and second cavity ply regions are respectively fitted to connect with corresponding connection points, ensuring overall connection reliability. Furthermore, the extended portions provide effective positioning during connection, facilitating installation. In addition, the first-cavity ply region, the second-cavity ply region, the upper skin ply region, and the lower skin ply region are all covered with multi-axial fabric. Combined with the ply structure, this gives the irregular double-cavity pultruded beam quasi-isotropic properties. Moreover, this ply structure is suitable for pultrusion molding, making it possible to use pultrusion molding for this beam structure.

[0023] To achieve the above objectives, the present invention also provides a rail vehicle comprising any of the aforementioned irregular double-cavity pultruded beam layup structures. Since the aforementioned irregular double-cavity pultruded beam layup structures possess the aforementioned technical effects, the rail vehicle having this irregular double-cavity pultruded beam layup structure should also possess the corresponding technical effects.

[0024] To achieve the above objectives, the present invention also provides the following technical solution:

[0025] A method for realizing the layup of an irregularly shaped double-cavity pultruded beam, comprising fabricating a layup structure of any of the irregularly shaped double-cavity pultruded beams described above, including:

[0026] The first cavity layer area is formed by using a straight-line layup and sequentially passing through corresponding pre-forming and forming molds.

[0027] After the first cavity layup area is formed, the second cavity layup area is formed by sequentially forming the first cavity layup area by using a straight layup and passing through the corresponding pre-forming and forming molds.

[0028] After the second cavity layup area is formed, the upper skin layup area is formed step by step by using a straight layup and passing through the corresponding pre-forming and forming molds.

[0029] After the upper skin ply area is formed, the lower skin ply area is formed by sequentially forming the lower skin ply area through corresponding preforming and forming molds, thereby obtaining the ply structure of the irregular double-cavity pultruded beam.

[0030] Optionally, in the above-described method for achieving the plying of a non-circular double-cavity pultruded beam, after the second cavity plying region is formed and before the upper skin plying region is formed, the method further includes:

[0031] The flange layup area is formed by sequentially forming the corresponding pre-forming and forming molds using a straight layup pattern.

[0032] The layup implementation method for irregular double-cavity pultruded beams provided by the present invention has the corresponding technical effects of the layup structure of the aforementioned irregular double-cavity pultruded beams. Attached Figure Description

[0033] 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 drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1 This is a schematic diagram of the ply structure of a non-circular double-cavity pultruded beam according to a specific embodiment of the present invention;

[0035] Figure 2 This is a schematic diagram of the structure of the first cavity layered region;

[0036] Figure 3 This is a schematic diagram of the structure of the second cavity plywood region;

[0037] Figure 4 A schematic diagram of the skin layering process;

[0038] Figure 5 A schematic diagram of the lower skin layering process;

[0039] Figure 6 A schematic diagram of the flange layup gradient process.

[0040] The following labels are shown in the attached diagram:

[0041] First cavity ply area 1, second cavity ply area 2, upper skin ply area 3, lower skin ply area 4, flange ply area 5, corner position 6, first cavity ply 11, first cavity ply interface 12, second cavity ply 21, second cavity ply interface 22. Detailed Implementation

[0042] This invention discloses a layup structure and layup implementation method for a rail vehicle and a shaped double-cavity pultruded beam, so as to realize the molding of a composite material shaped double-cavity pultruded beam.

[0043] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0044] Please see Figure 1 , Figure 1 This is a schematic diagram of the ply structure of a non-circular double-cavity pultruded beam according to a specific embodiment of the present invention.

[0045] In some embodiments, the ply structure of the irregular double-cavity pultruded beam provided by the present invention includes a first cavity ply region 1, a second cavity ply region 2, an upper skin ply region 3, and a lower skin ply region 4. It is understood that the irregular double-cavity pultruded beam is divided into the above-mentioned different ply regions for separate plying. The second cavity ply region 2 is adjacent to one side of the first cavity ply region 1, that is, the first cavity ply region 1 and the second cavity ply region 2 cooperate to form a double-cavity structure to provide good stiffness. The upper skin ply region 3 is laid above the first cavity ply region 1 and the second cavity ply region 2, and both sides of the upper skin ply region 3 extend outwards from the first cavity ply region 1 and the second cavity ply region 2, that is, the two sides of the upper skin ply region 3 extend beyond the first cavity ply region 1 and the second cavity ply region 2. It should be noted that "above" here is only for distinguishing relative positional relationships and does not limit the absolute orientation in the use state. The vertical orientation of other components corresponds to the vertical orientation of the upper skin ply area 3 and the lower skin ply area 4. The lower skin ply area 4 is laid below the first cavity ply area 1 and the second cavity ply area 2, and both sides of the lower skin ply area 4 extend outwards from the first cavity ply area 1 and the second cavity ply area 2, that is, the two sides of the lower skin ply area 4 extend beyond the first cavity ply area 1 and the second cavity ply area 2. The upper skin ply area 3 located on the side of the first cavity ply area 1 away from the second cavity ply area 2 cooperates with the lower skin ply area 4, and the upper skin ply area 3 located on the side of the second cavity ply area 2 away from the first cavity ply area 1 cooperates with the lower skin ply area 4 to connect with the corresponding connecting components. The first cavity ply area 1, the second cavity ply area 2, the upper skin ply area 3, and the lower skin ply area 4 are all covered with multi-axis fabric. Multi-axis fabrics are fabrics composed of yarns in different directions, specifically four-axis fabrics composed of warp yarns, weft yarns, and twill yarns on the left and right sides.

[0046] The ply structure of the irregular double-cavity pultruded beam provided by this invention, with the first cavity ply region 1 and the second cavity ply region 2 working together to provide good rigidity, allows for reinforcement. The upper skin ply region 3 and the lower skin ply region 4 are respectively plyed at the upper and lower ends of the first cavity ply region 1 and the second cavity ply region 2, providing reinforcement. The portions of the upper skin ply region 3 and the lower skin ply region 4 extending beyond the first cavity ply region 1 and the second cavity ply region 2 respectively engage with corresponding connection points to ensure overall connection reliability. Furthermore, the extended portions provide effective positioning during connection, facilitating installation. In addition, the first cavity ply region 1, the second cavity ply region 2, the upper skin ply region 3, and the lower skin ply region 4 are all covered with multiaxial fabric, which, combined with the ply structure, gives the irregular double-cavity pultruded beam quasi-isotropic properties. Moreover, this ply structure is suitable for pultrusion molding, making it possible to use pultrusion molding for this beam structure.

[0047] In some embodiments, the upper skin ply region 3 and the lower skin ply region 4, located on the side of the first cavity ply region 1 away from the second cavity ply region 2, are arranged in a straight line and adjacent to each other. That is, a straight flange is formed on the outer side of the first cavity ply region 1, and the straight flange can be fixedly connected to the corresponding connection part by means of bonding or riveting. The straight flange can provide a larger contact area, improve connection reliability, and provide a positioning function. When this irregularly shaped double-cavity pultruded beam is used as the upper side beam of a rail vehicle, the straight flange can better connect to the roof of the rail vehicle.

[0048] In some embodiments, the upper skin ply region 3 and the lower skin ply region 4, located on the side of the second cavity ply region 2 away from the first cavity ply region 1, are disposed opposite each other. The ply structure also includes a U-shaped flange ply region 5, which is located within the U-shaped cavity formed by the upper skin ply region 3, the lower skin ply region 4, and the second cavity ply region 2, and is adjacent to all three. That is, the ply structure includes the first cavity ply region 1, the second cavity ply region 2, the upper skin ply region 3, the lower skin ply region 4, and the flange ply region 5. The upper skin ply region 3, the lower skin ply region 4, and the flange ply region 5 form a U-shaped flange on the outer side of the second cavity ply region 2, which can be fixedly connected to corresponding connection parts by means of bonding or riveting. The U-shaped flange can provide connection from different directions, further improving connection reliability. When this irregular double-cavity pultruded beam is used as the upper side beam of a rail vehicle, the U-shaped flange can better connect with the side wall of the rail vehicle.

[0049] In some embodiments, a straight flange is formed on the outer side of the first cavity layup region 1, and a U-shaped flange is formed on the outer side of the second cavity layup region 2. This forms a double-cavity pultruded beam with a three-free-side flange structure. The three-free-side flange structure can provide reliable connections with corresponding connection parts from different orientations. Simultaneously, one side uses a U-shaped flange, and the other side uses a straight flange. After the U-shaped flange is positioned with the corresponding connection part, the straight flange is easy to position and install, thus facilitating the installation of the double-cavity pultruded beam.

[0050] In some embodiments, the upper skin ply region 3, from the second cavity ply region 2 to the first cavity ply region 1, sequentially includes an upper arc-shaped segment, a concave segment, and an upper straight segment. The concave segment is adjacent to the side of the top surface of the first cavity ply region 1 away from the second cavity ply region 2, extending to the sidewall of the first cavity away from the second cavity. Specifically, the concave segment corresponds to the side of the top surface of the first cavity ply region 1 away from the second cavity ply region 2, extending to the sidewall of the first cavity away from the second cavity. The upper straight segment is used to cooperate with the lower skin ply region 4 to form a straight flange structure, while the upper arc-shaped segment and the concave segment are irregular arc structures. Compared to conventional regular-shaped pultruded structures, the ply structure of the irregular double-cavity pultruded beam provided in this embodiment is an irregular structure. Through the reasonable division of the ply regions and the gradual transition of each ply region, the irregular pultruded structure becomes possible.

[0051] In some embodiments, the upper skin ply region 3 includes at least two upper skin plies, specifically, the thickness of each upper skin ply is not less than 400 g / m². 2 To ensure rigidity.

[0052] In some embodiments, the lower skin ply region 4, from the second cavity ply region 2 to the first cavity ply region 1, sequentially includes a lower arc-shaped segment and a lower straight segment, with the lower arc-shaped segment and the lower straight segment forming a predetermined angle. The lower skin ply region 4 has an L-shaped structure, and its lower straight segment is used to cooperate with the upper skin ply region 3 as the upper straight segment to form a straight flange structure. The lower arc-shaped segment can specifically be an irregular arc structure.

[0053] In some embodiments, the lower skin ply region 4 includes at least two lower skin plies, specifically, the thickness of each lower skin ply is not less than 400 g / m². 2 To ensure rigidity.

[0054] In some embodiments, the thickness of the flange ply region 5 is less than 400 g / m. 2 .

[0055] In some embodiments, please refer to Figure 2 The first cavity layup region 1 includes at least two first cavity layups 11, and the interface 12 of the inner first cavity layup 11 and the interface 12 of the outer first cavity layup 11 are respectively located at the middle of opposite ends of the first cavity layup region 1. Specifically, the thickness of a single first cavity layup 11 is not less than 400 g / m². 2To ensure rigidity, the first cavity layup 11 is specifically formed by pre-forming and molding of a straight layup to create a U-shaped cavity, thus having an interface. To reduce the impact of the weaker mechanical properties at the interface on the overall structure, the interfaces 12 of the inner and outer first cavity layups 11 are respectively located at the middle of opposite ends of the first cavity layup area 1. On the one hand, the middle area experiences less stress and requires less structural rigidity. On the other hand, the interfaces of the inner and outer layups are positioned opposite each other, avoiding overlap and thus ensuring overall rigidity. Specifically, the interface 12 of the inner first cavity layup 11 is located at the bottom of the cavity, and the interface 12 of the outer first cavity layup 11 is located at the top of the cavity.

[0056] In some embodiments, please refer to Figure 3 The second cavity layup region 2 includes at least two layers of second cavity layup 21, and the interface 22 of the inner second cavity layup 21 and the interface 22 of the outer second cavity layup 21 are respectively located at the middle of opposite ends of the second cavity layup region 2. That is, the second cavity layup region 2 also adopts the same configuration as the first cavity layup region 1 described above.

[0057] In some embodiments, the multiaxial fabric comprises a four-axis warp-knitted fabric. A four-axis warp-knitted fabric with 0°, +45°, 90°, and -45° angles is used, exhibiting good quasi-isotropy to achieve the quasi-isotropy of the irregularly shaped double-cavity pultruded beam of the rail vehicle body.

[0058] Specifically, the four-axis warp-knitted fabric uses four-axis carbon fiber warp-knitted fabric. Compared with metal materials, four-axis carbon fiber warp-knitted fabric has higher specific stiffness and specific strength, which is beneficial to the lightweight design of rail vehicle bodies.

[0059] In some embodiments, the uppermost layer of the four-axis carbon fiber warp-knitted fabric in the upper skin layup region 3 has carbon fiber yarn bundles arranged in a 0-degree angle direction. It should be noted that in this application, the 0-degree angle direction is the pultrusion direction, and the layup direction perpendicular to the pultrusion direction is 90°. The 0-degree angle direction of the upper skin layup region 3 faces the outer surface of the profile. On the one hand, during the pultrusion process, the arrangement direction of the carbon fiber yarn bundles on the outer surface is the same as the pultrusion direction, thereby reducing the frictional resistance during the pultrusion process and facilitating pultrusion molding. On the other hand, the 0-degree angle direction of the upper skin layup region 3 facing the outer surface of the profile allows the molded layup structure to provide better bending stiffness.

[0060] In some embodiments, the bottom layer of the four-axis carbon fiber warp-woven fabric in the lower skin layup area 4 has carbon fiber yarn bundles arranged in a 0-degree angle direction. That is, the 0-degree angle direction of the lower skin layup area 4 faces the outer side of the profile, and its function is the same as that of the upper skin layup area 3 facing the outer side of the profile in the 0-degree angle direction, which will not be described again here.

[0061] In some embodiments, fiber yarns are laid at the corner positions 6 where the first cavity ply region 1, the second cavity ply region 2, the upper skin ply region 3, and the lower skin ply region 4 are respectively connected. By placing fiber yarns at the corner positions 6 where any one of the first cavity ply region 1, the second cavity ply region 2, the upper skin ply region 3, and the lower skin ply region 4 is connected to the other ply regions, the overall stiffness and strength of the ply structure are further enhanced and effectively improved. Meanwhile, irregular cavities can be formed at the corners 6 where the first cavity plywood area 1, the second cavity plywood area 2, the upper skin plywood area 3, and the lower skin plywood area 4 meet. If the corners of each plywood area are rounded, irregular cavities are formed between the rounded corners. In order to better fill the cavities, fiber yarns are laid at the corners 6 where the first cavity plywood area 1, the second cavity plywood area 2, the upper skin plywood area 3, and the lower skin plywood area 4 meet. The fiber yarns are in bundles, so they can fill the irregular cavities well, thus ultimately forming a dense overall structure.

[0062] Based on the ply structure of the irregular double-cavity pultruded beam provided in the above embodiments, the present invention also provides a rail vehicle, which includes any one of the ply structure of the irregular double-cavity pultruded beam in the above embodiments. Since the rail vehicle adopts the ply structure of the irregular double-cavity pultruded beam in the above embodiments, the beneficial effects of the rail vehicle are explained in the above embodiments.

[0063] The present invention also provides a method for realizing the layup of a non-standard double-cavity pultruded beam, wherein any of the layup structures of the non-standard double-cavity pultruded beams described in the above embodiments is fabricated. In one specific embodiment, the layup realization method includes the following steps:

[0064] S11: The first cavity layup area 1 is formed by using a straight layup and sequentially passing through the corresponding pre-forming and forming molds;

[0065] S12: After the first cavity layup area 1 is formed, the second cavity layup area 2 is formed by sequentially forming the first cavity layup area 2 through the corresponding pre-forming and forming molds.

[0066] S13: After the second cavity layup area 2 is formed, the upper skin layup area 3 is formed by using a straight layup and passing through the corresponding pre-forming and forming molds in sequence.

[0067] S14: After the upper skin ply area 3 is formed, the lower skin ply area 4 is formed by sequentially forming the ply area through the corresponding preforming and forming molds, and the ply structure of the irregular double cavity pultruded beam is obtained.

[0068] The overall ply structure follows the sequence: first cavity ply area 1 → second cavity ply area 2 → upper skin ply area 3 → lower skin ply area 4. Specifically, the first cavity ply area 1 is formed first, then the second cavity ply area 2 is formed based on it. Next, the upper skin ply area 3 is formed based on both the first and second cavity ply areas 1, and finally, the lower skin ply area 4 is formed based on all the aforementioned ply areas.

[0069] When the ply structure of the irregular double-cavity pultruded beam includes the flange ply region 5, the corresponding ply implementation method includes the following steps:

[0070] S21: The first cavity layup area 1 is formed by using a straight layup and sequentially passing through the corresponding pre-forming and forming molds;

[0071] S22: After the first cavity layup area 1 is formed, the second cavity layup area 2 is formed by sequentially forming the first cavity layup area 2 through the corresponding pre-forming and forming molds.

[0072] S23: After the second cavity layup area 2 is formed, the flange layup area 5 is formed by sequentially forming the corresponding pre-forming and forming molds using a straight layup pattern.

[0073] S24: After the flange layup is formed, a straight layup is adopted and the upper skin layup area 3 is gradually formed by passing through the corresponding pre-forming and forming molds in sequence.

[0074] S25: After the upper skin ply area 3 is formed, the lower skin ply area 4 is formed by sequentially forming the lower skin ply area 4 through the corresponding preforming and forming molds, and the ply structure of the irregular double cavity pultruded beam is obtained.

[0075] The overall layup structure follows the sequence: first cavity layup area 1 → second cavity layup area 2 → flange layup area 5 → upper skin layup area 3 → lower skin layup area 4. Specifically, the first cavity layup area 1 is formed first, then the second cavity layup area 2 is formed based on it. Next, the flange layup area 5 is formed based on the first and second cavity layup areas 1 and 2. Finally, the upper skin layup area 3 is formed based on the first, second, and flange layup areas 1 and 2, and the lower skin layup area 4 is formed based on all the aforementioned layup areas. The layup implementation methods described in these embodiments are applicable to pultrusion molding processes.

[0076] In the above embodiments, each layup region can be formed using a straight layup and sequentially through corresponding preforming and forming molds. Specifically, the first cavity layup 11 of the first cavity layup region 1 is formed according to the following gradual process: straight straight layup → arc shape → open trapezoidal structure → U-shaped structure → layup structure with trapezoidal inner cavity. Each first cavity layup 11 of the first cavity layup region 1 is formed according to the above process. The second cavity layup 21 of the second cavity layup region 2 is formed sequentially according to the same process as the first cavity layup 11.

[0077] The upper skin layup of the upper skin layup zone 3 is formed according to the following gradual process; please refer to [link / reference]. Figure 4 The structure consists of a straight, linear fabric → a shape combining arcs and bevels → an upper skin layer structure combining arcs, concave irregular shapes, and bevels.

[0078] The lower skin layup of the lower skin layup zone 4 is formed according to the following gradual process. Please refer to [link / reference]. Figure 5 A straight, linear fabric → a lower skin layer structure with a straight, slanted edge.

[0079] The flange ply of flange ply region 5 is formed according to the following gradual process. Please refer to [link / reference]. Figure 6 Straight layup → Trapezoidal open structure → U-shaped layered structure.

[0080] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0081] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A ply structure for an irregularly shaped double-cavity pultruded beam, characterized in that, include: First cavity layered region (1); The second cavity plywood region (2) is located adjacent to one side of the first cavity plywood region (1); The upper skin ply area (3) is laid above the first cavity ply area (1) and the second cavity ply area (2), and the two sides of the upper skin ply area (3) extend to the outside of the first cavity ply area (1) and the second cavity ply area (2), respectively. The lower skin ply area (4) is laid below the first cavity ply area (1) and the second cavity ply area (2), and the two sides of the lower skin ply area (4) extend to the outside of the first cavity ply area (1) and the second cavity ply area (2), respectively. The first cavity ply area (1), the second cavity ply area (2), the upper skin ply area (3) and the lower skin ply area (4) are all covered with multi-axial fabric; The upper skin ply region (3) located on the side of the first cavity ply region (1) away from the second cavity ply region (2) is arranged in a straight line and adjacent to the lower skin ply region (4); And / or, the upper skin ply region (3) located on the side of the second cavity ply region (2) away from the first cavity ply region (1) is disposed opposite to the lower skin ply region (4), and the ply structure further includes a U-shaped flange ply region (5), which is disposed in the U-shaped cavity formed by the upper skin ply region (3), the lower skin ply region (4) and the second cavity ply region (2) and is adjacent to the three.

2. The ply structure of the irregular double-cavity pultruded beam according to claim 1, characterized in that, The upper skin ply area (3) includes an upper arc-shaped section, an inner concave section and an upper straight section in the direction from the second cavity ply area (2) to the first cavity ply area (1). The inner concave section is adjacent to the top surface of the first cavity ply area (1) to the side wall of the first cavity ply area (1) away from the second cavity ply area (2). And / or, the lower skin layup area (4) includes a lower arc segment and a lower straight segment in sequence from the second cavity layup area (2) to the first cavity layup area (1), and the lower arc segment and the lower straight segment form a preset angle.

3. The ply structure of the irregular double-cavity pultruded beam according to claim 1, characterized in that, The first cavity layup region (1) includes at least two first cavity layups (11), and the interface (12) of the inner first cavity layup (11) and the interface (12) of the outer first cavity layup (11) are respectively located at the middle of opposite ends of the first cavity layup region (1); And / or, the second cavity layup region (2) includes at least two layers of second cavity layup (21), and the interface (22) of the inner layer of the second cavity layup (21) and the interface (22) of the outer layer of the second cavity layup (21) are respectively located at the middle of opposite ends of the second cavity layup region (2).

4. The ply structure of the irregular double-cavity pultruded beam according to any one of claims 1-3, characterized in that, The multiaxial fabric includes a four-axis carbon fiber warp-knitted fabric.

5. The ply structure of the irregular double-cavity pultruded beam according to claim 4, characterized in that, The uppermost layer of the four-axis carbon fiber warp-knitted fabric in the upper skin layup area (3) has carbon fiber yarn bundles arranged in a 0-degree angle direction; the lowermost layer of the four-axis carbon fiber warp-knitted fabric in the lower skin layup area (4) has carbon fiber yarn bundles arranged in a 0-degree angle direction.

6. The ply structure of the irregular double-cavity pultruded beam according to any one of claims 1-3, characterized in that, The corner positions (6) where the first cavity layered area (1), the second cavity layered area (2), the upper skin layered area (3) and the lower skin layered area (4) are respectively connected are covered with fiber yarn.

7. A rail vehicle, characterized in that, Including the ply structure of the irregular double-cavity pultruded beam as described in any one of claims 1-6.

8. A method for realizing the layup of a non-standard double-cavity pultruded beam, comprising fabricating the layup structure of the non-standard double-cavity pultruded beam as described in any one of claims 1-6, characterized in that, include: The first cavity layup area (1) is formed by using a straight layup and sequentially passing through corresponding pre-forming and forming molds. After the first cavity layup area (1) is formed, the second cavity layup area (2) is formed by using a straight layup and sequentially passing through the corresponding pre-forming and forming molds. After the second cavity layup area (2) is formed, the upper skin layup area (3) is formed by sequentially passing through the corresponding pre-forming and forming molds using a straight layup pattern. After the upper skin ply area (3) is formed, the lower skin ply area (4) is formed by sequentially forming the ply structure of the irregular double cavity pultruded beam by using a straight ply and passing through the corresponding preforming and forming molds.

9. The method for achieving ply-layout of a non-circular double-cavity pultruded beam according to claim 8, characterized in that, After the second cavity layup area (2) is formed, and before the upper skin layup area (3) is formed, it further includes: The flange layup area (5) is formed by sequentially forming the corresponding pre-forming and forming molds using a straight layup pattern.

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