Railway freight car composite side wall and method of manufacture

Abstract

The present application relates to a kind of railway freight car composite material side wall and manufacturing method, it is related to railway freight train technical inspection technical field.The present application includes: skin, inner skin and outer skin are made of;First support component, set in the inside of skin, including crossbeam component and side vertical beam;Second support component, set in the inside of skin, including vertical beam component and oblique connecting beam;Filler component, fill in the inside of skin;Crossbeam component, vertical beam component, side vertical beam are all composite material structure scheme, compared with the most advanced aluminum alloy side wall can reduce weight 30% or more;Crossbeam component, vertical beam component, side vertical beam, oblique connecting beam and third sandwich material are solidified in the inside of skin, the outer surface structure of side wall is simple, for no outside column structure, so as to can make full use of the clearance of wagon, also facilitate cleaning residual in wagon goods;Using solidification forming scheme, can reduce welding point or rivet point, so as to can improve the structural strength, reduce production labor intensity.

Description

Technical Field

[0001] This invention relates to the field of technical inspection technology for railway freight trains, and particularly to a composite material sidewall for railway freight cars and its manufacturing method. Background Technology

[0002] Lightweighting of railway freight cars refers to maximizing the structural load-bearing capacity while ensuring structural safety and reliability under limited load-bearing structural mass, thereby improving vehicle carrying capacity and energy consumption.

[0003] The lightweighting technology and advanced lightweight materials used in railway freight cars are closely related to this.

[0004] The body of a railway freight car is mainly composed of a chassis, end walls, and side walls. The chassis is mainly welded together from a central beam, sleeper beams, crossbeams, longitudinal beams, and floor. The end walls are mainly composed of end plates, upper end beams, crossbars, and corner posts. The side walls are mainly composed of upper side beams, sleeper posts, side posts, and side wall panels. Together, these three components enclose the cargo loading space and the overall load-bearing structure. The end walls and side walls are mainly used to withstand the lateral pressure of the loaded cargo and the lateral forces generated during the operation of the vehicle. In particular, the longitudinally arranged side walls need to withstand greater pressure. Therefore, the side walls must have sufficient strength and rigidity to ensure the safety of railway open wagon operation. Summary of the Invention

[0005] This invention provides a composite material sidewall for railway freight cars and a manufacturing method thereof, which is used to enhance the strength and rigidity of the sidewall and ensure the safety of railway open wagon operation.

[0006] This invention provides a composite material sidewall for railway freight cars and a manufacturing method thereof, comprising:

[0007] The skin, which consists of an inner skin and an outer skin;

[0008] A first support assembly is disposed between the inner skin and the outer skin. The first support assembly includes multiple sets of crossbeam assemblies and multiple sets of side vertical beams. The multiple sets of crossbeam assemblies are evenly spaced and distributed laterally. The multiple sets of side vertical beams are disposed at both ends inside the skin and are vertically arranged.

[0009] The second support assembly is disposed between the inner skin and the outer skin. The second support assembly includes vertical beam assemblies and diagonal connecting beams. Multiple sets of vertical beam assemblies are provided, and the multiple sets of vertical beam assemblies are distributed vertically at intervals. The diagonal connecting beams are located on both sides of the inner bottom end of the skin.

[0010] A filling component, which fills the interior of the skin, the filling component comprising a third sandwich material.

[0011] Preferably, the inner skin and the outer skin are the same size, and the inner skin includes one layer of epoxy prepreg reinforced with glass fiber plain weave fabric, one layer of epoxy prepreg reinforced with carbon fiber plain weave fabric, eighteen layers of unidirectional epoxy prepreg reinforced with carbon fiber, and one layer of epoxy prepreg reinforced with carbon fiber plain weave fabric.

[0012] Preferably, the outer skin comprises one layer of epoxy prepreg reinforced with carbon fiber plain weave fabric, eighteen layers of unidirectional tape reinforced with carbon fiber, and one layer of epoxy prepreg reinforced with carbon fiber plain weave fabric, with the following laying order: one layer of fabric, twelve to eighteen layers of unidirectional tape, and one layer of fabric.

[0013] Preferably, the unidirectional tape layer is laid at a longitudinal angle of [45°, The prepreg is laid symmetrically in the directions of 45° and 0°, and the curing temperature of the prepreg is 80°C. 120℃.

[0014] Preferably, both the crossbeam assembly and the side vertical beam are composed of an I-beam and a first sandwich material. The first sandwich material fills the interior of the I-beam, and the outer surface of the first sandwich material is coated with a first epoxy resin film. The first sandwich material is connected to the inner side of the I-beam through the first epoxy resin film.

[0015] Preferably, the crossbeam assembly is provided in three sets, and the three sets of crossbeam assemblies are respectively arranged in the upper, middle and lower positions inside the skin;

[0016] The side vertical beams are provided in four sections, which are respectively located on both sides of the third sandwich material.

[0017] Preferably, the vertical beam assembly includes a surface composite material layer, the front end or rear end of the surface composite material layer is configured as a drilling area, the front end of the drilling area is provided with an insert joint area, the insert joint area is adapted to the crossbeam assembly, and the interior of the drilling area is filled with thermosetting phenolic resin.

[0018] The drilling area has multiple sets of spaced nail holes at the positions corresponding to the crossbeam assembly, and the vertical beam assembly is connected to the crossbeam assembly through the multiple sets of nail holes.

[0019] Preferably, the interior of the surface composite material layer is filled with a second sandwich material, and a second epoxy resin film is coated between the outer surface of the second sandwich material and the thermosetting phenolic resin and the inner wall of the surface composite material layer.

[0020] Preferably, the cross-section of the inclined connecting beam is trapezoidal, and multiple sets of spaced nail holes are provided on the inclined connecting beam;

[0021] The bottom sides of the skin are provided with reinforcement areas corresponding to the positions of the oblique connecting beams.

[0022] Preferably, the method for manufacturing composite material sidewalls for railway freight cars includes the following steps:

[0023] S1. Mold making: Make side wall molds according to design specifications;

[0024] S2. Material laying: Lay the inner skin according to the design requirements. After the inner skin is laid, lay a layer of epoxy film.

[0025] The crossbeam assembly, vertical beam assembly, side vertical beam, diagonal connecting beam, and third sandwich material are placed in the designed positions on the inner skin, and the positions are positioned by tooling clamps to ensure that each component fits together.

[0026] A layer of expanding foam is filled between the third sandwich material and the crossbeam assembly, vertical beam assembly, side vertical beam, and diagonal connecting beam;

[0027] After the horizontal beam assembly, vertical beam assembly, side vertical beam, diagonal connecting beam and third sandwich material are laid, a layer of epoxy film is laid.

[0028] Lay the outer skin according to the design requirements;

[0029] S3, Integrated Curing: Vacuum sealing is applied to the installed side wall panels, with the vacuum level ≤ during sealing. 90 kPa, and then placed in a curing device to cure and shape according to the curing regime requirements;

[0030] S4. Demolding and Trimming: After curing, the product is demolded, the edges are trimmed and sanded, and the surface is coated as needed to complete the sidewall preparation.

[0031] Preferably, there are 12 sets of vertical beam assemblies, and the 12 sets of vertical beam assemblies are evenly arranged vertically.

[0032] Preferably, the oblique connecting beam is a thermosetting phenolic resin molded plate.

[0033] Preferably, the third sandwich material can be PMI foam, which has a compressive strength of 2.8 MPa.

[0034] Preferably, the third sandwich material can be aramid honeycomb with a compressive strength of 1.5 MPa.

[0035] Preferably, the I-beam is produced by pultrusion of carbon fiber and epoxy resin.

[0036] Preferably, the crossbeam assembly, vertical beam assembly, side vertical beam, and diagonal connecting beam have the same thickness.

[0037] Preferably, the first sandwich material is PMI foam.

[0038] Preferably, the second sandwich material is PMI foam.

[0039] Compared with the prior art, the advantages of the present invention are as follows:

[0040] 1. The crossbeam assembly, vertical beam assembly, and side vertical beams are all made of composite materials, which can reduce weight by more than 30% compared to the most advanced aluminum alloy sidewalls currently available.

[0041] 2. The side wall adopts an integral structure of skin, third sandwich material, crossbeam assembly, vertical beam assembly, side vertical beam, and diagonal connecting beam. The crossbeam assembly, vertical beam assembly, side vertical beam, diagonal connecting beam, and third sandwich material are all solidified inside the skin. The external structure of the side wall is simple and has no external columns, which can make full use of the truck clearance and facilitate the removal of goods left in the truck.

[0042] 3. By adopting a curing molding method, the number of welding points or riveting points can be reduced, thereby improving structural strength and reducing the labor intensity of production. Attached Figure Description

[0043] The invention will now be described in more detail with reference to embodiments and the accompanying drawings.

[0044] Figure 1 This is a schematic diagram of the side wall structure in an embodiment of the present invention;

[0045] Figure 2 This is a schematic cross-sectional view of the side wall structure in an embodiment of the present invention;

[0046] Figure 3 This is a schematic cross-sectional view of the crossbeam assembly and the side vertical beam structure of the present invention;

[0047] Figure 4 This is a vertical cross-sectional view of the vertical beam assembly of the present invention;

[0048] Figure 5 This is a schematic cross-sectional view of the vertical beam assembly of the present invention;

[0049] Figure 6 This is a schematic cross-sectional view of the oblique connecting beam of the present invention.

[0050] Figure label:

[0051] Skin 1, Inner Skin 11, Outer Skin 12;

[0052] 2. Crossbeam assembly; 21. I-beam; 22. First sandwich material; 23. First epoxy resin film;

[0053] Vertical beam assembly 3, nail hole 31, insert joint area 32, drilling area 33, second sandwich material 34, second epoxy resin film 35, surface composite material layer 36;

[0054] Side vertical beam 4;

[0055] 5. Inclined connecting beam;

[0056] Third sandwich material 6;

[0057] 7. Epoxy structural adhesive film layer;

[0058] Strengthen area 8. Detailed Implementation

[0059] To more clearly illustrate the overall concept of the present invention, a detailed description will be provided below with reference to the accompanying drawings and examples.

[0060] It should be noted that many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the scope of protection of the present invention is not limited to the specific embodiments disclosed below.

[0061] Furthermore, in the description of this invention, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0062] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral unit; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. However, specifying a direct connection indicates that the two connected entities do not establish a connection relationship through an intermediate structure, but are simply connected to form a whole through a connecting structure. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0063] In this invention, unless otherwise expressly specified and limited, the first feature "on" or "below" the second feature may be in direct contact with the first and second features, or indirect contact through an intermediate medium. In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0064] A composite material sidewall for railway freight cars, comprising:

[0065] Skin 1, wherein skin 1 is composed of inner skin 11 and outer skin 12;

[0066] The inner skin 11 and the outer skin 12 have the same size, and the inner skin 11 includes a glass fiber plain weave fabric reinforced epoxy prepreg wear-resistant layer, a carbon fiber plain weave fabric reinforced epoxy prepreg layer, eighteen carbon fiber reinforced epoxy prepreg unidirectional tape layers, and a carbon fiber plain weave fabric reinforced epoxy prepreg layer.

[0067] The outer skin 12 includes one layer of epoxy prepreg reinforced with carbon fiber plain weave fabric, twelve to eighteen layers of unidirectional epoxy prepreg reinforced with carbon fiber, and one layer of epoxy prepreg reinforced with carbon fiber plain weave fabric.

[0068] The unidirectional tape layer is laid at a longitudinal angle of [45°, The prepreg is laid symmetrically in the directions of 45° and 0°, and the curing temperature of the prepreg is 80°C. 120℃;

[0069] A first support assembly is disposed between the inner skin 11 and the outer skin 12. The first support assembly includes multiple sets of crossbeam assemblies 2 and multiple sets of side vertical beams 4. The multiple sets of crossbeam assemblies 2 and the multiple sets of side vertical beams 4 are all composed of I-beams 21 and a first sandwich material 22. The multiple sets of crossbeam assemblies 2 are evenly spaced laterally distributed, and the multiple sets of side vertical beams 4 are disposed at both ends inside the skin 1 and are arranged vertically.

[0070] The crossbeam assembly 2 is provided in three sets, and the three sets of crossbeam assemblies 2 are respectively located at the upper, middle and lower positions inside the skin 1;

[0071] The side vertical beams 4 are provided in four sections, and the four side vertical beams 4 are respectively provided on both sides of the two ends of the third sandwich material 6.

[0072] The first sandwich material 22 is filled inside the I-beam 21, and the outer surface of the first sandwich material 22 is coated with a first epoxy resin film 23. The first sandwich material 22 is connected to the inner side of the I-beam 21 through the first epoxy resin film 23.

[0073] The second support assembly is disposed between the inner skin 11 and the outer skin 12. The second support assembly includes a vertical beam assembly 3 and an oblique connecting beam 5. Multiple sets of vertical beam assemblies 3 are provided, and the multiple sets of vertical beam assemblies 3 are vertically spaced. The vertical beam assembly 3 is composed of a surface composite material layer 36 and a second sandwich material 34. The oblique connecting beam 5 is located on both sides of the inner bottom end of the skin 1.

[0074] The front or rear end of the surface composite material layer 36 is set as a drilling area 33. The front end of the drilling area 33 is provided with an insert joint area 32. The insert joint area 32 is adapted to the crossbeam assembly 2. The interior of the surface composite material layer 36 is filled with thermosetting phenolic resin at the position corresponding to the drilling area 33.

[0075] The drilling area 33 has multiple sets of spaced nail holes 31 at the position corresponding to the crossbeam assembly 2, and the vertical beam assembly 3 is connected to the crossbeam assembly 2 through the multiple sets of nail holes 31.

[0076] The interior of the surface composite material layer 36 is filled with a second sandwich material 34, and a second epoxy resin film 35 is coated between the outer surface of the second sandwich material 34 and the thermosetting phenolic resin and the inner wall of the surface composite material layer 36.

[0077] The cross-section of the inclined connecting beam 5 is trapezoidal, and multiple sets of spaced nail holes 31 are provided on the inclined connecting beam 5.

[0078] A filling component, which fills the interior of the skin 1, the filling component comprising a third sandwich material 6;

[0079] An epoxy structural adhesive film layer 7 is coated between the crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the diagonal connecting beam 5, and the third sandwich material 6 and the skin 1 and the crossbeam assembly 2;

[0080] The bottom sides of the skin 1 are provided with reinforcing areas 8 corresponding to the positions of the oblique connecting beams 5.

[0081] A method for manufacturing a composite material sidewall for railway freight cars includes the following steps:

[0082] S1. Mold making: Make side wall molds according to design specifications;

[0083] S2. Material laying: Lay the inner skin 11 according to the design requirements. After the inner skin 11 is laid, lay a layer of epoxy film.

[0084] Place the crossbeam assembly 2, vertical beam assembly 3, side vertical beam 4, diagonal connecting beam 5, and third sandwich material 6 in the designed positions on the inner skin 11, and use tooling clamps to position them to ensure that each component fits together.

[0085] A layer of expanding foam is filled between the third sandwich material 6 and the crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, and the diagonal connecting beam 5;

[0086] After the horizontal beam assembly 2, vertical beam assembly 3, side vertical beam 4, diagonal connecting beam 5 and third sandwich material 6 are laid, a layer of epoxy film is laid.

[0087] Lay the outer skin 12 according to the design requirements;

[0088] S3, Integrated Curing: The laid side wall panels are vacuum sealed with a vacuum degree of ≤-90kPa, and then placed in a curing device to cure and form according to the curing regime requirements;

[0089] S4. Demolding and Trimming: After curing, the product is demolded, the edges are trimmed and sanded, and the surface is coated as needed to complete the sidewall preparation.

[0090] Example 1:

[0091] See Figure 1 As shown, Figure 1 This is a schematic diagram of the side wall structure in an embodiment of the present invention;

[0092] See Figure 2 As shown, Figure 2 This is a schematic cross-sectional view of the side wall structure in an embodiment of the present invention;

[0093] like Figure 1 Figure 2 As shown, a composite material sidewall for railway freight cars is composed of a skin 1, a crossbeam assembly 2, a vertical beam assembly 3, a side vertical beam 4, an oblique connecting beam 5, and a third sandwich material 6. The skin 1 is composed of an inner skin 11 and an outer skin 12. The crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the oblique connecting beam 5, and the third sandwich material 6 are all disposed between the inner skin 11 and the outer skin 12. An epoxy structural adhesive film layer 7 is covered between the crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the oblique connecting beam 5, the third sandwich material 6 and the inner skin 11 and the outer skin 12. Under high temperature, the epoxy structural adhesive film layer 7 is cured, which can fix the crossbeam assembly 2, the vertical beam assembly 3, the side vertical beam 4, the oblique connecting beam 5, and the third sandwich material 6 inside the skin 1.

[0094] The side wall adopts an integral structure of skin 1 plus third sandwich material 6 plus crossbeam assembly 2, vertical beam assembly 3, side vertical beam 4, and diagonal connecting beam 5. The crossbeam assembly 2, vertical beam assembly 3, side vertical beam 4, diagonal connecting beam 5 and third sandwich material 6 are all solidified inside skin 1. The external structure of the side wall is simple and has no external columns, which can make full use of the truck clearance and facilitate the cleaning of goods left in the truck.

[0095] Meanwhile, the use of a curing molding method can reduce the number of welding points or rivets, thereby improving structural strength and reducing the labor intensity of production.

[0096] The third sandwich material 6 can be PMI foam;

[0097] The third sandwich material 6 can be an aramid honeycomb.

[0098] Example 2:

[0099] Based on Embodiment 1, the inner skin 11 and the outer skin 12 have the same size, and the inner skin 11 includes one layer of epoxy prepreg wear-resistant layer reinforced with glass fiber plain weave fabric, one layer of epoxy prepreg layer reinforced with carbon fiber plain weave fabric, eighteen layers of unidirectional epoxy prepreg tape layer reinforced with carbon fiber, and one layer of epoxy prepreg layer reinforced with carbon fiber plain weave fabric.

[0100] The outer skin 12 includes one layer of epoxy prepreg reinforced with carbon fiber plain weave fabric, twelve to eighteen layers of unidirectional epoxy prepreg reinforced with carbon fiber, and one layer of epoxy prepreg reinforced with carbon fiber plain weave fabric.

[0101] The unidirectional tape layer is laid at a longitudinal angle of [45°, The prepreg is laid symmetrically in the directions of 45° and 0°, and the curing temperature of the prepreg is 80°C. 120℃;

[0102] The outer surface strength of the sidewall is enhanced by combining epoxy prepreg wear-resistant layer, epoxy prepreg layer, epoxy prepreg unidirectional tape layer and epoxy prepreg layer, as well as fabric layer and fabric layer.

[0103] Example 3:

[0104] See Figure 3 As shown, Figure 3 This is a schematic cross-sectional view of the crossbeam assembly and the side vertical beam structure of the present invention;

[0105] like Figure 3As shown, a composite material sidewall for railway freight cars includes a first support assembly disposed between the inner skin 11 and the outer skin 12. The first support assembly includes multiple sets of horizontal beam assemblies 2 and multiple sets of side vertical beams 4. The multiple sets of horizontal beam assemblies 2 and the multiple sets of side vertical beams 4 are all composed of I-beams 21 and a first sandwich material 22. The multiple sets of horizontal beam assemblies 2 are evenly spaced laterally distributed, and the multiple sets of side vertical beams 4 are disposed at both ends inside the skin 1 and are arranged vertically.

[0106] The crossbeam assembly 2 is provided in three sets, and the three sets of crossbeam assemblies 2 are respectively located at the upper, middle and lower positions inside the skin 1;

[0107] The side vertical beams 4 are provided in four sections, and the four side vertical beams 4 are respectively provided on both sides of the two ends of the third sandwich material 6.

[0108] The first sandwich material 22 is filled inside the I-beam 21, and the outer surface of the first sandwich material 22 is coated with a first epoxy resin film 23. The first sandwich material 22 is connected to the inner side of the I-beam 21 through the first epoxy resin film 23.

[0109] The horizontal beam assembly 2 and the side vertical beam 4 form a composite material through the cooperation of the I-beam 21 and the first sandwich material 22, which reduces the overall weight of the side wall. At the same time, the arrangement and cooperation of multiple sets of horizontal beam assemblies 2 and side vertical beams 4 improves the strength and rigidity of the side wall.

[0110] The I-beam 21 is produced by pultrusion of carbon fiber and epoxy resin.

[0111] Example 4:

[0112] See Figure 4 As shown, Figure 4 This is a vertical cross-sectional view of the vertical beam assembly of the present invention;

[0113] See Figure 5 As shown, Figure 5 This is a schematic cross-sectional view of the vertical beam assembly of the present invention;

[0114] like Figure 4 Figure 5 As shown, a composite material sidewall for railway freight cars includes a second support assembly disposed between the inner skin 11 and the outer skin 12. The second support assembly includes a vertical beam assembly 3 and an oblique connecting beam 5. Multiple sets of vertical beam assemblies 3 are provided, and the multiple sets of vertical beam assemblies 3 are vertically spaced. Each vertical beam assembly 3 is composed of a surface composite material layer 36 and a second sandwich material 34. The oblique connecting beam 5 is located on both sides of the inner bottom end of the skin 1.

[0115] The front or rear end of the surface composite material layer 36 is set as a drilling area 33. The front end of the drilling area 33 is provided with an insert joint area 32. The insert joint area 32 is adapted to the crossbeam assembly 2. The interior of the surface composite material layer 36 is filled with thermosetting phenolic resin at the position corresponding to the drilling area 33.

[0116] The drilling area 33 has multiple sets of spaced nail holes 31 at the position corresponding to the crossbeam assembly 2, and the vertical beam assembly 3 is connected to the crossbeam assembly 2 through the multiple sets of nail holes 31.

[0117] The interior of the surface composite material layer 36 is filled with a second sandwich material 34, and a second epoxy resin film 35 is coated between the outer surface of the second sandwich material 34 and the thermosetting phenolic resin and the inner wall of the surface composite material layer 36.

[0118] The strength of the vertical beam assembly 3 is achieved by the surface composite material layer 36 and the second sandwich material 34 and thermosetting phenolic resin filled inside the surface composite material layer 36. At the same time, an insertable joint area 32 is provided at the end of the vertical beam assembly 3 to connect the vertical beam assembly 3 and the crossbeam assembly 2. Meanwhile, nail holes 31 are opened on the insertable joint area 32 to fix the crossbeam assembly 2 and the vertical beam assembly 3.

[0119] Example 5:

[0120] See Figure 6 As shown, Figure 6 This is a schematic cross-sectional view of the oblique connecting beam of the present invention;

[0121] like Figure 6 As shown, the inclined connecting beam is a thermosetting phenolic resin molded plate, the cross-section of the inclined connecting beam 5 is trapezoidal, and multiple sets of spaced nail holes 31 are opened on the inclined connecting beam 5.

[0122] The oblique connecting beam 5 is fixed to the inside of the skin 1 through the nail holes 31 opened on the oblique connecting beam 5;

[0123] The edge of the oblique connecting beam 5 is aligned with the edge of the third sandwich material 6 inside the skin 1.

[0124] Example 6:

[0125] See Figure 2 As shown, Figure 2 This is a schematic cross-sectional view of the side wall structure in an embodiment of the present invention;

[0126] See Figure 3 As shown, Figure 3 This is a schematic cross-sectional view of the crossbeam assembly and the side vertical beam structure of the present invention;

[0127] See Figure 4 As shown, Figure 4 This is a vertical cross-sectional view of the vertical beam assembly of the present invention;

[0128] See Figure 5 As shown, Figure 5 This is a schematic cross-sectional view of the vertical beam assembly of the present invention;

[0129] like Figure 2 Figure 5 As shown, the crossbeam assembly 2, vertical beam assembly 3, side vertical beam 4, and diagonal connecting beam 5 are aligned in the thickness direction and fixed inside the skin 1 by tooling clamps, thereby ensuring the fit of the third sandwich material 6. A layer of expanding foam can be applied between the third sandwich material 6 and the crossbeam assembly 2, vertical beam assembly 3, side vertical beam 4, and diagonal connecting beam 5.

[0130] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention (including the claims) is limited to these examples; within the framework of the invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of the different aspects of the invention as described above, which are not provided in the details for the sake of brevity.

[0131] This invention is intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A railway freight car composite side wall, characterized by, include: The skin is composed of an inner skin and an outer skin, the inner skin comprises an epoxy prepreg wear-resistant layer, an epoxy prepreg layer, an epoxy prepreg unidirectional tape layer and an epoxy prepreg layer, and the outer skin comprises a fabric layer, a unidirectional tape layer and a fabric layer; wherein the inner skin comprises one layer of glass fiber plain cloth reinforced epoxy prepreg wear-resistant layer, one layer of carbon fiber plain cloth reinforced epoxy prepreg layer, eighteen layers of carbon fiber reinforced epoxy prepreg unidirectional tape layer, and one layer of carbon fiber plain cloth reinforced epoxy prepreg layer; the outer skin comprises one layer of carbon fiber plain cloth reinforced epoxy prepreg layer, twelve to eighteen layers of carbon fiber reinforced epoxy prepreg unidirectional tape layer, and one layer of carbon fiber plain cloth reinforced epoxy prepreg layer; the unidirectional tape layer is symmetrically laid in the direction of [45°, 45°, 0°] in the longitudinal direction. A first support assembly is disposed between the inner skin and the outer skin. The first support assembly includes multiple sets of crossbeam assemblies and multiple sets of side vertical beams. Each set of crossbeam assemblies and side vertical beams is composed of an I-beam and a first sandwich material. The crossbeam assemblies are evenly spaced laterally distributed, and the side vertical beams are disposed at both ends of the inner skin and are vertically arranged. There are three sets of crossbeam assemblies, which are respectively disposed at the upper, middle, and lower positions inside the skin. The first sandwich material fills the interior of the I-beam, and the outer surface of the first sandwich material is coated with a first epoxy resin film. The first sandwich material is connected to the inner side of the I-beam through the first epoxy resin film. A second support assembly is disposed between the inner skin and the outer skin. The second support assembly includes vertical beam assemblies and diagonal connecting beams. Multiple sets of vertical beam assemblies are arranged vertically at intervals, and each vertical beam assembly consists of a surface composite material layer and a second sandwich material. The diagonal connecting beams are located on both sides of the inner bottom end of the skin. The front or rear end of the surface composite material layer is configured as a drilling area, and the front end of the drilling area has an insert-type connector area adapted to the crossbeam assembly. The interior of the surface composite material layer, corresponding to the position of the drilling area, is filled with thermosetting phenolic resin. Multiple sets of spaced-apart nail holes are opened in the drilling area corresponding to the position of the crossbeam assembly, and the vertical beam assembly is connected to the crossbeam assembly through these nail holes. The diagonal connecting beam has a trapezoidal cross-section and multiple sets of spaced-apart nail holes are opened on it. A filling component, which fills the interior of the skin, the filling component comprising a third sandwich material; An epoxy structural adhesive film layer is provided, wherein the crossbeam assembly, the vertical beam assembly, the side vertical beam, the diagonal connecting beam, and the third sandwich material are all disposed between the inner skin and the outer skin, and the crossbeam assembly, the vertical beam assembly, the side vertical beam, the diagonal connecting beam, the third sandwich material and the inner skin and the outer skin are all covered with an epoxy structural adhesive film layer; The bottom sides of the skin are provided with reinforcement areas corresponding to the positions of the oblique connecting beams.

2. The railway freight car composite side wall of claim 1, wherein, The inner skin and the outer skin are the same size.

3. The railway freight car composite side wall of claim 1, wherein, The curing temperature of the prepreg is 80 120°C.

4. The railway car composite side wall of claim 3, wherein, The side vertical beams are provided in four sections, which are respectively located on both sides of the third sandwich material.

5. The railway freight car composite side wall of claim 4, wherein, The interior of the surface composite material layer is filled with a second sandwich material, and a second epoxy resin film is coated between the outer surface of the second sandwich material and the thermosetting phenolic resin and the inner wall of the surface composite material layer.

6. A method for manufacturing a composite material sidewall for railway freight cars, for producing a composite material sidewall for railway freight cars as described in any one of claims 1-5, comprising the following steps: S1. Mold making: Make side wall molds according to design specifications; S2. Material laying: Lay the inner skin according to the design requirements. After the inner skin is laid, lay a layer of epoxy film. Place the crossbeam assembly, vertical beam assembly, side vertical beam, diagonal connecting beam, and third sandwich material in the designed positions on the inner skin, and use tooling clamps to position them to ensure that each component fits together. A layer of expanding foam is filled between the third sandwich material and the crossbeam assembly, vertical beam assembly, side vertical beam, and diagonal connecting beam; After the horizontal beam assembly, vertical beam assembly, side vertical beam, diagonal connecting beam and third sandwich material are laid, a layer of epoxy film is laid. Lay the outer skin according to the design requirements; S3, integral curing: the laid side wall plate is vacuum packaged, the vacuum degree is ≤ 90 kPa during packaging, and then is placed into a curing device to be cured and formed according to a curing system requirement; S4. Demolding and Trimming: After curing, the product is demolded, the edges are trimmed and sanded, and the surface is coated as needed to complete the sidewall preparation.

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