A lay-up structure and lay-up method for thick-walled mesh-shaped multi-cavity pultruded beams of a vehicle body

Abstract

The present application discloses a layup structure and a layup implementation method for a thick-walled eye-shaped multi-cavity pultruded beam of a vehicle body, which relates to the technical field of rail transit. The layup structure includes a first cavity area, a second cavity area, a third cavity area and an outer skin area that are all laid with multi-axial fabrics. The second cavity area is located between the first cavity area and the third cavity area, and the three together are wrapped by the outer skin area to form a rectangular structure in the shape of an eye character. For the above-mentioned layup structure of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body, by using multi-axial fabric layup, the quasi-isotropic mechanical properties of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body are realized. At the same time, it adapts to the pultrusion process, optimizes the structural design, and improves the overall stiffness and strength.

Description

Technical Field

[0001] The present application relates to the field of rail transit technology, and in particular to a layup structure and a layup implementation method of a thick-walled mesh-shaped multi-cavity pultruded beam of a vehicle body. Background Art

[0002] While pursuing greater operational efficiency and safety, rail transit vehicles are placing higher demands on lightweight and strong vehicle structures. Carbon fiber reinforced plastic (CFRP), due to its lightweight and high-strength properties, is an ideal choice for vehicle body structural materials. The pultrusion process, with its high efficiency and cost-effectiveness, has made it possible to use CFRP in thick-walled vehicle body structures. However, achieving high-performance layups that meet complex mechanical performance requirements remains a key challenge in technological development.

[0003] Currently, a major challenge facing layup technology for thick-walled, multi-cavity train structures is the anisotropy of mechanical properties, which limits the structure's performance under multi-directional loads. Existing layup methods struggle to achieve uniform and efficient mechanical load-bearing capacity while maintaining structural lightweighting. This limitation directly impacts the operational efficiency and safety of rail vehicles, highlighting the urgent need to develop new layup structures and processes. Summary of the Invention

[0004] The purpose of this application is to provide a layup structure for a thick-walled, mesh-shaped, multi-cavity pultruded beam for a vehicle body. By using a multi-axial fabric layup, the structure achieves quasi-isotropic mechanical properties while adapting to the pultrusion process, optimizing the structural design, and improving overall stiffness and strength. Another purpose of this application is to provide a layup method for a thick-walled, mesh-shaped, multi-cavity pultruded beam for a vehicle body.

[0005] To achieve the above-mentioned purpose, the present application provides a laying structure of a thick-walled mesh-shaped multi-cavity pultruded beam for a vehicle body, comprising a first cavity area, a second cavity area, a third cavity area and an outer skin area, all of which are laid with multi-axial fabrics. The second cavity area is located between the first cavity area and the third cavity area, and the three are jointly wrapped by the outer skin area to form a rectangular structure in the shape of a mesh.

[0006] In some embodiments, it also includes a vertical rib area laid with multi-axial fabric, and the number of the vertical rib areas is two, the first vertical rib area is located between the first cavity area and the second cavity area, and the second vertical rib area is located between the second cavity area and the third cavity area.

[0007] In some embodiments, it also includes corner areas laid with fiber yarn, and the number of the corner areas is four. The first and second corner areas are located between the two ends of the first vertical rib area and the skin area, and the third and fourth corner areas are located between the two ends of the second vertical rib area and the skin area.

[0008] In some embodiments, the first cavity region sequentially includes a first multi - axial fabric layer of the cavity, a unidirectional fabric layer of the cavity, and a second multi - axial fabric layer of the cavity from inside to outside; and / or,

[0009] The second cavity region sequentially includes a first multi - axial fabric layer of the cavity, a unidirectional fabric layer of the cavity, and a second multi - axial fabric layer of the cavity from inside to outside; and / or,

[0010] The third cavity region sequentially includes a first multi - axial fabric layer of the cavity, a unidirectional fabric layer of the cavity, and a second multi - axial fabric layer of the cavity from inside to outside;

[0011] Wherein, any multi - axial fabric layer includes at least two layers of multi - axial fabrics, and the areal density of a single - layer multi - axial fabric is not less than 200 g / m 2 .

[0012] In some embodiments, both the first multi - axial fabric layer of the cavity and the second multi - axial fabric layer of the cavity include two layers of four - axial warp - knitted fabrics, and the unidirectional fabric layer of the cavity includes one layer of unidirectional fiber cloth.

[0013] In some embodiments, the outer skin region sequentially includes a first multi - axial fabric layer of the skin and a second multi - axial fabric layer of the skin from inside to outside;

[0014] The first multi - axial fabric layer of the skin includes multiple layers of four - axial warp - knitted fabrics, and the second multi - axial fabric layer of the skin includes one layer of bi - axial warp - knitted fabric.

[0015] In some embodiments, the rib region includes a first multi - axial fabric layer of the rib and a unidirectional fabric layer of the rib;

[0016] The first multi - axial fabric layer of the rib includes one layer of four - axial warp - knitted fabric, and the unidirectional fabric layer of the rib includes one layer of unidirectional fiber cloth.

[0017] This application also provides a method for realizing the lay - up of a thick - walled eye - shaped multi - cavity pultruded beam of a vehicle body, which is used to manufacture the above - mentioned lay - up structure, including:

[0018] Sequentially lay up the first cavity region, the second cavity region, and the third cavity region with multi - axial fabrics;

[0019] Lay up the outer skin region with multi - axial fabrics, and the outer skin region simultaneously wraps the first cavity region, the second cavity region, and the third cavity region and forms a rectangular structure in the shape of an eye character.

[0020] In some embodiments, before laying up the outer skin region with multi - axial fabrics, it further includes:

[0021] The multi-axis fabric is used to lay the rib regions. The number of the rib regions is two. The first rib region is located between the first cavity region and the second cavity region, and the second rib region is located between the second cavity region and the third cavity region;

[0022] The fiber yarn is used to lay the corner regions. The number of the corner regions is four. The first and the second corner regions are located between the two ends of the first rib region and the skin region, and the third and the fourth corner regions are located between the two ends of the second rib region and the skin region.

[0023] In some embodiments, the first cavity region, the second cavity region and the third cavity region adopt the cavity laying method, and the number of laying layers is not less than two. The cavity laying method includes:

[0024] The first layer laying gradient process: The laying is made from a straight cloth in a straight shape, bent into an arc-shaped structure, then bent into an open trapezoidal structure, then bent into a U-shaped structure, and finally made into an inner cavity trapezoidal laying structure;

[0025] The second layer laying gradient process: The laying is made from a straight cloth in a straight shape, bent into an arc-shaped structure, then bent into an open trapezoidal structure, then bent into a U-shaped structure, and finally made into an outer cavity mouth-shaped laying structure;

[0026] The outer skin region adopts the skin laying method. The skin laying method includes:

[0027] The skin laying deformation process: The laying is made from a straight cloth in a straight shape, bent into an arc-shaped structure, then bent into an open trapezoidal structure, then bent into a U-shaped structure, and finally made into a skin rectangular laying structure.

[0028] Compared with the above background technology, the laying structure provided by the present application mainly includes a first cavity region, a second cavity region, a third cavity region and an outer skin region. The first cavity region, the second cavity region, the third cavity region and the outer skin region all adopt multi-axis fabric laying. The second cavity region is located between the first cavity region and the third cavity region, and the three together are wrapped by the outer skin region to form a rectangular structure in the shape of a Chinese character "mu".

[0029] In the body structure design of rail transit vehicles, the isotropy of mechanical properties is a key technical issue. Traditional materials and structural designs are often difficult to provide uniform mechanical properties in all directions, which may lead to uneven performance of the vehicle when subjected to forces in multiple directions, affecting the stability and safety of the vehicle. In response to this technical problem, the ply structure provided in the present application adopts an innovative design method. By using multi-axial fabrics for laying in the first cavity area, the second cavity area, the third cavity area and the outer skin area, a rectangular structure in the shape of a mesh is formed, thereby achieving structural optimization. Multi-axial fabrics can provide more uniform mechanical properties due to the distribution of their fibers in multiple directions, thereby improving the load-bearing capacity of the body structure in different directions. In addition, the use of multi-axial fabrics also enables the ply structure to adapt to pultrusion molding, which is a high-efficiency, low-cost production method suitable for large-scale production. The pultrusion process can ensure the uniform distribution and directional accuracy of the fibers during the laying process, thereby further improving the mechanical properties of the thick-walled mesh-shaped multi-cavity pultruded beam of the body.

[0030] Combined with the above structure and process description, it can be seen that the layup structure of the thick-walled mesh-type multi-cavity pultruded beam of the vehicle body has at least the following beneficial effects: the layup structure of the thick-walled mesh-type multi-cavity pultruded beam of the vehicle body achieves the quasi-isotropic mechanical properties of the thick-walled mesh-type multi-cavity pultruded beam of the vehicle body by using multi-axial fabric layup, while adapting to the pultrusion process, optimizing the structural design, and improving the overall stiffness and strength. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are merely embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without any creative work.

[0032] Figure 1 A schematic diagram of the layup structure of a thick-walled mesh-shaped multi-cavity pultruded beam for a vehicle body provided in an embodiment of the present application;

[0033] Figure 2 A dimensional diagram of the layup structure of a thick-walled mesh-shaped multi-cavity pultruded beam for a vehicle body provided in an embodiment of the present application;

[0034] Figure 3 A layup diagram of the layup structure of a thick-walled mesh-shaped multi-cavity pultruded beam for a vehicle body provided in an embodiment of the present application;

[0035] Figure 4 A schematic diagram of the layering process provided in an embodiment of the present application.

[0036] in:

[0037] First cavity zone 1, first cavity first layer 101, first cavity second layer 102, first cavity third layer 103, first cavity fourth layer 104, first cavity fifth layer 105,

[0038] Second cavity zone 2, second cavity first layer 201, second cavity second layer 202, second cavity third layer 203, second cavity fourth layer 204, second cavity fifth layer 205,

[0039] Third cavity zone 3, third cavity first layer 301, third cavity second layer 302, third cavity third layer 303, third cavity fourth layer 304, third cavity fifth layer 305,

[0040] Outer skin area 4, skin first layer 401, skin second layer 402, skin third layer 403, skin fourth layer 404, skin fifth layer 405, skin sixth layer 406, skin seventh layer 407, skin eighth layer 408,

[0041] Stiffener area 5, first layer of stiffener 501, second layer of stiffener 502, third layer of stiffener 503, fourth layer of stiffener 504,

[0042] Corner zone 6, first corner ply 601, second corner ply 602, third corner ply 603, fourth corner ply 604. DETAILED DESCRIPTION

[0043] Carbon fiber is stronger than conventional steel, yet lower in density than aluminum. When combined with resin, carbon fiber composites exhibit higher tensile strength and mechanical properties, as well as resistance to deformation, magnetization, high temperatures, and corrosion. Building on their widespread success in sports products, wind power, and aerospace, and with the continuous advancement of carbon fiber composite manufacturing processes, their application in rail transit vehicles is also increasing, effectively broadening the design scope and application areas of rail vehicles. The main load-bearing beams of rail vehicle composite materials are long, uniform sections, making the efficient, low-cost, and high-quality pultrusion process the most suitable solution for their formation.

[0044] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0045] To enable those skilled in the art of this technology to better understand the solution of this application, the following further detailed description of this application will be given in conjunction with the drawings and specific embodiments.

[0046] Please refer to Figure 1 , Figure 1 which is a schematic diagram of the layup structure of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body provided by the embodiment of this application. The different divisions between regions can be more conveniently understood through the dashed lines in the figure. Therefore, for the sake of distinction, the distance between the dashed lines is not the actual distance between regions. Figure 1 Special treatment has been done to the positions of the dashed lines in

[0047] As Figure 1 shown, in the first specific embodiment, the layup structure provided by the embodiment of this application mainly includes a first cavity region 1, a second cavity region 2, a third cavity region 3, and an outer skin region 4. The first cavity region 1, the second cavity region 2, the third cavity region 3, and the outer skin region 4 are all laid with multi-axial fabrics. The second cavity region 2 is located between the first cavity region 1 and the third cavity region 3, and the three together are wrapped by the outer skin region 4 to form a rectangular structure in the shape of an eye character.

[0048] In the design of the vehicle body structure of rail transit vehicles, the isotropy of mechanical properties is a key technical issue. Traditional materials and structural designs often have difficulty providing uniform mechanical properties in all directions, which may lead to unbalanced performance of the vehicle when受力 in multiple directions, affecting the stability and safety of the vehicle. To address this technical issue, the layup structure provided by this application adopts an innovative design method. By laying multi-axial fabrics in the first cavity region 1, the second cavity region 2, the third cavity region 3, and the outer skin region 4, a rectangular structure in the shape of an eye character is formed, achieving the optimization of the structure. Due to the distribution of its fibers in multiple directions, multi-axial fabrics can provide more uniform mechanical properties, thereby improving the bearing capacity of the vehicle body structure in different directions. In addition, the use of multi-axial fabrics also enables the layup structure to adapt to the pultrusion process for forming, which is a high-efficiency and low-cost production method suitable for large-scale production. The pultrusion process can ensure the uniform distribution of fibers and the accuracy of their directions during the layup process, further improving the mechanical properties of the thick-walled eye-shaped multi-cavity pultruded beam of the vehicle body.

[0049] Combined with the above structure and process description, it can be seen that the layup structure of the thick-walled mesh-type multi-cavity pultruded beam of the vehicle body has at least the following beneficial effects: the layup structure of the thick-walled mesh-type multi-cavity pultruded beam of the vehicle body achieves the quasi-isotropic mechanical properties of the thick-walled mesh-type multi-cavity pultruded beam of the vehicle body by using multi-axial fabric layup, while adapting to the pultrusion process, optimizing the structural design, and improving the overall stiffness and strength.

[0050] It should be noted that the multiaxial fabric referred to in this application includes but is not limited to four-axial warp knitted fabrics, biaxial warp knitted fabrics, etc.; the use of multiaxial fabric plies in the ply structure is not limited to the use of only multiaxial fabric plies, but means that the fabric used includes multiaxial fabric, so it is also possible to use multiaxial fabrics and uniaxial fabrics such as unidirectional fiber cloth plies at the same time, which should also fall within the scope of the description of this application.

[0051] Furthermore, the laying structure of the thick-walled mesh-type multi-cavity pultruded beam of the vehicle body also includes a vertical rib area 5 laid with a multi-axial fabric. The number of the vertical rib areas 5 is two, the first vertical rib area 5 is located between the first cavity area 1 and the second cavity area 2, and the second vertical rib area 5 is located between the second cavity area 2 and the third cavity area 3.

[0052] In this embodiment, in addition to the enhanced rigidity and load-bearing capacity of the U-shaped rectangular structure, the technical solution also incorporates the design of a ribbed area 5 to further enhance the structural stability and mechanical properties. The provision of ribbed area 5 not only strengthens the connection strength between the cavities but also helps distribute and transfer loads, thereby improving the bending and torsional resistance of the thick-walled beams throughout the vehicle body.

[0053] At the same time, the use of multiaxial fabric ensures that the rib area 5 has balanced mechanical properties in multiple directions, which is critical for structural integrity under complex loading conditions. Through this design, the rib area 5 works in conjunction with the cavity area and outer skin area to form an efficient and reliable structural system that meets the stringent structural performance requirements of rail transit vehicles.

[0054] Furthermore, the layup structure of the thick-walled mesh-type multi-cavity pultruded beam of the vehicle body also includes corner areas 6 laid with fiber yarn. There are four corner areas 6. The first and second corner areas 6 are located between the two ends of the first vertical rib area 5 and the skin area, and the third and fourth corner areas 6 are located between the two ends of the second vertical rib area 5 and the skin area.

[0055] In this embodiment, in addition to the cavity and rib areas where the multiaxial fabric is laid, specially designed corner areas 6 are also included. The primary purpose of these corner areas 6 is to enhance the local stability and load-bearing capacity of the structure, particularly at the junctions between the rib and skin areas, and also at the intersections of the rib, skin, and cavity areas. These areas are often areas of mechanical stress concentration. By providing these corner areas 6 at these critical points, stress can be effectively dispersed, reducing stress concentrations, thereby improving the durability and reliability of the entire structure.

[0056] The use of fiber yarns provides the necessary tensile strength while maintaining a lightweight structure. The fiber yarns laid in the corners work synergistically with the studs and skin to form a more balanced and stable structural system. This design not only improves the overall mechanical performance of the thick-walled beams, but also enhances their adaptability and durability in practical applications.

[0057] In summary, the present application provides a laying structure of a thick-walled mesh-shaped multi-cavity pultruded beam for a vehicle body. The laying structure is designed for a rail vehicle body and has the characteristics of a mesh-shaped thick-walled pultruded beam. This structure is a three-cavity, rectangular design with vertical ribs, forming a unique mesh-shaped structure.

[0058] To achieve near-isotropic mechanical properties in the pultruded beam, the present invention's layup structure utilizes multiaxial fabric, supplemented by fiber yarns where necessary. This multiaxial fabric is laid in five primary layup areas, while the fiber yarns are placed in the adjacent corners of these areas to enhance the overall stability of the structure and localized load-bearing capacity.

[0059] This laminate structure not only achieves the quasi-isotropic mechanical properties of composite beams using multiaxial fabrics, but also perfectly adapts to the requirements of pultrusion. This structural design allows the beams to be continuously produced through pultrusion, meeting the engineering requirements of lightweight and high strength while maintaining the efficiency and economy of the production process.

[0060] In some embodiments, the first cavity region 1 includes, from inside to outside, a cavity first multiaxial fabric layer, a cavity unidirectional fabric layer, and a cavity second multiaxial fabric layer.

[0061] In some embodiments, the second cavity region 2 includes, from inside to outside, a cavity first multiaxial fabric layer, a cavity unidirectional fabric layer, and a cavity second multiaxial fabric layer.

[0062] In some embodiments, the third cavity region 3 includes, from inside to outside, a cavity first multiaxial fabric layer, a cavity unidirectional fabric layer, and a cavity second multiaxial fabric layer.

[0063] Wherein, any multiaxial fabric layer comprises at least two layers of multiaxial fabric, and the area density of a single layer of multiaxial fabric is not less than 200g / m 2 .

[0064] Optionally, the first cavity area 1 , the second cavity area 2 and the third cavity area 3 adopt the same cavity lamination method, and the formed cavity lamination structures are similar.

[0065] Taking the first cavity area 1 as an example, the first cavity area 1 includes three different fabric layers from the inside to the outside. The first is the first multi-axial fabric layer of the cavity. This layer uses the multi-directional fiber reinforcement of the multi-axial fabric to provide initial mechanical properties for the structure. Next is the unidirectional fabric layer of the cavity, which is reinforced with unidirectional fibers to provide higher load-bearing capacity in a specific direction. Finally, the second multi-axial fabric layer of the cavity again uses the characteristics of the multi-axial fabric to enhance the overall stability and mechanical properties of the structure. This stacked structure design from the inside to the outside aims to achieve a more balanced and optimized mechanical load-bearing capacity through the combination of different fabric layers.

[0066] It's important to note that each multiaxial fabric layer is constructed from at least two layers of multiaxial fabric, ensuring the structure's strength and rigidity. Crucially, each layer boasts a high areal density of at least 200 grams per square meter. This high-density design allows each layer to withstand significant loads while maintaining the overall lightweight structure. This design not only improves the material's mechanical efficiency but also meets the stringent requirements for lightweight and high-strength rail vehicle structures.

[0067] In some embodiments, the first cavity multiaxial fabric layer and the second cavity multiaxial fabric layer each include two layers of quadriaxial warp knitted fabrics, and the cavity unidirectional fabric layer includes a layer of unidirectional fiber cloth.

[0068] In this embodiment, the four-axial warp knitted fabric can provide more uniform mechanical properties and enhance the load-bearing capacity in all directions. Due to its special weaving method, the four-axial warp knitted fabric has high strength and stability in multiple directions, which is crucial for improving the overall performance of the cavity. At the same time, the unidirectional fabric layer in the cavity is composed of a layer of unidirectional fiber cloth. This layer of unidirectional fiber cloth provides a concentrated reinforcement effect in a specific direction, which helps to improve the longitudinal strength of the structure. Through this design, the unidirectional fiber cloth is combined with the multi-axial fabric layer, so that the entire cavity area can exhibit excellent mechanical properties while maintaining lightweight.

[0069] In some embodiments, the outer skin region 4 includes, from the inside to the outside, a first skin multiaxial fabric layer and a second skin multiaxial fabric layer;

[0070] The first multiaxial fabric layer of the skin comprises multiple layers of quad-axial warp knitted fabrics, and the second multiaxial fabric layer of the skin comprises one layer of biaxial warp knitted fabric.

[0071] In this embodiment, the outer skin region is designed using a laminated structure from the inside out, which includes two different multiaxial fabric layers. First, the first multiaxial fabric layer of the skin is composed of multiple layers of quad-axial warp knitted fabric. This structural design enables the outer skin region to obtain balanced mechanical properties in multiple directions, enhancing the overall load-bearing capacity and deformation resistance. This is followed by the second multiaxial fabric layer of the skin, which is composed of biaxial warp knitted fabric, further enhancing the structural performance of the outer skin region, especially in the warp knitting direction. The biaxial fabric provides additional stability and strength, allowing the outer skin region to better withstand external loads and stresses under various operating conditions.

[0072] In some embodiments, the stud area 5 includes a stud first multiaxial fabric layer and a stud unidirectional fabric layer;

[0073] The first multi-axial fabric layer of the vertical reinforcement includes a layer of four-axial warp knitted fabric, and the unidirectional fabric layer of the vertical reinforcement includes a layer of unidirectional fiber cloth.

[0074] In this embodiment, the first multi-axial fabric layer of the ribs is composed of a layer of four-axial warp knitted fabric, which can provide reinforcement effects in multiple directions, thereby bringing higher structural stability and mechanical properties to the rib area. The unidirectional fabric layer of the ribs is composed of unidirectional fiber cloth. This layer of unidirectional fabric provides concentrated strength in a specific direction, which helps to improve the longitudinal bearing capacity of the rib area. The use of this unidirectional fabric ensures that the rib area has sufficient mechanical properties in key directions, and also helps to achieve lightweight structure. The rib area 5 achieves structural optimization through the combination of multi-axial and unidirectional fabrics, which not only enhances the overall stiffness and strength, but also helps to disperse and transfer loads, and improves the bending and torsional properties of the thick-walled pultruded beams of the entire vehicle body. This design meets the strict requirements of rail transit vehicles for vehicle body structural performance and ensures the stability and safety of vehicle operation.

[0075] Please refer to Figure 2 and Figure 3 , Figure 2 This is a dimension diagram of the layup structure of the thick-walled mesh-shaped multi-cavity pultruded beam for the vehicle body provided in the embodiment of the present application. Figure 3 This is a layup diagram of the layup structure of the thick-walled mesh-shaped multi-cavity pultruded beam for the vehicle body provided in an embodiment of the present application.

[0076] like Figure 3 As shown, the first cavity area 1 comprises, from inside to outside, a first cavity first ply 101 , a first cavity second ply 102 , a first cavity third ply 103 , a first cavity fourth ply 104 , and a first cavity fifth ply 105 .

[0077] Among them, the first ply 101 of the first cavity and the second ply 102 of the first cavity serve as the first multiaxial fabric layer of the first cavity area 1, the third ply 103 of the first cavity serves as the unidirectional fabric layer of the first cavity area 1, and the fourth ply 104 of the first cavity and the fifth ply 105 of the first cavity serve as the second multiaxial fabric layer of the first cavity area 1.

[0078] The fabric used in the first layer 101 of the first cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m 2 .

[0079] The fabric used in the second layer 102 of the first cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m 2 .

[0080] The fabric used for the third ply 103 of the first cavity is unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m².

[0081] The fabric used for the fourth ply 104 of the first cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0082] The fabric used for the fifth ply 105 of the first cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0083] like Figure 3 As shown, the second cavity area 2 comprises, from inside to outside, a second cavity first layer 201 , a second cavity second layer 202 , a second cavity third layer 203 , a second cavity fourth layer 204 , and a second cavity fifth layer 205 .

[0084] Among them, the first ply 201 of the second cavity and the second ply 202 of the second cavity serve as the first multiaxial fabric layer of the second cavity area 2, the third ply 203 of the second cavity serves as the unidirectional fabric layer of the second cavity area 2, and the fourth ply 204 of the second cavity and the fifth ply 205 of the second cavity serve as the second multiaxial fabric layer of the second cavity area 2.

[0085] The fabric used in the first ply 201 of the second cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m².

[0086] The fabric used for the second ply 202 of the second cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0087] The fabric used for the third ply 203 of the second cavity is unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m².

[0088] The fabric used for the fourth ply 204 of the second cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0089] The fifth ply 205 of the second cavity is made of a four-axial warp knitted fabric (0°, +45°, 90°, -45°), made of T700 with a specification of 800 g / m².

[0090] like Figure 3 As shown, the third cavity area 3 comprises, from inside to outside, a third cavity first layer 301 , a third cavity second layer 302 , a third cavity third layer 303 , a third cavity fourth layer 304 , and a third cavity fifth layer 305 .

[0091] Among them, the first ply 301 of the third cavity and the second ply 302 of the third cavity serve as the first multiaxial fabric layer of the third cavity area 3, the third ply 303 of the third cavity serves as the unidirectional fabric layer of the third cavity area 3, and the fourth ply 304 of the third cavity and the fifth ply 305 of the third cavity serve as the second multiaxial fabric layer of the third cavity area 3.

[0092] The fabric used for the first ply 301 of the third cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m².

[0093] The fabric used for the second ply 302 of the third cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0094] The fabric used for the third ply 303 of the third cavity is unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m².

[0095] The fabric used for the fourth ply 304 of the third cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), made of T700 with a specification of 800 g / m².

[0096] The fabric used for the fifth ply 305 of the third cavity is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), made of T700 with a specification of 800 g / m².

[0097] like Figure 3As shown, the outer skin area 4 comprises, from inside to outside, the first skin layer 401, the second skin layer 402, the third skin layer 403, the fourth skin layer 404, the fifth skin layer 405, the sixth skin layer 406, the seventh skin layer 407, and the eighth skin layer 408.

[0098] Among them, the first skin layer 401, the second skin layer 402, the third skin layer 403, the fourth skin layer 404, the fifth skin layer 405, the sixth skin layer 406, and the seventh skin layer 407 serve as the first multiaxial fabric layer of the skin of the outer skin area 4, and the eighth skin layer 408 serves as the second multiaxial fabric layer of the skin of the outer skin area 4.

[0099] The fabric used for the first layer 401 of the skin is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0100] The fabric used for the second layer 402 of the skin is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0101] The fabric used for the third layer 403 of the skin is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0102] The fabric used for the fourth layer 404 of the skin is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0103] The fabric used for the fifth layer 405 of the skin is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0104] The fabric used for the sixth layer 406 of the skin is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0105] The fabric used for the seventh layer 407 of the skin is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 800g / m².

[0106] The fabric used for the eighth layer 408 of the skin is a biaxial warp knitted fabric (+45°, -45°), the material is T700, and the specification is 200g / m².

[0107] like Figure 3As shown, the first vertical rib area 5 is located between the first cavity area 1 and the second cavity area 2, including the first vertical rib ply 501 and the second vertical rib ply 502; the second vertical rib area 5 is located between the second cavity area 2 and the third cavity area 3, including the third vertical rib ply 503 and the fourth vertical rib ply 504.

[0108] Among them, the first ply 501 of the vertical reinforcement is used as the unidirectional fabric layer of the vertical reinforcement in the first vertical reinforcement area 5, the second ply 502 of the vertical reinforcement is used as the first multiaxial fabric layer of the vertical reinforcement in the first vertical reinforcement area 5, the third ply 503 of the vertical reinforcement is used as the unidirectional fabric layer of the vertical reinforcement in the second vertical reinforcement area 5, and the fourth ply 504 of the vertical reinforcement is used as the first multiaxial fabric layer of the vertical reinforcement in the second vertical reinforcement area 5.

[0109] The fabric used for the first ply 501 of the vertical reinforcement is unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m².

[0110] The fabric used for the second ply 502 of the vertical reinforcement is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m².

[0111] The fabric used for the third ply 503 of the vertical reinforcement is unidirectional fiber cloth (0°), the material is T700, and the specification is 200g / m².

[0112] The fabric used for the fourth ply 504 of the vertical ribs is a four-axial warp knitted fabric (0°, +45°, 90°, -45°), the material is T700, and the specification is 400g / m².

[0113] like Figure 3 As shown, the four corner regions 6 include a first corner ply 601 , a second corner ply 602 , a third corner ply 603 , and a fourth corner ply 604 .

[0114] Among them, the first corner ply 601 and the second corner ply 602 serve as the corner areas 6 at both ends of the first vertical rib area 5, and the third corner ply 603 and the fourth corner ply 604 serve as the corner areas 6 at both ends of the second vertical rib area 5.

[0115] The fabrics used for the first corner ply 601 , the second corner ply 602 , the third corner ply 603 , and the fourth corner ply 604 are all 12K carbon fiber yarns, and the material is T700.

[0116] The present application also provides a method for laying out a thick-walled mesh-shaped multi-cavity pultruded beam for a vehicle body, which is used to produce the above-mentioned layup structure, comprising:

[0117] The first cavity area 1, the second cavity area 2 and the third cavity area 3 are laid sequentially using multiaxial fabrics;

[0118] The outer skin area 4 is laid with a multi-axial fabric. The outer skin area 4 simultaneously wraps the first cavity area 1, the second cavity area 2, and the third cavity area 3 and forms a rectangular structure in the shape of a Chinese character "mu".

[0119] In some embodiments, before laying the outer skin area 4 with a multi-axial fabric, it further includes:

[0120] The rib area 5 is laid with a multi-axial fabric. The number of rib areas 5 is two. The first rib area 5 is located between the first cavity area 1 and the second cavity area 2, and the second rib area 5 is located between the second cavity area 2 and the third cavity area 3;

[0121] The corner area 6 is laid with fiber yarns. The number of corner areas 6 is four. The first and second corner areas 6 are located between the two ends of the first rib area 5 and the skin area, and the third and fourth corner areas 6 are located between the two ends of the second rib area 5 and the skin area.

[0122] In summary, by using the laying implementation method of the thick-walled mu-shaped multi-cavity pultruded beam of the vehicle body, the laying structure of the thick-walled mu-shaped multi-cavity pultruded beam of the rail vehicle suitable for the pultrusion process and meeting the mechanical requirements can be manufactured.

[0123] Exemplarily, according to the laying structure, the overall laying structure sequence is laid according to the following process: the first cavity area 1 → the second cavity area 2 → the third cavity area 3 → the rib area 5 → the outer skin area 4.

[0124] Please refer to Figure 4 , Figure 4 , which is a schematic diagram of the laying process provided by the embodiment of the present application.

[0125] In some embodiments, the first cavity area 1, the second cavity area 2, and the third cavity area 3 adopt a cavity laying method, and the number of laying layers is not less than two. The cavity laying method includes:

[0126] The first layer laying gradient process: The laying is made from a straight cloth in a straight shape, bent into an arc-shaped structure, then bent into an open trapezoidal structure, then bent into a U-shaped structure, and finally made into an inner cavity trapezoidal laying structure;

[0127] The second layer laying gradient process: The laying is made from a straight cloth in a straight shape, bent into an arc-shaped structure, then bent into an open trapezoidal structure, then bent into a U-shaped structure, and finally made into an outer cavity mouth-shaped laying structure.

[0128] In this embodiment, the number of laying layers of the first cavity area 1, the second cavity area 2, and the third cavity area 3 shall not be less than two, and the single layer shall not be less than 200 g / m 2 , for example, the first multi-axial fabric layer of the cavity shall not be less than two layers, and the second multi-axial fabric layer of the cavity shall not be less than two layers.

[0129] Taking the first cavity area 1 as an example, Figure 3 As shown, the two layers of the first cavity area 1 are deformed in sequence according to the following gradual transformation method. The gradual transformation process of the first layer is: straight line (straight cloth) → arc type → open trapezoidal structure → U-shaped structure → finally the inner cavity trapezoidal structure. The gradual transformation process of the second layer is: straight line (straight cloth) → arc type → open trapezoidal structure → U-shaped structure → finally the outer cavity mouth-shaped structure.

[0130] The two layers of the second cavity area 2 and the third cavity area 3 are laid in sequence according to the same gradual process as the first cavity area 1.

[0131] In some embodiments, the outer skin region 4 adopts a skin layup method, which includes:

[0132] Skin layup deformation process: The layup is made of a straight cloth in the shape of a straight line, which is bent into an arc-shaped structure, then bent into an open trapezoidal structure, and then bent into a U-shaped structure, and finally into a rectangular layup structure of the skin.

[0133] It should be noted that many of the components mentioned in this application are universal standard parts or components known to those skilled in the art, and their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0134] It should be noted that, in this specification, relational terms such as first and second are merely used to distinguish one entity from other entities, but do not necessarily require or imply any actual relationship or order between these entities.

[0135] The above is a detailed introduction to the layup structure and layup implementation method of the thick-walled mesh multi-cavity pultruded beam for the vehicle body provided by this application. Specific examples are used herein to illustrate the principles and implementation methods of this application. The description of the above embodiments is only used to help understand the method and core ideas of this application. It should be pointed out that for ordinary technicians in this technical field, without departing from the principles of this application, several improvements and modifications can be made to this application, and these improvements and modifications also fall within the scope of protection of the claims of this application.

Claims

1. A laminated structure of a thick-walled mesh multi-cavity pultruded beam for a vehicle body, characterized in that: It includes a first cavity area, a second cavity area, a third cavity area, and an outer skin area that are all laid with multi-axial fabrics. The second cavity area is located between the first cavity area and the third cavity area, and the three together are wrapped by the outer skin area to form a rectangular structure in the shape of a Chinese character "mu". The first cavity area successively includes a first multi-axial fabric layer of the cavity, a unidirectional fabric layer of the cavity, and a second multi-axial fabric layer of the cavity from the inside to the outside. and / or The second cavity area successively includes a first multi-axial fabric layer of the cavity, a unidirectional fabric layer of the cavity, and a second multi-axial fabric layer of the cavity from the inside to the outside. and / or The third cavity area successively includes a first multi-axial fabric layer of the cavity, a unidirectional fabric layer of the cavity, and a second multi-axial fabric layer of the cavity from the inside to the outside. The outer skin area successively includes a first multi-axial fabric layer of the skin and a second multi-axial fabric layer of the skin from the inside to the outside. The first multi-axial fabric layer of the skin includes multiple layers of four-axial warp knitted fabrics, and the second multi-axial fabric layer of the skin includes one layer of bi-axial warp knitted fabric.

2. The laminated structure of the thick-walled mesh multi-cavity pultruded beam for a vehicle body according to claim 1 is characterized in that: It further includes a rib area laid with multi-axial fabrics. The number of rib areas is two. The first rib area is located between the first cavity area and the second cavity area, and the second rib area is located between the second cavity area and the third cavity area.

3. The layer structure of the thick-walled mesh multi-cavity pultruded beam for a vehicle body according to claim 2 is characterized in that: It further includes a corner area laid with fiber yarns. The number of corner areas is four. The first and second corner areas are located between the two ends of the first rib area and the outer skin area, and the third and fourth corner areas are located between the two ends of the second rib area and the outer skin area.

4. The layer structure of the thick-walled mesh multi-cavity pultruded beam for a vehicle body according to claim 1 is characterized in that: Any multiaxial fabric layer includes at least two layers of multiaxial fabric, and the area density of a single layer of multiaxial fabric is not less than 200g / m 2 .

5. The layer structure of the thick-walled mesh multi-cavity pultruded beam for a vehicle body according to claim 4 is characterized in that: Both the first multi-axial fabric layer of the cavity and the second multi-axial fabric layer of the cavity include two layers of four-axial warp knitted fabrics, and the unidirectional fabric layer of the cavity includes one layer of unidirectional fiber cloth.

6. The layer structure of the thick-walled mesh multi-cavity pultruded beam for a vehicle body according to claim 2, characterized in that: The rib area includes a first multi-axial fabric layer of the rib and a unidirectional fabric layer of the rib. The first multi-axial fabric layer of the rib includes one layer of four-axial warp knitted fabric, and the unidirectional fabric layer of the rib includes one layer of unidirectional fiber cloth.

7. A method for laying out thick-walled mesh multi-cavity pultruded beams for vehicle bodies, characterized in that: For manufacturing the layup structure as described in any one of claims 1 to 6, it includes: Successively laying the first cavity area, the second cavity area, and the third cavity area with multi-axial fabrics. Laying the outer skin area with multi-axial fabrics. The outer skin area simultaneously wraps the first cavity area, the second cavity area, and the third cavity area and forms a rectangular structure in the shape of a Chinese character "mu".

8. The method for laying out thick-walled mesh multi-cavity pultruded beams for vehicle bodies according to claim 7, characterized in that: Before laying the outer skin area with multi-axial fabrics, it further includes: Laying the rib area with multi-axial fabrics. The number of rib areas is two. The first rib area is located between the first cavity area and the second cavity area, and the second rib area is located between the second cavity area and the third cavity area. Laying the corner area with fiber yarns. The number of corner areas is four. The first and second corner areas are located between the two ends of the first rib area and the outer skin area, and the third and fourth corner areas are located between the two ends of the second rib area and the outer skin area.

9. The method for laying out thick-walled mesh multi-cavity pultruded beams for vehicle bodies according to claim 7, characterized in that: The first cavity area, the second cavity area, and the third cavity area adopt a cavity layup method, and the number of layups is not less than two layers. The cavity layup method includes: The first layer of ply gradient process: the ply is made of a straight cloth in the shape of a straight line, which is bent into an arc-shaped structure, then bent into an open trapezoidal structure, and then bent into a U-shaped structure, and finally into a trapezoidal ply structure with an inner cavity; The second layer of gradual ply transition process: the ply is formed from a straight, straight fabric in a straight line, which is then bent into an arc-shaped structure, then bent into an open trapezoidal structure, then bent into a U-shaped structure, and finally into an outer cavity mouth-shaped ply structure; The outer skin area adopts a skin layer method, and the skin layer method includes: Skin layup deformation process: The layup is made of a straight cloth in the shape of a straight line, which is bent into an arc-shaped structure, then bent into an open trapezoidal structure, and then bent into a U-shaped structure, and finally into a rectangular layup structure of the skin.

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