Preparation method of composite material hoisting type movable top cover

Abstract

The invention relates to a preparation method of a composite material hoisting type movable top cover, which comprises the following steps of: manufacturing a top cover main body mold by taking an outer molded surface of the movable top cover as a mold surface which comprises walkway bulges and ventilation opening sinking characteristics; processing a reinforcing rib sandwich, a metal filling block and a limiting edge precast slab; a top cover main body is integrally formed by adopting a vacuum infusion, OOA or autoclave process; step areas are machined at the limiting edges, the limiting edge prefabricated plates are placed at the steps, and the fiber fabric is manually pasted to the limiting edges after being soaked with structural adhesive; forming a plate in a ventilation opening symmetrical area on the mold, and processing and cutting into a ventilation opening cover; a ventilation opening sinking area on the top cover main body is cut to form a ventilation opening; the ventilation opening cover is installed at the ventilation opening in a mechanical connection mode. The top cover main body structure can be formed through one mold, the reinforcing ribs, the ventilation opening cover, the limiting edges and the pedestrian path do not need to be formed through additional manufacturing molds, the lightweight requirement is met, meanwhile, the manufacturing cost is reduced, and the machining period is shortened.

Description

Technical Field

[0001] The present invention belongs to the technical fields of high-performance composite materials and the application of rail freight vehicles, and particularly relates to a preparation method for a composite material hoisting type movable roof cover. Background Art

[0002] The movable roof cover of rail transit freight vehicles is mainly used to facilitate the loading and unloading of goods and the maintenance and repair of equipment. Common movable roof cover structures include sliding type, folding type, rotating type and hoisting type. The existing hoisting type movable roof cover of freight vehicles is generally made of steel structure, which is relatively heavy and requires relatively large hoisting equipment, bringing difficulties to the hoisting of the roof cover and greatly reducing the efficiency of goods loading and unloading.

[0003] Composite materials have the characteristics of light weight and high strength. Using them to design and manufacture the hoisting type movable roof cover can greatly reduce the weight of the roof cover. The composite material hoisting type movable roof cover needs to retain the functional auxiliary components of the steel hoisting type movable roof cover, such as pedestrian walkways, limit edges, ventilation openings, ventilation covers, etc., and reserve hoisting interfaces for the subsequent installation of parts such as lifting lugs. The hoisting interfaces need to meet the anti-seepage requirements. According to the existing design and manufacturing methods, these functional auxiliary components generally need to design and manufacture independent molds, and after being independently processed, they are assembled with other auxiliary components for the second time to form a shape, resulting in an increase in the production cycle and cost. At the same time, the secondary assembly cycle and quality risk are also greatly increased. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a preparation method for a composite material hoisting type movable roof cover in view of the deficiencies of the above-mentioned existing technologies, so that these auxiliary components do not need to be formed by independent molds and then assembled for the second time, but can be directly formed on the overall mold, reducing the production cycle and cost; the designed lifting lug connection embedded structure can make the installation and later replacement of the lifting lug simple and convenient, and prevent water seepage at the connection of the lifting lug bolts to the greatest extent.

[0005] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows:

[0006] A preparation method for a composite material hoisting type movable roof cover, the movable roof cover includes a roof cover main body and a ventilation cover, the roof cover main body is a panel rib structure, including a panel and reinforcing ribs, the panel is a laminated board or a sandwich panel, and the reinforcing ribs are sandwich structures;

[0007] The preparation method includes the following steps:

[0008] S1. Make a roof cover main body mold with the outer surface of the movable roof cover as the mold surface, and the mold surface includes a walkway protrusion and a ventilation opening depression feature;

[0009] S2. Machine-process the stiffener sandwich according to the shape of the internal filling. An embedded metal area shall be set at the position corresponding to the lifting lug of the stiffener sandwich, and the thickness shall be thinned to facilitate the subsequent separate wrapping of the fabric or prepreg during forming; if the panel is a sandwich panel, machine-process the panel sandwich layer according to the shape of the internal filling.

[0010] S3. Machine-process a metal filling block adapted to the shape of the embedded metal area.

[0011] S4. Pre-form a flat plate for making the limiting edge. The thickness of the flat plate is 1 / 3 - 2 / 3 of the designed thickness of the limiting edge. After the flat plate is formed, cut it into a follow-up shape according to the top cover curved surface to obtain several prefabricated limiting edge plates.

[0012] S5. Use the vacuum infusion, OOA or autoclave process to form the top cover main body: first lay the panel, then position and lay the stiffeners, and finally integrally form using the vacuum infusion, OOA or autoclave process.

[0013] S6. After the top cover main body is formed, machine-process a step area at the limiting edge, and place the prefabricated limiting edge plate at the step; fully soak the fiber fabric with the structural adhesive and hand-lay it to the limiting edge. The fiber fabric shall be continuous, and the hand-laying areas on the left and right sides of the limiting edge shall not be less than 50 mm.

[0014] S7. Use the vacuum infusion, OOA or autoclave process to form a plate in the symmetric area of the ventilation opening on the top cover main body mold. The size of the plate extends more than 20 mm beyond the designed size of the ventilation opening cover. After the plate is formed, process and cut it according to the designed size of the ventilation opening cover.

[0015] S8. Machine-process and cut the sunken area of the ventilation opening on the top cover main body according to the designed size of the ventilation opening.

[0016] S9. Install the ventilation opening cover at the ventilation opening by mechanical connection and make good sealing treatment.

[0017] In the above solution, in S1, the top cover main body mold is one of a fiberglass mold, an aluminum alloy mold, a steel mold, and a wood substitute mold, and the top cover main body mold is a female mold.

[0018] In the above solution, in S2, except for the shape of the reserved metal filling block, the thickness of the stiffener sandwich reserves the thickness of 3 - 5 layers of fabric or prepreg to facilitate the subsequent separate wrapping of the fabric or prepreg during forming.

[0019] In the above solution, in S2, the materials of the stiffener sandwich and the panel sandwich layer are one or several mixtures of PVC foam, PMI foam, PET foam, balsa wood, and balsa.

[0020] In the above solution, in S4, the flat panel adopts one of the vacuum infusion, OOA or autoclave processes. The production of the flat panel does not require additional preparation of a mold and is directly produced on a vacuum platform or an operating platform.

[0021] In the above solution, in S5, if the vacuum infusion process is adopted, the specific method for forming the top cover body is as follows: Apply a release agent on the top cover body mold, lay one or several of glass fiber fabric, carbon fiber fabric, aramid fiber fabric, quartz fiber fabric, and basalt fiber fabric according to the designed laying angle and number of layers. When the panel is a sandwich panel, lay the panel sandwich layer in sequence; after the reinforcement of the panel is laid, place the stiffener sandwich at the designed position. When placing the stiffener sandwich, fix the bottom with spray adhesive. The periphery of the stiffener sandwich corresponding to the metal filling block is completely covered with fabric for at least 3 layers, and each layer is fixed with spray adhesive to form a flat surface with other areas; after the position of the stiffener sandwich is fixed, lay the surface fabric of the stiffener sandwich, and the fabric is cut at the intersection area for lapping; finally, lay the release cloth, flow guide net, and vacuum bag film, place a spiral tube at the edge, seal the edge of the vacuum bag film with a sealant strip, connect the vacuum pipeline and valve, evacuate and exhaust to infuse resin, introduce the resin through the resin inlet pipe, the resin fully infiltrates the fabric, and after the resin is completely cured under certain temperature conditions, demold.

[0022] In the above solution, in S5, if the OOA or autoclave process is adopted, the specific method for forming the top cover body is as follows: Apply a release agent on the top cover body mold, lay one or several of glass fiber prepreg, carbon fiber prepreg, aramid fiber prepreg, quartz fiber prepreg, and basalt fiber prepreg according to the designed laying angle and number of layers. When the panel is a sandwich panel, lay the panel sandwich layer in sequence; after the reinforcement of the panel is laid, place the stiffener sandwich at the designed position. When placing the stiffener sandwich, fix the bottom by adding an additional layer of adhesive film. The periphery of the stiffener sandwich corresponding to the metal filling block is completely covered with prepreg for at least 3 layers, and an additional layer of adhesive film is added to the contact surface between the prepreg and the stiffener sandwich to form a flat surface with other areas; after the position of the stiffener sandwich is fixed, lay the surface prepreg of the stiffener sandwich, and the prepreg is cut at the intersection area for lapping; finally, lay the release cloth, breather felt, and vacuum bag film, seal the edge of the vacuum bag film with a sealant strip, connect the vacuum pipeline and valve, pre-evacuate and exhaust, send the whole mold into a curing furnace or autoclave, and the prepreg is completely cured under certain temperature and pressure conditions. After the temperature drops below 60°C, demold.

[0023] In the above solution, during the laying process of the reinforcement of the panel, when laying in the aisle area, first lay several layers of continuous fabric close to the mold surface, then cut the fabric into narrow strips, fully infiltrate them with resin, and fill them into the grooves formed in the aisle area. After laying until the aisle area is flush with other areas, continue to lay the continuous fabric.

[0024] In the above solution, during the process of laying the reinforcing material on the panel, when laying in the sunken area of the ventilation opening, the fiber fabric is laid on the sunken area in conformity with the die surface. To ensure the forming quality, the fiber fabric is cut and fixed by spraying glue. When the panel is a sandwich panel, the panel core layer is not laid in the sunken area.

[0025] In the above solution, the specific method of S9 is as follows: an airtight support plate nut is installed inside the sinking edge, and the airtight support plate nut is fastened to the inner side of the sunken area by a rivet. After the installation of the airtight support plate nut is completed, sealant is coated around the nut; the ventilation opening cover is drilled in cooperation with the threaded hole of the airtight support plate nut and connected by screws. After the connection is completed, sealant is coated around the screws for further waterproofing; the installed ventilation opening cover is flush and smoothly transitioned with the curved surface of the top cover main body in the closed state.

[0026] The beneficial effects of the present invention are as follows:

[0027] 1. The present invention designs a manufacturing method of a hoisting type movable top cover by using fiber reinforced composite materials, which can make full use of the characteristics of low cost and high performance of fiber reinforced composite materials. The designed main structure of the top cover can be formed by one die, and the reinforcing ribs, ventilation opening covers, limiting edges and pedestrian walkways do not need to be formed by additional dies. While meeting the lightweight requirements, the manufacturing cost is greatly reduced and the processing cycle is shortened.

[0028] 2. The limiting edge designed by the present invention is manufactured in two steps. The first step is to preform a flat plate and cut it into a shape conforming to the top cover curved surface. The second step is to machine the limiting edge area into a stepped area, place the prefabricated limiting edge plate at the step, fully infiltrate the fiber fabric with low-viscosity structural adhesive and then lay it on both sides of the limiting edge to ensure the continuity of the fabric. In this way, the limiting edge does not need to be formed by a die. In the two-step forming, the first step can ensure the conforming shape, and the second step can ensure the strength after forming.

[0029] 3. The present invention forms a plate by vacuum infusion process in the symmetric area of the ventilation opening on the main die and forms the ventilation opening cover by cutting. Since the curved surface line type in the symmetric area of the ventilation opening on the top cover main body is completely the same as that before the ventilation opening sinks, using this method to prepare the ventilation opening cover can reduce the die making.

[0030] 4. The embedded metal filling block at the connection of the lifting lugs designed by the present invention can make the installation and later replacement of the lifting lugs simple and convenient, and at the same time, prevent water seepage at the connection of the lifting lug bolts to the greatest extent. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The present invention will be further described below in conjunction with the drawings and embodiments. In the drawings:

[0032] Figure 1It is a schematic diagram of the outer structure of the top cover body of the hoisting type movable top cover made of composite materials of the present invention;

[0033] Figure 2 It is a schematic diagram of the inner structure of the top cover body of the hoisting type movable top cover made of composite materials of the present invention;

[0034] Figure 3 It is a side sectional view of the top cover body of the hoisting type movable top cover made of composite materials of the present invention;

[0035] Figure 4 It is a schematic diagram of the structure of the machined reinforcing rib sandwich core;

[0036] Figure 5 It is a schematic diagram of the structure of the machined metal filling block;

[0037] Figure 6 It is a connection diagram of the metal filling block and the lifting lug;

[0038] Figure 7 It is a schematic diagram of the structure of the limit edge prefabricated plate formed by cutting the flat plate according to the top cover curved surface;

[0039] Figure 8 It is a sectional view of the structure of the limit edge.

[0040] In the figure: 10, top cover body; 11, panel; 12, reinforcing rib; 121, reinforcing rib sandwich core; 122, metal filling block; 13, walkway; 14, ventilation opening; 15, limit edge; 151, limit edge prefabricated plate; 152, hand lay-up area; 20, lifting lug. Detailed implementation manners

[0041] For a clearer understanding of the technical features, objectives and effects of the present invention, the specific implementation manners of the present invention will now be described in detail with reference to the accompanying drawings.

[0042] As Figures 1-3 shown, the hoisting type movable top cover made of composite materials includes a top cover body 10 and a ventilation opening cover (not shown in the figure). The top cover body 10 is a sheet metal structure, including a panel 11 and a reinforcing rib 12. The panel 11 is a laminated board or a sandwich board. The laminated board is composed of 1 to 20 mm of composite materials, and the composite materials are one or several mixtures of fiberglass composite materials, carbon fiber composite materials, aramid fiber composite materials, quartz fiber composite materials, and basalt fiber composite materials. The sandwich board consists of upper and lower skin layers and a core layer. The thickness of the upper and lower skin layers is 0.5 to 10 mm, and the thickness of the core layer is 2 mm to 100 mm; the upper and lower skin layers are one or several mixtures of fiberglass composite materials, carbon fiber composite materials, aramid fiber composite materials, quartz fiber composite materials, and basalt fiber composite materials; the core layer is one or several mixtures of PVC foam, PMI foam, PET foam, balsa wood, and balsa wood.

[0043] The reinforcing rib 12 is arranged inside the laminated plate or between the upper and lower skin layers of the sandwich panel. The lengthwise reinforcing ribs 12 are arranged at intervals of 100 - 1500 mm in the width direction, and the widthwise reinforcing ribs 12 are arranged at intervals of 100 - 2000 mm in the length direction. The cross-sectional type of the reinforcing rib 12 is one of square or hat-shaped. The reason for using square or hat-shaped profiles is that metal blocks can be embedded in these two profiles, which is convenient for the connection, assembly and anti-seepage of the lifting lugs. The outer skin of the reinforcing rib 12 is one or a mixture of glass fiber composite material, carbon fiber composite material, aramid fiber composite material, quartz fiber composite material, basalt fiber composite material. The inside of the reinforcing rib 12 is filled with sandwich materials, which is one or a mixture of PVC foam, PMI foam, PET foam, balsa wood, balsa wood.

[0044] A limit edge 15 is also arranged inside the top cover main body 10. The limit edge 15 is spaced 10 - 100 mm from the four sides of the top cover and 5 - 50 mm from the vehicle body. The limit edge 15 is convenient for the position calibration during the lifting and installation of the top cover and the installation of the vehicle body connecting parts.

[0045] A pedestrian walkway 13 is arranged along the length direction on the outside of the top cover main body 10. The pedestrian walkway 13 protrudes slightly 0 - 20 mm from the highest point on the surface of the top cover main body 10, forming a straight passage with a width of 300 mm - 800 mm and the same length as the top cover main body 10, which is convenient for personnel to pass through when inspecting and repairing on the top cover. The edge of the pedestrian walkway 13 and the top cover main body 10 are smoothly transitioned. The pedestrian walkway 13 is anti-slip treated, and anti-slip paint can be sprayed, or semi-circular grooves with a radius of 0.5 mm - 2 mm can be processed, and the grooves are spaced 20 - 100 mm along the length direction.

[0046] Due to the need for lifting, installation interfaces for the lifting lugs 20 need to be reserved on the outside of the top cover main body 10. The number of lifting lugs 20 is not less than 4 and is symmetrically distributed, which is convenient for the stability and stress dispersion during the lifting process. The lifting lugs 20 are generally connected to the outside of the top cover main body 10 by bolts. When connecting with bolts, through holes need to be opened in the composite material, and there is a risk of water tightness at the opening. In the present invention, metal filling blocks 122 are embedded inside the square or hat-shaped reinforcing ribs 12. After embedding the metal filling blocks 122, there is no need to open through holes, and there are multiple layers of composite materials and sandwich materials stacked at the position of the reinforcing rib 12, which can minimize the risk of water seepage during long-term use. At the same time, the local strength at the position of the reinforcing rib 12 is relatively large, which can improve the strength of the connection. Another beneficial effect of the embedded metal filling blocks 122 is that it is convenient for the assembly of the lifting lugs 20, and drilling can be carried out on-site.

[0047] At least one ventilation opening 14 is provided on the top cover main body 10. The ventilation opening 14 is circular or polygonal, and the area of the ventilation opening 14 is not less than 0.01 m 2, the area of the edge of the ventilation opening 14 with a depth of 20 mm to 50 mm is sunken, and the sunken depth is increased by 0.4 to 1 mm based on the thickness of the ventilation opening cover.

[0048] The ventilation opening cover is a part that is installed in matching with the ventilation opening 14. After installation, the watertightness of the top cover main body 10 needs to be ensured. The shape and size of the ventilation opening cover are determined by the shape of the ventilation opening 14. The ventilation opening cover area extends 20 mm to 50 mm along the top cover curved surface at the ventilation opening 14, corresponding to the width of the sunken area at the edge of the ventilation opening 14. After the ventilation opening cover is installed, it should be flush with the curved surface of the top cover main body 10 and have a smooth transition.

[0049] The present invention provides a preparation method for the above-mentioned composite material hoisting type movable top cover, including the following steps:

[0050] S1. Taking the outer surface of the movable top cover as the mold surface to make the top cover main body mold, and the mold surface includes a walkway protrusion and a ventilation opening sinking feature.

[0051] Preferably, the top cover main body mold is one of a fiberglass mold, an aluminum alloy mold or a steel mold, and the top cover main body mold is a female mold.

[0052] S2. Machining the reinforcing rib sandwich 121 according to the shape of the internal filling. It is necessary to set a pre-embedded metal area at the installation position of the corresponding lifting lug 20 on the reinforcing rib sandwich 121, and reduce the thickness to facilitate the subsequent forming of individually wrapping the fabric or prepreg. The reinforcing rib sandwich 121 is as Figure 4 shown. If the panel 11 of the top cover main body 10 uses a sandwich panel, the sandwich layer of the panel 11 is machined according to the shape of the internal filling.

[0053] Preferably, except for the shape of the reserved metal filling block 122, the thickness of the reinforcing rib sandwich 121 is reserved with a thickness of 3 to 5 layers of fabric or prepreg to facilitate the subsequent forming of individually wrapping the fabric or prepreg.

[0054] Preferably, the materials of the reinforcing rib sandwich 121 and the sandwich layer of the panel 11 are one or several mixtures of PVC foam, PMI foam, PET foam, balsa wood, and balsa wood.

[0055] S3. Machining a metal filling block 122 adapted to the shape of the pre-embedded metal area, as Figure 5 shown.

[0056] Preferably, the metal filling block 122 corresponding to the lifting lug 20 is made of 304 stainless steel, and the metal filling block 122 does not need to be drilled. During the subsequent assembly of the top cover, it can be drilled on-site, as Figure 6 shown.

[0057] S4. Pre - form a flat plate for making the limiting edge 15. The thickness of the flat plate is 1 / 3 - 2 / 3 of the designed thickness of the limiting edge 15. After the flat plate is formed, it is cut into a conforming shape according to the top cover curved surface to obtain a number of pre - formed plates 151 of the limiting edge, as Figure 7 shown.

[0058] Preferably, the flat plate is made by one of the vacuum infusion, OOA or autoclave processes. The flat plate can be made directly on a vacuum platform or an operating platform without preparing additional molds.

[0059] S5. The top cover body 10 is formed by vacuum infusion, OOA or autoclave process: First, lay the reinforcing material of the panel 11, then position and lay the reinforcing ribs 12, and finally form it integrally by vacuum infusion, OOA or autoclave process.

[0060] If the vacuum infusion process is adopted, the forming method of the top cover body 10 is as follows: Coat the release agent on the top cover body mold, lay one or several of glass fiber fabric, carbon fiber fabric, aramid fiber fabric, quartz fiber fabric, basalt fiber fabric according to the designed laying angle and number of layers. When the panel 11 is a sandwich panel, lay the core layer of the panel 11 in sequence. After the reinforcing material of the panel 11 is laid, place the reinforcing rib core 121 at the designed position. When placing the reinforcing rib core 121, fix the bottom with spray adhesive. The periphery of the reinforcing rib core 121 corresponding to the metal filling block 122 is fully covered with fabric for at least 3 layers, and each layer is fixed with spray adhesive to form a flat surface with other areas. After the position of the reinforcing rib core 121 is fixed, lay the surface fabric of the reinforcing rib core 121, and cut slits at the intersection area of the fabric for overlapping. Finally, lay the release cloth, flow - guiding net, and vacuum bag film, place a spiral tube at the edge, seal the edge of the vacuum bag film with a sealant strip, connect the vacuum pipeline and valve, evacuate the air and infuse resin, introduce the resin through the feed pipe, the resin fully infiltrates the fabric, and demold after the resin is completely cured under certain temperature conditions.

[0061] If the OOA or autoclave process is adopted, the forming method of the top cover body 10 is specifically as follows: Apply a release agent on the top cover body mold, and lay one or more of glass fiber prepreg, carbon fiber prepreg, aramid fiber prepreg, quartz fiber prepreg, and basalt fiber prepreg according to the designed laying angle and number of layers. When the panel 11 is a sandwich panel, lay the sandwich layer of the panel 11 in sequence. After the reinforcement of the panel 11 is laid, place the stiffener sandwich 121 at the designed position. When placing the stiffener sandwich 121, fix the bottom with an additional layer of adhesive film. The periphery of the stiffener sandwich 121 corresponding to the metal filling block 122 is fully coated with prepreg for at least 3 layers, and an additional layer of adhesive film is added to the contact surface between the prepreg and the stiffener sandwich 121 to form a flat surface with other areas. After the position of the stiffener sandwich 121 is fixed, lay the prepreg on the surface layer of the stiffener sandwich 121, and cut slits in the overlapping area of the prepreg for overlapping. Finally, lay the release cloth, breather felt, and vacuum bag film, seal the edge of the vacuum bag film with a sealant strip, connect the vacuum pipeline and valve, pre-vacuum and exhaust, send the whole mold into the curing furnace or autoclave, and the prepreg is completely cured under certain temperature and pressure conditions. After the temperature drops below 60°C, demold.

[0062] Preferably, during the laying process of the reinforcement of the panel 11, when laying in the aisle 13 area, first lay several layers of continuous fabric close to the mold surface, then cut the fabric into narrow strips, fully soak them with resin, and fill them into the grooves formed in the aisle 13 area. After laying until the aisle 13 area is flush with other areas, continue to lay the continuous fabric.

[0063] Preferably, during the laying process of the reinforcement of the panel 11, when laying in the sunken area of the ventilation opening 14, lay the fiber fabric in contact with the mold surface in the sunken area. To ensure the forming quality, cut slits in the fiber fabric and fix it with spray adhesive. When the panel 11 is a sandwich panel, do not lay the sandwich layer of the panel 11 in the sunken area.

[0064] S6. After the top cover body 10 is formed, machine-process a stepped area at the limit edge 15, and place the limit edge prefabricated plate 151 at the step. Hand-lay one or more of glass fiber fabric, carbon fiber fabric, aramid fiber fabric, quartz fiber fabric, and basalt fiber fabric onto the limit edge 15 after fully soaking them with structural adhesive. The fabric needs to be continuous, and the hand-laying areas 152 on both sides of the limit edge 15 should not be less than 50 mm, as Figure 8 shown.

[0065] S7. Use the vacuum infusion, OOA or autoclave process to form a plate in the symmetric area of the ventilation opening 14 on the top cover body mold. The size of the plate extends more than 20 mm beyond the designed size of the ventilation opening cover. After the plate is formed, process and cut it according to the designed size of the ventilation opening cover.

[0066] S8. The sunken area of the ventilation opening 14 on the top cover main body 10 is processed and cut according to the designed size of the ventilation opening 14.

[0067] S9. Install the ventilation opening cover at the ventilation opening 14 by mechanical connection and perform sealing treatment.

[0068] Preferably, the installation method of the ventilation opening cover is as follows: install an airtight support plate nut on the inner side of the sunken edge, and fasten the airtight support plate nut to the inner side of the sunken area with a rivet. After the installation of the airtight support plate nut is completed, apply sealant around the nut; drill holes in the ventilation opening cover to match the threaded holes of the airtight support plate nut and connect them with screws. After the connection is completed, apply sealant around the screws for further waterproofing; the installed ventilation opening cover is flush with the surrounding top cover main body 10 area in the closed state.

[0069] The following introduces a specific embodiment of the method of the present invention.

[0070] The composite material hoisting type movable top cover to be prepared by the method of the present invention has the following characteristics:

[0071] (1) Both ends of the composite material hoisting type movable top cover in the length direction are provided with 50-mm-long vertical flanges as eaves.

[0072] (2) The panel 11 of the top cover main body 10 is made of a laminated board with a thickness of 5 mm, and the laminated board material is a large tow carbon fiber composite material.

[0073] (3) The reinforcing ribs 12 are arranged on the inner side of the laminated board. Three reinforcing ribs 12 in the length direction are arranged along the width direction at an interval of 850 mm, and three reinforcing ribs 12 in the width direction are arranged along the length direction at an interval of 1550 mm.

[0074] (4) The cross-sectional type of the reinforcing rib 12 is a hat shape, the profile height is 50 mm, the width is 30 mm, the outer layer of the profile is a 2-mm large tow carbon fiber composite material, and the inside is filled with PVC foam.

[0075] (5) A circle of limiting edges 15 is further arranged on the inner side of the top cover main body 10. The thickness of the limiting edge 15 is 6 mm, the distance between the limiting edge 15 and the four sides of the top cover is 50 mm, and the distance from the vehicle body is 20 mm. The limiting edge 15 is convenient for position calibration during the hoisting and installation process of the top cover and convenient for the installation of vehicle body connectors.

[0076] (6) A pedestrian walkway 13 is arranged in the outer area of the top cover main body 10. The pedestrian walkway 13 is a plane, which slightly protrudes 1 mm from the highest point of the top cover main body 10 surface, with a width of 500 mm and a length the same as that of the top cover main body 10.

[0077] (7) There are 5 lifting lug 20 interfaces arranged above the outside of the top cover main body 10, with 4 symmetrically distributed. The metal filling block 122 is embedded in the foam sandwich of the reinforcing rib 12. There are 4 layers of composite materials designed on the outer layer of the foam at this place to prevent the foam from being compressed and deformed under the action of the metal filling block 122 during long-term use.

[0078] (8) There is 1 ventilation opening 14 on the top cover main body 10. The ventilation opening 14 is a circular shape with a diameter of 200 mm. The area of 30 mm at the edge of the ventilation opening 14 is designed to sink, and the sinking depth is increased by 0.5 mm on the basis of the thickness of the ventilation opening cover, that is, 4.5 mm.

[0079] (9) The ventilation opening cover is a part installed in matching with the ventilation opening 14. After installation, the watertightness of the top cover structure needs to be ensured. Its shape and size are determined by the shape of the ventilation opening 14. The ventilation opening cover area extends 30 mm along the curved surface of the top cover main body 10 at the ventilation opening 14, corresponding to the sunken area at the edge of the ventilation opening 14, that is, with a diameter of 260 mm. The thickness of the ventilation opening cover is 4 mm. After the installation of the ventilation opening cover is completed, it should be flush and smoothly transition with the curved surface of the top cover main body 10.

[0080] The preparation method of the above-mentioned composite material hoisting type movable top cover includes the following steps:

[0081] 1) Making the top cover main body mold with the outer shape surface of the top cover as the mold surface. The mold is a fiberglass mold. The mold is a female mold, and the mold surface includes features such as the protrusion of the walkway 13, the sinking of the ventilation opening 14, and the 50 mm vertical flanging at both ends, without the need to separately make a mold for forming.

[0082] 2) Machining the foam of the reinforcing rib sandwich 121 according to the shape of the internal filling. In the area where the foam of the reinforcing rib sandwich 121 is embedded with metal, except for reserving the shape of the metal block, the thickness is thinned by the thickness of 4 layers of fabric to facilitate the subsequent separate wrapping of the fabric during forming.

[0083] 3) The metal filling block 122 corresponding to the lifting lug 20 is made of 304 stainless steel and machined according to the designed structure. The metal filling block 122 does not need to be drilled. During the subsequent assembly of the top cover, the holes can be drilled on-site.

[0084] 4) The limiting edge 15 is formed in two steps. In the first step, a flat plate is pre-formed, and the thickness of the flat plate is 2 mm. The flat plate is made by the vacuum infusion process. There is no need to separately prepare a mold for making the flat plate, and it can be formed on the vacuum platform. After the flat plate is formed, it is cut into the shape following the curved surface of the top cover.

[0085] 5) The top cover body 10 is formed by the vacuum infusion process. First, the panel 11 is laid. The mold release agent is applied by laying on the top cover body mold. The large tow carbon fiber fabric is laid according to the designed laying angle and number of layers. When laying in the aisle 13 area, 5 layers of continuous fabric are first laid close to the mold surface. Then the fabric is cut into narrow strips, fully infiltrated with resin, and filled into the groove formed in the aisle 13 area. After laying until the aisle 13 area is flush with other areas, continuous fabric is continued to be laid. When the narrow strip fabric is pre-infiltrated with resin, it is to avoid that the resin cannot be fully infiltrated due to the excessive thickness of the groove area of the aisle 13 during the subsequent perfusion process. The narrow strip fabric is filled in the inner layer to ensure that there is continuous fabric on the outermost layer and the innermost layer, which can improve the forming quality and service life. When laying in the sunken area of the ventilation port 14, the fiber fabric is laid in the sunken area by fitting the mold surface. To ensure the forming quality, the fiber fabric is cut and fixed by spraying glue.

[0086] After the fabric laying of the panel 11 is completed, the reinforcing rib sandwich 121 foam is placed at the designed position. When placing the foam, it is fixed at the bottom with spraying glue; the foam around the corresponding position of the metal filling block 122 is fully covered with fabric for 4 layers, and each layer is fixed with spraying glue to form a flat surface with other areas. When placing the foam, it is fixed at the bottom with spraying glue. After the position is fixed, the fabric on the surface of the foam is laid. The fabric should be cut at the intersection area for overlapping. After the position of the reinforcing rib sandwich 121 is fixed, the fabric on the surface of the reinforcing rib sandwich 121 is laid. The fabric is cut at the intersection area for overlapping. After the fabric on the surface of the foam is laid, the release cloth, the flow guiding net, and the vacuum bag film are laid. The spiral tube is placed at the edge, and the edge of the vacuum bag film is sealed with a sealant strip. The vacuum pipeline and the valve are connected, and the resin is introduced by vacuum exhaust perfusion. The resin fully infiltrates the fabric. After the resin is completely cured under certain temperature conditions, demolding is carried out.

[0087] 6) After the top cover body 10 is demolded, the limiting edge 15 area is machined into a stepped area. The limiting edge prefabricated plate is placed at the step. The large tow carbon fiber fabric is fully infiltrated with low-viscosity structural adhesive and then laid on both sides of the limiting edge 15 with the fabric being continuous. The function of using the low-viscosity structural adhesive is that it can fully infiltrate the large tow carbon fiber fabric and has relatively high interlayer strength. The hand-laid areas on both sides of the limiting edge 15 extend 50 mm. The outermost surface is covered with a release cloth, and then a square wooden block is used as a tooling and bonded to the release cloth to fix the limiting edge 15, preventing the deflection of the fiber edge angle during the curing process and reducing deformation at the same time. The advantage of this forming method is that there is no need to prepare the mold for the limiting edge 15, and the strength of the limiting edge 15 can be ensured at the same time.

[0088] 7) A plate is formed by vacuum infusion process in the symmetric area of the vent 14 on the main mold. The size of the plate extends 20 mm from the design size of the vent cover. In this embodiment, the shape of the plate is square, which is convenient for cutting large tow carbon fiber fabric and improves the material utilization rate. The size is 300 mm * 300 mm. The curved line type in the symmetric area of the vent 14 on the top cover is exactly the same as that before the vent 14 sinks. Preparing the cover in this way can reduce the mold making. After the vent cover is formed, it is processed and cut according to the design size of the cover. After cutting, the diameter of the vent cover is 260 mm.

[0089] 8) The sunken area of the vent 14 on the top cover body 10 is processed and cut according to the design size of the vent 14. After cutting, the diameter of the vent 14 is 200 mm, and the edge width of 30 mm is the sunken area.

[0090] 9) The width of the sunken edge of the vent 14 is 30 mm. At a circumference 15 mm from the edge of the lower panel 11 under the sunken edge, M6 airtight support nuts are installed. The spacing of the airtight support nuts is 50 mm, and the number is 14. Each airtight support nut is fastened to the lower panel 11 under the sunken edge with a rivet. After the installation of the airtight support nuts, a circle of sealant is coated around the nuts to ensure watertightness. The cover is drilled to match the threaded holes of the airtight support nuts and connected with screws. After the connection, a circle of sealant is coated around the screws for further waterproofing and easy disassembly.

[0091] In this specification, each embodiment is described in a progressive manner. The key point of each embodiment is to illustrate the differences from other embodiments. For the same or similar parts among the embodiments, reference can be made to each other.

[0092] The embodiments of the present invention have been described above in conjunction with the accompanying drawings. However, the present invention is not limited to the above specific embodiments. The above specific embodiments are only illustrative and not restrictive. Under the inspiration of the present invention, those of ordinary skill in the art can also make many forms without departing from the purpose of the present invention and the scope protected by the claims. All of these fall within the protection scope of the present invention.

Claims

1. A preparation method of a hoisting type movable top cover made of composite materials, characterized in that The movable top cover includes a top cover main body and a ventilation opening cover. The top cover main body is a sheet metal structure, including a panel and reinforcing ribs. The panel is a laminated board or a sandwich panel, and the reinforcing ribs are sandwich structures; The preparation method includes the following steps: S1. Make a top cover main body mold with the outer surface of the movable top cover as the mold surface. The mold surface includes a walkway protrusion and a ventilation opening depression feature; S2. Machine-process the reinforcing rib sandwich according to the shape of the internal filling. It is necessary to set a pre-embedded metal area at the corresponding lifting lug installation position of the reinforcing rib sandwich, and reduce the thickness to facilitate the subsequent forming of separately covering the fabric or prepreg. If the panel is a sandwich panel, machine-process the panel sandwich layer according to the shape of the internal filling; S3. Machine-process a metal filling block adapted to the shape of the pre-embedded metal area; S4. Pre-form a flat plate for making the limiting edge. The thickness of the flat plate is 1 / 3 to 2 / 3 of the designed thickness of the limiting edge. After the flat plate is formed, cut it into a follow-up shape according to the top cover curved surface to obtain several limiting edge prefabricated plates; S5. Use the vacuum infusion, OOA or autoclave process to form the top cover main body: first lay the panel, then position and lay the reinforcing ribs, and finally integrally form using the vacuum infusion, OOA or autoclave process; S6. After the top cover main body is formed, machine-process a stepped area at the limiting edge, and place the limiting edge prefabricated plate at the step; fully infiltrate the fiber fabric with structural adhesive and hand-lay it to the limiting edge. The fiber fabric needs to be continuous, and the hand-laying areas on the left and right sides of the limiting edge are not less than 50 mm; S7. Use the vacuum infusion, OOA or autoclave process to form a plate in the symmetric area of the ventilation opening on the top cover main body mold. The size of the plate extends more than 20 mm beyond the designed size of the ventilation opening cover. After the plate is formed, process and cut it according to the designed size of the ventilation opening cover; S8. Machine-process and cut the ventilation opening depression area on the top cover main body according to the designed size of the ventilation opening; S9. Install the ventilation opening cover at the ventilation opening by mechanical connection and make good sealing treatment.

2. The preparation method of the composite material hoisting movable top cover according to claim 1, characterized in that, In S1, the top cover main body mold is one of a fiberglass mold, an aluminum alloy mold, a steel mold, and a wood substitute mold, and the top cover main body mold is a female mold.

3. The preparation method of the composite material hoisting type movable top cover according to claim 1, characterized in that, In S2, except for reserving the shape of the metal filling block, the thickness of the reinforcing rib sandwich reserves the thickness of 3 to 5 layers of fabric or prepreg to facilitate the subsequent forming of separately covering the fabric or prepreg.

4. The preparation method of the composite material hoisting type movable roof according to claim 1, characterized in that In S2, the materials of the reinforcing rib sandwich and the panel sandwich layer are one or several mixtures of PVC foam, PMI foam, PET foam, balsa wood, and balsa.

5. The preparation method of the composite material hoisting type movable top cover according to claim 1, characterized in that, In S4, the flat plate is made by using one of the vacuum infusion, OOA or autoclave processes. The flat plate production does not require additional mold preparation and is directly made on a vacuum platform or an operating platform.

6. The preparation method of the composite material hoisting type movable roof according to claim 1, characterized in that, In S5, if the vacuum infusion process is adopted, the forming method of the top cover body is specifically as follows: Apply and coat a release agent on the top cover body mold, and lay one or more of glass fiber fabric, carbon fiber fabric, aramid fiber fabric, quartz fiber fabric, and basalt fiber fabric according to the designed laying angle and number of layers. When the panel is a sandwich panel, lay the panel core layer in sequence; after the reinforcement of the panel is laid, place the stiffener core at the designed position. When placing the stiffener core, fix the bottom with spray adhesive. The periphery of the stiffener core corresponding to the metal filling block is fully covered with fabric for at least 3 layers, and each layer is fixed with spray adhesive to form a flat surface with other areas; after the position of the stiffener core is fixed, lay the surface fabric of the stiffener core, and cut the fabric at the intersection area for overlapping; finally, lay the release cloth, flow guide net, and vacuum bag film, place a spiral tube at the edge, seal the edge of the vacuum bag film with a sealing strip, connect the vacuum pipeline and valve, evacuate and exhaust air, infuse resin, introduce the resin through the resin inlet pipe, the resin fully infiltrates the fabric, and demold after the resin is completely cured under certain temperature conditions.

7. The preparation method of the composite material hoisting movable top cover according to claim 1, characterized in that In S5, if the OOA or autoclave process is adopted, the forming method of the top cover body is specifically as follows: Apply and coat a release agent on the top cover body mold, and lay one or more of glass fiber prepreg, carbon fiber prepreg, aramid fiber prepreg, quartz fiber prepreg, and basalt fiber prepreg according to the designed laying angle and number of layers. When the panel is a sandwich panel, lay the panel core layer in sequence; after the reinforcement of the panel is laid, place the stiffener core at the designed position. When placing the stiffener core, fix the bottom by adding an additional layer of adhesive film. The periphery of the stiffener core corresponding to the metal filling block is fully covered with prepreg for at least 3 layers, and an additional layer of adhesive film is added to the contact surface between the prepreg and the stiffener core to form a flat surface with other areas; after the position of the stiffener core is fixed, lay the surface prepreg of the stiffener core, and cut the prepreg at the intersection area for overlapping; finally, lay the release cloth, breather felt, and vacuum bag film, seal the edge of the vacuum bag film with a sealing strip, connect the vacuum pipeline and valve, pre-evacuate and exhaust air, send the whole mold into the curing furnace or autoclave, and the prepreg is completely cured under certain temperature and pressure conditions, and demold after the temperature drops below 60°C.

8. The preparation method of the composite material hoisting type movable top cover according to claim 6 or 7, characterized in that, During the laying process of the panel reinforcement, when laying in the aisle area, first lay several layers of continuous fabric close to the mold surface, then cut the fabric into narrow strips, fully infiltrate them with resin, and fill them into the grooves formed in the aisle area. Continue to lay the continuous fabric after laying until the aisle area is flush with other areas.

9. The preparation method of the composite material hoisting movable roof according to claim 6 or 7, characterized in that, During the laying process of the panel reinforcement, when laying in the sunken area of the ventilation opening, lay the fiber fabric in the sunken area in contact with the mold surface. To ensure the forming quality, cut the fiber fabric and fix it with spray adhesive; when the panel is a sandwich panel, do not lay the panel core layer in the sunken area.

10. The preparation method of the composite material hoisting movable top cover according to claim 1, characterized in that, The specific method for S9 is as follows: Install an airtight backing nut on the inner side of the sinking edge. The airtight backing nut is fastened to the inner side of the sinking area using a rivet. After the installation of the airtight backing nut, apply sealant around the nut; Open holes in the vent cover to match the threaded holes of the airtight backing nut and connect them with screws. After the connection, apply sealant around the screws for further waterproofing; The installed vent cover is flush with the curved surface of the top cover body and has a smooth transition in the closed state.

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