Railway vehicle composite material car body roof air duct integrated structure

Abstract

A rail vehicle composite material car body roof air duct integrated structure, comprising a car body roof and an interior roof, wherein a cold air duct and a hot air duct are arranged between the car body roof and the interior roof, the cold air duct and the hot air duct are divided into two independent parts through an air duct partition beam, an interior and exterior air duct partition, a cold air duct partition and an air outlet connecting piece, the main air duct and the side air duct in the original vehicle are cancelled, the number of car body parts is reduced, the production and manufacturing efficiency is improved, the whole vehicle carrying efficiency is improved, the car body structure weight is reduced, the cold and hot partition air supply of the car body main air duct is realized, the air conditioner working efficiency is improved, the design space of the car body roof air duct integrated structure is increased, different multi-layer core materials can be arranged, the sound insulation and heat insulation and the electromagnetic compatibility core material can be selected, and different functional requirements of the car body can be realized.

Description

Technical Field

[0001] This invention belongs to the field of rail transit vehicle body technology, and in particular relates to an integrated structure of composite material vehicle body roof and air duct. Background Technology

[0002] Against the backdrop of the national "dual-carbon" strategy, the requirements for lightweight structures in the rail transit sector are increasing year by year, and the application of carbon fiber composite materials in rail vehicles is also constantly expanding. The application of carbon fiber composite materials in rail vehicles is gradually shifting from non-load-bearing components and secondary load-bearing components such as vehicle interiors and equipment compartments to main load-bearing components such as the entire vehicle body.

[0003] Existing composite material vehicle body load-bearing structures are mostly "sandwich" structures. When designing the composite material vehicle body roof, only the load-bearing function of the vehicle structure is considered, while the interior components, such as air conditioning ducts and interior roof panels, are independent parts, manufactured separately and assembled to the vehicle body structure via hoisting. The vehicle's load-bearing structural components and interior functional components are independent of each other, failing to fully utilize the excellent thermal insulation properties and high design flexibility of composite materials. This affects the overall weight reduction efficiency and manufacturing costs of the vehicle body, severely restricting the development of lightweight structures for rail vehicles. Summary of the Invention

[0004] The present invention aims to design a composite material roof duct integrated structure that integrates structure and function, making full use of the structural space of the vehicle body, effectively improving the load-bearing efficiency of the vehicle body, reducing the number of vehicle parts and interior assembly work, and reducing vehicle production and manufacturing costs.

[0005] To achieve the above objectives, the present invention provides an integrated structure for the air duct of a composite material roof panel of a rail vehicle, comprising a roof panel and an interior roof panel, wherein an air duct is provided between the roof panel and the interior roof panel, and the roof panel, the interior roof panel, and the air duct are co-bonded into an integrated structure; wherein:

[0006] The air duct includes a cold air duct and a hot air duct;

[0007] The cold air duct is composed of the vehicle body roof panel, the interior roof panel, the inner air duct partition, and the cold air duct partition; the hot air duct is composed of the vehicle body roof panel, the inner air duct partition, and the outer air duct partition.

[0008] The vehicle body roof panel and the interior roof panel are connected by a duct partition beam, and the duct partition beam has hot air duct ventilation holes and cold air duct ventilation holes.

[0009] The interior top plate and the cold air duct partition are bonded together by an air outlet connector. The air outlet connector has a cold air duct ventilation hole and a cold air outlet hole respectively at the top and bottom of the connection with the interior top plate.

[0010] The inner and outer air duct partitions are respectively provided with inner air duct partition cold air duct ventilation holes and outer air duct partition cold air duct ventilation holes corresponding to the cold air duct ventilation holes of the partition beam. The other end of the outer air duct partition is provided with outer air duct partition hot air duct ventilation holes.

[0011] The interior roof panel and the cold air duct partition are bonded together by an air outlet connector. The air outlet connector is connected to the side wall of the vehicle body, and the side wall of the vehicle body is connected to the integrated structure of the air duct of the roof panel.

[0012] Furthermore, the vehicle body roof panel is integrally formed by bonding and pressing together a carbon fiber outer skin, a central foam core, a carbon fiber inner skin, longitudinal reinforcing beams, and connecting reinforcing beams. The connecting reinforcing beams are multi-chamber diagonally braced carbon fiber pultruded profiles; the longitudinal reinforcing beams are H-shaped carbon fiber pultruded profiles. The central foam core of the vehicle body roof panel is PMI foam or PET foam, with a minimum height of not less than 50mm.

[0013] Furthermore, the inner roof panel has a sandwich structure, consisting of an outer skin, an inner skin, and a foam core material. The inner and outer skins are made of carbon fiber or glass fiber. The foam core material is PMI foam or PET foam, with a minimum height of 20mm.

[0014] Furthermore, the air duct partition beam is a continuous J-shaped carbon fiber pultruded profile. The air duct partition beam is bonded to the vehicle body roof panel, and rivets are used to connect the ends of the air duct partition beam. The air duct partition beam is connected to the interior roof panel by connecting bolts and rivet nuts, and carbon fiber embedded blocks are correspondingly set in the connection area of ​​the interior roof panel.

[0015] Furthermore, both the inner and outer air duct partitions are carbon fiber sandwich structures, integrally formed by inner and outer skins and foam core material using a co-curing process.

[0016] Furthermore, the cold air duct partition is a carbon fiber laminate structure with a minimum thickness of 3mm.

[0017] Furthermore, the air outlet connector is an F-shaped carbon fiber pultruded profile with a flange. The air outlet connector is connected to the interior side wall panel connector by rivets through the flange of the air outlet connector. The middle part of the F-shaped air outlet connector overlaps and is bonded to the interior top panel.

[0018] Compared with the prior art, the advantages of the present invention are:

[0019] 1. The composite material roof panel air duct integrated structure eliminates the main air duct and side air duct in the original vehicle. Through the main structural components such as the roof panel, air duct partition beam, and interior roof panel, the functional requirements of the vehicle's main air duct are met while meeting the structural load-bearing requirements. This reduces the number of vehicle body parts and improves manufacturing efficiency.

[0020] 2. The composite material roof panel features a "sandwich" structure, with both the carbon fiber skin and foam core material exhibiting high thermal insulation efficiency. By adjusting the core material thickness and utilizing the insulating core material, the thermal insulation requirements of rail vehicles under different operating environments can be met without relying on additional cold-weather materials. Eliminating the original cold-weather materials increases structural space, improves the overall vehicle load-bearing efficiency, and reduces the structural weight of the car body.

[0021] 3. By using J-shaped air duct partition beams, cold air duct partitions, and hot air duct partitions, the cold and hot air ducts can be separated, greatly increasing the air supply area of ​​the air conditioner and realizing the cold and hot zone air supply of the main air duct of the vehicle body, thereby improving the working efficiency of the air conditioner.

[0022] 4. The use of J-shaped air duct baffle beams made of carbon fiber composite material serves as both an internal connecting component and a longitudinal stiffening member of the vehicle body, effectively increasing the overall axial stiffness of the vehicle. Since the vertical bending mode of the vehicle body is more sensitive to the longitudinal members of the roof plate, the use of J-shaped air duct baffle beams allows for meeting the overall vehicle modal requirements with a smaller structural weight, thus improving the weight reduction effect of the vehicle body.

[0023] 5. Both the vehicle body roof panel and the interior roof panel have a "sandwich" structure, which has high structural design flexibility. At the same time, the integrated structure of the vehicle body roof panel air duct has a large structural design space. Different functional requirements of the vehicle body can be achieved by selecting different multi-layer core materials, sound insulation, heat insulation and electromagnetic compatibility core materials. Attached Figure Description

[0024] Figure 1 This is a perspective view of the present invention;

[0025] Figure 2 This is a cross-sectional view of the present invention;

[0026] Figure 3 This is a partially enlarged view of the connection structure between the present invention and the side wall;

[0027] Figure 4 This is a cross-sectional view of the vehicle body roof panel of the present invention;

[0028] Figure 5 This is a schematic diagram showing the location and connection of the air duct partition beam of the present invention;

[0029] Figure 6 This is a schematic diagram of the connection between the air duct partition beam and the internal top plate of the present invention;

[0030] Figure 7 This is a schematic diagram of the antenna wiring groove structure of the present invention;

[0031] Figure 8 This is a cross-sectional view of the antenna wiring tube of the present invention;

[0032] Figure 9 This is a diagram of the air duct layout of the present invention;

[0033] In the diagram: 1-Car body roof panel, 101-Car body roof panel carbon fiber outer skin, 102-Car body roof panel carbon fiber inner skin, 103-Car body roof panel intermediate foam core material, 104-Longitudinal reinforcing beam, 105-Connecting reinforcing beam, 106-Embedded pipe, 107-Cable routing trough, 2-Interior roof panel, 201-Interior roof panel inner skin, 202-Interior roof panel foam core material, 203-Interior roof panel outer skin, 204-Carbon fiber embedded block, 3-Inner air duct partition, 301-Inner air duct partition cold air duct ventilation hole, 4-Outer air duct partition, 401- 402-Outer side duct partition cold air duct ventilation hole, 5-Cold air duct partition, 6-Air duct partition beam, 601-Partition beam hot air duct ventilation hole, 602-Partition beam cold air duct ventilation hole, 7-Cold air duct, 8-Hot air duct, 9-Side wall, 10-Outlet connector, 1001-Outlet connector cold air duct ventilation hole, 1002-Outlet connector cold air outlet hole, 11-Inner side wall panel connector, 12-Connecting rivet, 13-Connecting bolt, 14-Rivet nut, 15-Antenna mounting base, 16-Antenna cable.

[0034] Compared with the prior art, the advantages of the present invention are:

[0035] 1. The composite material roof panel air duct integrated structure eliminates the main air duct and side air duct in the original vehicle. Through the main structural components such as the roof panel, air duct partition beam, and interior roof panel, the functional requirements of the vehicle's main air duct are met while meeting the structural load-bearing requirements. This reduces the number of vehicle body parts and improves manufacturing efficiency.

[0036] 2. The composite material roof panel features a "sandwich" structure, with both the carbon fiber skin and foam core material exhibiting high thermal insulation efficiency. By adjusting the core material thickness and utilizing the insulating core material, the thermal insulation requirements of rail vehicles under different operating environments can be met without relying on additional cold-weather materials. Eliminating the original cold-weather materials increases structural space, improves the overall vehicle load-bearing efficiency, and reduces the structural weight of the car body.

[0037] 3. By using J-shaped partition beams, cold air duct partitions, and hot air duct partitions, the cold and hot air ducts can be separated, greatly increasing the air supply area of ​​the air conditioner and realizing the cold and hot air zoning of the main air duct of the vehicle body, thereby improving the working efficiency of the air conditioner.

[0038] 4. The use of carbon fiber composite J-shaped diaphragm beams serves as both internal connecting components and longitudinal stiffening members of the vehicle body, effectively increasing the overall axial stiffness. Since the vertical bending mode of the vehicle body is primarily sensitive to the longitudinal members of the roof plate, the use of J-shaped diaphragm beams allows for meeting the overall vehicle modal requirements with a smaller structural weight, thus improving the vehicle body's weight reduction effect.

[0039] 5. Both the vehicle body roof panel and the interior roof panel have a "sandwich" structure, which has high structural design flexibility. At the same time, the integrated structure of the vehicle body roof panel air duct has a large structural design space. Different functional requirements of the vehicle body can be achieved by selecting different multi-layer core materials, sound insulation, heat insulation and electromagnetic compatibility core materials. Detailed Implementation

[0040] Reference Figure 1 , Figure 2 , Figure 3 , Figure 5 The composite material vehicle roof air duct integrated structure includes: a carbon fiber sandwich structure vehicle roof 1, an interior roof 2, an inner air duct partition 3, an outer air duct partition 4, a cold air duct partition 5, a carbon fiber composite material J-shaped air duct partition beam 6, a cold air duct 7, and a hot air duct 8. The main part of the integrated structure is integrally formed using a co-bonding process.

[0041] The cold air duct 7 is composed of the vehicle body roof panel 1, the interior roof panel 2, the inner air duct partition 3, and the cold air duct partition 5; the hot air duct 8 is composed of the vehicle body roof panel 1, the inner air duct partition 3, and the outer air duct partition 4. The upper end of the air duct partition beam 6 is connected to the vehicle body roof panel 1, and the lower end is connected to the interior roof panel 2. The portion of the air duct partition beam 6 located in the hot air duct 8 has a partition beam hot air duct ventilation hole 601, and the portion located inside the cold air duct 7 has a partition beam cold air duct ventilation hole 602.

[0042] The inner air duct partition 3 is a Z-shaped profile; the outer air duct partition 4 is also a Z-shaped profile, but differs from the inner air duct partition 3 in that the middle of the Z-shape is curved, similar to the curve of the vehicle body roof panel 1; the cold air duct partition 5 is an inwardly bent curved plate structure, its curved part matching and overlapping the outer air duct partition 4, and the bent part is connected to the flange of the F-shaped air outlet connector 10. The inner air duct partition 3 and the outer air duct partition 4 are both symmetrically arranged on both sides, and the cold air duct partition 5 is symmetrically arranged on both sides. The inner air duct partition 3 and the outer air duct partition 4 are respectively provided with inner air duct partition cold air duct ventilation holes 301 and outer air duct partition cold air duct ventilation holes 401 corresponding to the cold air duct ventilation holes 602 of the partition beam. The other end of the outer air duct partition 4 is provided with outer air duct partition hot air duct ventilation holes 402.

[0043] The interior roof panel 2, the cold air duct partition 5, and the air outlet connector 10 are connected by a co-bonding process. The air outlet connector 10 is an F-shaped carbon fiber pultruded profile with a flange. The middle part of the air outlet connector 10 overlaps and is bonded to the interior roof panel 2 to form the vehicle passenger interior wall panel. The connecting flange of the air outlet connector 10 is riveted to one end of the interior side wall panel connector 11, and the other end of the interior side wall panel connector 11 is connected to the carbon fiber composite side wall 9. The side wall 9 is mechanically connected to the vehicle body roof panel 1 of the integrated structure main body by connecting rivets 12 to form a barrel-shaped integral load-bearing vehicle body structure. The air outlet connector 10 has a cold air duct ventilation hole 1001 and a cold air outlet hole 1002 respectively at the top and bottom of the connection point with the interior roof panel 2.

[0044] Reference Figure 4The vehicle roof panel comprises a carbon fiber outer skin 101, a carbon fiber inner skin 102, a central foam core 103, longitudinal reinforcing beams 104, and connecting reinforcing beams 105. The vehicle roof panel is integrally molded using a co-bonded bag pressing method. The connecting reinforcing beams 105 are multi-chamber diagonally braced carbon fiber pultruded profiles, used to improve the longitudinal stiffness of the vehicle roof panel and serve as a reinforcing structure connecting to the vehicle side walls. The longitudinal reinforcing beams 104 are H-shaped carbon fiber pultruded profiles, used to improve the longitudinal stiffness of the vehicle roof panel and serve as reinforcing components connecting to the carbon fiber composite air duct partition beams. The central foam core 103 of the vehicle roof panel can be PMI foam or PET foam, and the minimum height of the foam core should not be less than 50mm to ensure the thermal insulation effect of the sandwich structure vehicle roof panel. Meanwhile, the "sandwich" structure can meet different needs for vehicle body heat insulation and sound insulation under different operating environments by adjusting the height of the foam core material, selecting different functional foam core materials, and separating multiple layers of the sandwich structure, thus having a high degree of design flexibility.

[0045] Reference Figure 5 , Figure 6 The J-shaped air duct baffle beam 6, made of carbon fiber composite material, is a J-shaped continuous carbon fiber pultruded profile. This continuous structure improves the vehicle body's bending stiffness and longitudinal load-bearing capacity. The air duct baffle beam 6 is connected to the vehicle body roof plate 1 using a co-bonding process. In high-stress areas such as the longitudinal reinforcing beam 104 and the ends of the air duct baffle beam, mechanical connections are made using connecting rivets 12 to enhance the structure's load-bearing capacity and the adhesive layer's resistance to peeling.

[0046] The interior roof panel 2 and the air duct partition beam 6 are mechanically connected by connecting bolts 13 and rivet nuts 14. Carbon fiber embedded blocks 204 are arranged in the connection area of ​​the interior roof panel to improve the connection reliability and air conditioning sealing. The interior roof panel and the air duct partition beam adopt a detachable mechanical connection, which enables interchangeability and maintainability of the interior roof panel, facilitating subsequent inspection and maintenance.

[0047] Both the inner air duct partition 3 and the outer air duct partition 4 are carbon fiber sandwich structures, which are integrally formed by carbon fiber skin and foam core material using a co-curing process. The foam core material of both is PMI foam or PET foam, and the minimum height of the foam core material is not less than 15mm to ensure the heat insulation efficiency inside the air conditioning duct.

[0048] The cold air duct partition 5 is a carbon fiber laminate structure with a minimum thickness of 3mm. Since the hot and cold air ducts are already thermally insulated by the outer duct partition 4, the cold air duct partition 5 can be a laminate structure, only needing to meet the structural load-bearing and connection requirements. The inner top panel 2 is a sandwich structure, consisting of an inner top panel skin 201, an outer top panel skin 203, and an inner top panel foam core material 202. The load-bearing requirements of the inner top panel are relatively low, and the inner top panel skin can be made of carbon fiber or glass fiber according to different molding load-bearing requirements. The inner top panel foam core material 202 can be PMI foam or PET foam, and the minimum height of the foam core material should not be less than 20mm to ensure the thermal insulation efficiency inside the air conditioning duct.

[0049] Reference Figure 7 , Figure 8 The antenna mounting bracket 15 of the carbon fiber sandwich structure roof panel 1 requires the antenna cable 16 to be threaded into the vehicle compartment. This is achieved by embedding a carbon fiber pre-embedded tube 106 in the foam core material 103 area of ​​the roof panel at the desired cable insertion location. The pre-embedded tube 106 has an inner diameter of at least 20mm and a wall thickness of at least 3mm. The antenna cable is then guided to the cable connection location on the side of the vehicle compartment via a cap-shaped cable routing channel 107. The cap-shaped cable routing channel is a carbon fiber laminate structure, with a minimum cross-sectional dimension of 40mm*20mm (width*height), and is integrally bonded to the carbon fiber sandwich structure roof panel 1. This cap-shaped cable routing channel effectively solves the cable protection problem after the antenna cable enters the air conditioning chamber, preventing airflow in the duct from blowing the cable and causing abnormal noise in the vehicle body.

[0050] Reference Figure 9 The air conditioning cold air duct 7 chamber is formed by the carbon fiber sandwich structure roof panel 1, the inner air duct partition 3, the cold air duct partition 5, and the interior roof panel 2. An air supply path is formed by the cold air duct ventilation holes 602 on the partition beams of the air duct partition beams, delivering the cold air blown from the air conditioning vents to the upper part of the vehicle's passenger compartment. Similarly, the air conditioning hot air duct 8 chamber is formed by the carbon fiber sandwich structure roof panel 1, the inner air duct partition 3, and the outer air duct partition 4. An air supply path is formed by the hot air duct ventilation holes 601 on the partition beams of the air duct partition beams, delivering the hot air blown from the air conditioning vents to the lower part of the vehicle's passenger compartment. This allows the vehicle's air conditioning ducts to be independently connected to the main air conditioning cold and hot air outlets, achieving zoned cold and hot air supply, increasing the effective working area of ​​the air conditioning ducts, and improving the overall air conditioning efficiency of the vehicle.

Claims

1. An integrated structure for the ventilation duct of a composite material roof panel of a rail vehicle, comprising a roof panel (1) and an interior roof panel (2), characterized in that: An air duct is provided between the vehicle body roof panel (1) and the interior roof panel (2), and the vehicle body roof panel (1), the interior roof panel (2), and the air duct are a co-bonded integrated structure; wherein: The air duct includes a cold air duct (7) and a hot air duct (8); The cold air duct (7) is composed of the vehicle body roof plate (1), the interior roof plate (2), the inner air duct partition (3), and the cold air duct partition (5); the hot air duct (8) is composed of the vehicle body roof plate (1), the inner air duct partition (3), and the outer air duct partition (4). The vehicle body roof panel (1) and the interior roof panel (2) are connected by a duct partition beam (6). The duct partition beam (6) is a continuous J-shaped carbon fiber pultruded profile. The duct partition beam (6) and the vehicle body roof panel (1) are connected by a co-bonding process. The duct partition beam (6) has a hot air duct ventilation hole (601) and a cold air duct ventilation hole (602). The inner duct partition (3) and the outer duct partition (4) are respectively provided with an inner duct partition cold air duct ventilation hole (301) and an outer duct partition cold air duct ventilation hole (401) corresponding to the cold air duct ventilation hole (602) of the partition beam. The other end of the outer duct partition (4) has an outer duct partition hot air duct ventilation hole (402). The inner top plate (2) and the cold air duct partition (5) are bonded together by the air outlet connector (10). The air outlet connector (10) has a cold air duct ventilation hole (1001) and a cold air outlet hole (1002) respectively at the connection point with the inner top plate (2). The air outlet connector (10) is connected to the vehicle body side wall (9), and the vehicle body side wall (9) is connected to the vehicle body roof air duct integrated structure.

2. The integrated structure for the air duct of the composite material roof of a rail vehicle according to claim 1, characterized in that: The vehicle roof panel (1) is integrally formed by bonding the carbon fiber outer skin (101), the middle foam core material (102), the carbon fiber inner skin (103), the longitudinal reinforcing beam (104), and the connecting reinforcing beam (105) together using a bag pressing method. The connecting reinforcing beam (105) is a multi-chamber diagonally braced carbon fiber pultruded profile; the longitudinal reinforcing beam (104) is a H-shaped carbon fiber pultruded profile.

3. The integrated structure for the air duct of the composite material roof of a rail vehicle according to claim 1, characterized in that: The inner top panel (2) is a sandwich structure consisting of an inner skin (201), a foam core material (202), and an outer skin (203). The inner and outer skins of the inner top panel are made of carbon fiber or glass fiber.

4. The integrated structure for the air duct of the composite material roof of a rail vehicle according to claim 1, characterized in that: The air duct partition beam (6) is a continuous J-shaped carbon fiber pultruded profile. The air duct partition beam (6) is bonded to the vehicle body roof panel (1). At the same time, the air duct partition beam is connected by rivets (12) at the end position. The air duct partition beam (6) is connected to the interior roof panel (2) by connecting bolts (13) and rivet nuts (14). Carbon fiber embedded blocks (204) are set in the connection area of ​​the interior roof panel (2).

5. The integrated structure for the air duct of the composite material roof of a rail vehicle according to claim 1, characterized in that: The inner air duct partition (3) and the outer air duct partition (4) are both carbon fiber sandwich structures, which are integrally formed by inner and outer skin and foam core material using a co-curing process. The minimum height of the foam core material should not be less than 15mm.

6. The integrated structure for the air duct of the composite material roof of a rail vehicle according to claim 1, characterized in that: The cold air duct partition (5) is a carbon fiber laminate structure with a minimum thickness of 3mm.

7. The integrated structure for the air duct of the composite material roof of a rail vehicle according to claim 2, characterized in that: The foam core material (102) in the middle of the vehicle body roof panel is PMI foam or PET foam, and the minimum height of the foam core material should not be less than 50mm.

8. The integrated structure for the air duct of the composite material roof of a rail vehicle according to claim 3, characterized in that: The internal roof panel foam core material (203) is PMI foam or PET foam, and the minimum height of the foam core material should not be less than 20mm.

9. The integrated structure for the air duct of the composite material roof of a rail vehicle according to claim 1, characterized in that: The air outlet connector (10) is an F-shaped carbon fiber pultruded profile with a flange. It is connected to the interior side wall panel connector (11) through the flange of the air outlet connector (10). The middle part of the F-shaped air outlet connector (10) overlaps and is bonded to the interior top plate (2).

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