Composite material sliding chute, preparation method thereof and railway vehicle

Abstract

The invention relates to a composite material sliding groove, a preparation method thereof and a railway vehicle, and belongs to the technical field of composite material forming. The composite material sliding groove comprises a bottom bonding part, a bolt connecting part is arranged on the bottom bonding part, the two ends of the bolt connecting part are bent in the direction away from the bottom bonding part to form through groove side walls, the tail ends of the bolt connecting part are bent oppositely to form a through groove opening, and the outer side of the bottom bonding part and the outer side of the bolt connecting part are covered with surface layer paving parts. The included angle position of the bottom bonding part, the bolt connecting part and the surface layer paving part is filled with one-way fiber bundles. The bottom face and the inner wall of the through groove are made of continuously-laid fiber composite materials, the mechanical strength of the bent position is guaranteed, the outer side of the bolt connecting part in the sliding groove and the bottom bonding part are continuously covered with the surface layer laying part, and the sliding groove has the high bearing capacity.

Description

Technical Field

[0001] This invention belongs to the field of composite material molding technology, specifically relating to a composite material chute and its preparation method, and a rail vehicle. Background Technology

[0002] The information disclosed in this background section is intended only to enhance understanding of the overall background of the invention and is not necessarily to be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.

[0003] A swivel is a structure used to fix bolts, featuring a through groove. In use, the bolt head is inserted into the through groove while the bolt tail extends out, allowing the bolt to slide and change position within the groove. The polygonal bolt head cannot rotate due to the constraint of the groove's sidewalls. When installing a nut into the bolt in the swivel, the bolt head remains fixed without additional clamping; when removing the nut, the bolt head is retained in the groove, essentially maintaining its original installation position, simplifying the installation process.

[0004] The train has chutes at multiple locations, especially at the connection between the train's headliner and its frame. Existing chutes are mostly made of metal, which has drawbacks such as poor corrosion resistance and high weight. Replacing them with fiber composite materials can effectively reduce weight while maintaining strength, given the requirement for lightweight train bodies. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide a composite material chute, its preparation method, and a rail vehicle method. This method prepares a chute with a three-dimensional structure from common planar prepreg materials. The preparation method employs a mold-assisted autoclave forming process, which can produce a lightweight, high-strength, and well-dense chute to replace metal chute.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows: In a first aspect, a composite material chute includes a bottom adhesive portion, on which a bolt connection portion is provided. Both ends of the bolt connection portion are bent away from the bottom adhesive portion to form a through-groove sidewall, and the ends are bent toward each other to form a through-groove opening. The outer sides of the bottom adhesive portion and the bolt connection portion are covered by a surface layer covering portion, and the angle between the bottom adhesive portion, the bolt connection portion and the surface layer covering portion is filled with unidirectional fiber bundles.

[0007] Secondly, the method for preparing the aforementioned composite material groove includes the following steps: S1. The fiber prepreg is laid on the flat mold to become the bottom bonding material, and the fiber prepreg is laid on the side of the prismatic core mold to become the bolt connection material. S2. Hold the prismatic core mold with fiber prepreg on it under a set pressure and fix it on the flat mold, with the side of the prismatic core parallel to the flat mold. S3. Fill the angle between the bottom adhesive material and the bolt connection material with unidirectional fiber bundles; S4. Fiber prepreg is laid on the bottom adhesive material, bolt connection material and the outside of the unidirectional fiber bundle to become the surface material, and then cured by autoclave molding process. S5. After removing the prismatic core mold, a through groove opening is machined to obtain the composite material slide groove.

[0008] Thirdly, a rail vehicle includes a chute, the chute being a composite material chute as described above.

[0009] The beneficial effects of this invention are as follows: 1. This invention utilizes fiber composite materials to fabricate chutes. In the chute structure design, the bolt connection portion forms the inner side of the channel, with the bottom and inner wall of the channel made of continuously laid fiber composite material. There are no continuous seams at the bends, ensuring the mechanical strength of the channel sidewalls and openings, and providing effective constraint on the bolt heads. The surface layer forms the outer side of the channel, continuously covering the outer side of the bolt connection portion (channel) and the bottom adhesive portion. The bottom adhesive portion is also covered with continuously laid fiber composite material, eliminating continuous seams at the bends. This ensures a firm connection between the bolt connection portion and the entire chute product, enabling the chute to have a high load-bearing capacity and meet the load-bearing requirements of its application scenarios. It can replace traditional metal profile chutes, meeting the requirements of lightweight, high strength, and corrosion resistance.

[0010] 2. In the preparation process of this invention, a prismatic core mold is used to internally support the bolt connection part and the surface layer covering part, which effectively improves the forming accuracy inside the channel. In addition, the prismatic core mold can be fixed on the flat mold to apply a set pressure to the bottom bonding part material, which effectively reduces the interlayer defects between the bolt connection part and the surface layer covering part. The entire chute product is prepared by autoclave forming process, which makes the product dense and can obtain a zero-defect product under ultrasonic non-destructive testing characterization. Attached Figure Description

[0011] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0012] Figure 1 This is a schematic diagram of the composite material chute in Example 1, where (A) is an isometric view and (b) is a front view.

[0013] Figure 2This is a schematic diagram of the planar mold in Example 2.

[0014] Figure 3 This is a schematic diagram of the prism-shaped core mold in Example 2.

[0015] Figure 4 This is a schematic diagram of the positioning mounting base in Example 2.

[0016] Figure 5 This is a schematic diagram of the preparation process in step S2 of Example 2.

[0017] Figure 6 This is a schematic diagram of the preparation process in step S4 of Example 2.

[0018] The components are as follows: 1. Bottom bonding part; 2. Bolt connection part; 3. Surface layer laying part; 4. Unidirectional fiber bundle; 5. Through groove sidewall; 51. Through groove opening; 52. Slide groove mounting part; 6. Through hole; 7. Flat mold; 72. Mounting hole; 73. First prepreg laying position; 8. Prismatic core mold; 81. Second prepreg laying position; 9. Positioning mounting seat; 91. Mounting bolt; 92. Core mold mounting hole; 93. Fastening bolt. Detailed Implementation

[0019] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0020] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0021] One or more embodiments of the present invention provide a composite material chute, including a bottom adhesive portion, a bolt connection portion provided on the bottom adhesive portion, both ends of the bolt connection portion being bent away from the bottom adhesive portion to form a through groove sidewall, and the ends being further bent towards each other to form a through groove opening, the outer sides of the bottom adhesive portion and the bolt connection portion being covered by a surface layer covering portion, and the included angle position of the bottom adhesive portion, the bolt connection portion and the surface layer covering portion being filled with unidirectional fiber bundles.

[0022] In the above structure, the bolt connection forms the inner side of the through groove. The bottom surface and inner wall of the through groove are surrounded by a continuous fiber composite material, which ensures the mechanical strength of the side walls and bending points of the through groove. The bolt connection and bottom bonding part are surrounded by a continuous fiber composite material, forming the outer surface of the chute that covers the outside of the bolt connection. This ensures a firm connection between the bolt connection and the entire chute product, enabling the chute to have a high load-bearing capacity and meet the load-bearing requirements of the chute's application scenarios.

[0023] Optionally, through holes are provided on both sides of the through groove, penetrating the bottom adhesive part and the surface layer covering part, for fixing the chute to the surface of the set structure.

[0024] Optionally, the spacing of the sidewalls of the through groove is consistent with the distance between opposite sides of the polygonal bolt head, so that the bolt head cannot rotate after sliding into the groove, thereby achieving constraint and simple positioning of multiple bolts in the groove.

[0025] One or more embodiments of the present invention provide a method for preparing the above-mentioned composite material groove, comprising the following steps: S1. The fiber prepreg is laid on the flat mold to become the bottom bonding material, and the fiber prepreg is laid on the side of the prismatic core mold to become the bolt connection material. S2. Hold the prismatic core mold with fiber prepreg on it under a set pressure and fix it on the flat mold, with the side of the prismatic core parallel to the flat mold. S3. Fill the angle between the bottom adhesive material and the bolt connection material with unidirectional fiber bundles; S4. Fiber prepreg is laid on the bottom adhesive material, bolt connection material and the outside of the unidirectional fiber bundle to become the surface material, and then cured by autoclave molding process. S5. After removing the prismatic core mold, a through groove opening is machined to obtain the composite material slide groove.

[0026] In the above process, a prismatic core mold is used to internally support the bolt connection and the surface layer, thereby improving the forming accuracy inside the channel. Furthermore, the prismatic core mold can be used to press the bolt connection and the surface layer together, which helps to eliminate interlayer defects in this location. The entire chute product is manufactured using a hot autoclave forming process, which can achieve zero-defect quality under ultrasonic non-destructive testing.

[0027] Optionally, in S1, prepreg twill fabric is first laid on the flat mold to ensure the overall appearance of the product. Then, multiple layers of prepreg unidirectional tape are laid in a set manner. The mechanical properties of the product are improved by designing the laying method of the prepreg unidirectional tape.

[0028] Optionally, in S1, a prepreg twill fabric is first laid on the surface of the prismatic core mold to give the inner surface of the through groove that is in direct contact with the bolt head a high wear resistance. Then, multiple layers of prepreg unidirectional tape are laid in a set manner to improve the mechanical properties of the bolt connection.

[0029] Optionally, in S2, the prismatic core mold is connected to both ends exposed in the prepreg using a positioning mounting base. Then, the positioning mounting base is installed on the flat mold. By adjusting the distance between the prismatic core mold and the flat mold, the pressure between the bottom adhesive material and the bolt connection material is adjusted to a set range to eliminate interlayer defects between the bottom adhesive part and the bolt connection part.

[0030] Optionally, in S3, the length direction of the unidirectional fiber bundle is consistent with the axial direction of the prism-shaped mandrel, filling the gap between the bottom adhesive part, the bolt connection part and the surface layer covering part, so that the contour shape of the groove is smoothly transitioned, preventing the formation of a mechanically weak area at the bending position.

[0031] Optionally, in S4, first lay multiple layers of prepreg unidirectional tape according to the set method, so that it is in firm contact with the prepreg unidirectional tape of the bottom adhesive part and the bolt connection part, and then lay the prepreg twill fabric on the outermost side to obtain a good appearance.

[0032] Optionally, in S4, during the autoclave molding process, the unidirectional fiber bundle is completely impregnated by the surrounding flowing resin material.

[0033] Optionally, in S5, through holes are machined on both sides of the through groove, penetrating the bottom adhesive part and the surface covering part, to fix the chute product at its installation position.

[0034] The present invention will be further described below with reference to the embodiments.

[0035] Example 1 A composite material chute, its isometric view is as follows: Figure 1 As shown in (A), the front view is as follows Figure 1 As shown in (B), it includes a bottom adhesive part 1, a bolt connection part 2 is provided on the bottom adhesive part 1, the two ends of the bolt connection part 2 are bent away from the bottom adhesive part 1 to form the inner surface of the through groove sidewall 5, and the ends are further bent towards each other to form the through groove opening 51. The outer sides of the bottom adhesive part 1 and the bolt connection part 2 are covered by a surface layer covering part 3, and the angle between the bottom adhesive part 1, the bolt connection part 2 and the surface layer covering part 3 is filled with unidirectional fiber bundles 4.

[0036] In the above structure, the bolt connection part 2 forms the inner side of the through groove. The bottom surface and inner wall of the through groove are surrounded by a continuous fiber composite material, which ensures the mechanical strength of the through groove side wall 5 and the through groove opening 51 and other bending points. The bolt connection part 12 and the bottom adhesive part 1 are surrounded by a continuous fiber composite material, which forms the outer surface of the chute covering the outside of the bolt connection part 2. This makes the outer surface of the through groove side wall 5 and the outer surface of the chute mounting part 52 become a whole, ensuring a firm connection between the bolt connection part 2 and the entire chute product. This enables the chute to have a high load-bearing capacity and meet the load-bearing requirements of the chute's application scenario.

[0037] The sliding groove mounting parts 52 on both sides of the through groove are respectively provided with through holes 6 that penetrate the bottom adhesive part 1 and the surface layer covering part 3, for fixing the sliding groove on the surface of the set structure.

[0038] The spacing between the inner surfaces of the opposite sidewalls 5 of the through groove is consistent with the distance between opposite sides of the polygonal bolt head, so that the bolt head cannot rotate after sliding into the through groove, thereby achieving constraint and simple positioning of multiple bolts in the groove.

[0039] Example 2 The method for preparing the composite material groove in Example 1 uses a molding die including, for example, Figure 2 The flat mold 7 shown is as follows: Figure 3 The prism-shaped core mold 8 shown and as follows Figure 4 The positioning mounting base 9 is shown.

[0040] Among them, such as Figure 2 As shown, the flat mold 7 is used for forming the bottom adhesive part 1, and it is set in... Figure 2 The autoclave forming device in the middle is used to support the entire mold and the composite material chute to enter the autoclave; the flat mold 7 is provided with mounting holes 72 for mounting the positioning mounting seat 9.

[0041] like Figure 4 As shown, the positioning mounting base 9 is provided with multiple mounting bolts 91, which can be installed in the mounting holes 72 of the flat mold 7 to connect the positioning mounting base 9 and the flat mold 7 into one unit. The positioning mounting base 9 is provided with a through core mold mounting hole 92, the shape of which matches the cross section of the prism-shaped core mold 8. When the prism-shaped core mold 8 is inserted into the core mold mounting hole 92 and tightened with fastening bolts 93, the prism-shaped core mold 8 and the positioning mounting base 9 are connected into one unit.

[0042] The method for preparing composite material grooves includes the following steps: S1, such as Figure 2 As shown, the fiber prepreg is laid on the first prepreg laying position 73 of the flat mold 7 to become the bottom adhesive material, as shown. Figure 3As shown, fiber prepreg is laid on the second prepreg laying position 81 on the circumferential side of the prismatic core mold 8 to become the bolt connection material; S2. Connect using positioning mounting bracket 9 Figure 3 The central prismatic core mold 8 is exposed at both ends of the prepreg, and then... Figure 5 As shown, the positioning mounting base 9 is installed on the flat mold 7 so that the side of the prism is parallel to the flat mold 7. Then, by adjusting the mounting bolt 91 and the fastening bolt 93, the distance between the prism core mold 8 and the flat mold 7 is adjusted, thereby fixing the prism core mold 8 with fiber prepreg on the flat mold 7 under a set pressure. That is, the bottom adhesive material and the bolt connection material are squeezed together under a set pressure to eliminate interlayer defects between the bottom adhesive material and the bolt connection material. S3, then follow Figure 1 As shown, unidirectional fiber bundles 4 are filled into the angle between the bottom adhesive material and the bolt connection material. The length direction of the unidirectional fiber bundles 4 is consistent with the axial direction of the prism-shaped core mold 8, so that the joint between the bottom adhesive material and the bolt connection material is smoothly transitioned, thereby making the outline shape of the groove product smoothly transitioned and preventing the formation of a mechanically weak area at the bending position. S4, such as Figure 6 As shown, fiber prepreg is laid on the outside of the bottom adhesive material, bolt connection material, and unidirectional fiber bundle 4 to form the surface layer material. At this time, the surface layer material completely covers the surface of the first prepreg laying position 73 and the second prepreg laying position 81, which is represented by multiple areas with the same stripe shape in the figure. Then, it is cured by autoclaving. The process parameters during the curing process include: (curing temperature and time: 80±5℃ for 60min, 125±5℃ for 180min; curing pressure: negative pressure ≥ -0.09Mpa, positive pressure ≥ 0.6Mpa). S5. After the autoclave forming process is completed, the prismatic core mold 8 is removed from the solidified chute blank, and then the blank is machined using a machining method. Figure 1 The through slot opening 51 shown in (B) and as shown in the figure Figure 1 The through hole 6 shown in (A) in the figure is used to obtain a composite material groove.

[0043] In S1, the method of laying the bottom adhesive material includes: first laying a layer of 3K carbon fiber prepreg twill fabric, and then laying T700 prepreg unidirectional tape layer by layer in the order of 45° / 0° / -45° / 90° until the thickness is slightly more than 2mm.

[0044] In S1, the method of laying the bolt connection material includes: first laying a layer of 3K carbon fiber prepreg twill fabric, and then laying T700 prepreg unidirectional tape layer by layer in the order of 45° / 0° / -45° / 90° until the thickness is slightly more than 2mm.

[0045] The designed gap between the prismatic core mold 8 and the flat mold 7 is 4mm. In actual application, due to insufficient interlayer density during the application process, the sum of the thickness of the bottom adhesive material and the bolt connection material is about 4.3~4.5mm. The prismatic core mold 8 is compacted using the fastening bolts 93 of the positioning mounting seats 9 on both sides, and positive pressure is applied to the bottom adhesive material and the bolt connection material to achieve an interference fit. This allows the resin to melt under the action of positive pressure during the subsequent product curing process, thereby enhancing the interlayer density of the prepreg.

[0046] In S4, the surface layer material is laid in the following manner: first, T700 prepreg unidirectional tape is laid layer by layer in the manner of 90° / -45° / 0° / 45° until its thickness reaches 2mm, and then a layer of 3K carbon fiber prepreg twill fabric is laid.

[0047] The thickness of the obtained product at different locations is approximately 4 mm, which is conducive to uniform curing during the autoclave molding process. During the autoclave molding process, the unidirectional fiber bundle 4 is gradually impregnated by the surrounding flowing resin material, making the entire composite material chute a whole with uniform material and dense internal structure.

[0048] The obtained product has no surface defects, and the area of ​​internal defects in the ultrasonic non-destructive testing results is less than 5% of the total area.

[0049] Example 3 A rail vehicle includes a chute, which is a composite material chute as described in Example 1, and is disposed at the connection position between the train head cover and the car body frame.

[0050] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A composite material chute, characterized in that, The device includes a bottom adhesive portion, on which a bolt connection portion is provided. Both ends of the bolt connection portion are bent away from the bottom adhesive portion to form a through groove sidewall, and the ends are further bent towards each other to form a through groove opening. The bottom adhesive portion and the bolt connection portion are covered with a surface layer covering portion. The angle between the bottom adhesive portion, the bolt connection portion and the surface layer covering portion is filled with unidirectional fiber bundles.

2. The composite material chute as claimed in claim 1, characterized in that, The groove has through holes on both sides that penetrate the bottom bonding part and the surface layer laying part.

3. The composite material chute as claimed in claim 1, characterized in that, The spacing between the sidewalls of the through groove is consistent with the distance between opposite sides of the polygonal bolt head.

4. A method for preparing a composite material groove as described in any one of claims 1-3, characterized in that, Includes the following steps: S1. The fiber prepreg is laid on the flat mold to become the bottom bonding material, and the fiber prepreg is laid on the side of the prismatic core mold to become the bolt connection material. S2. Hold the prismatic core mold with fiber prepreg on it under a set pressure and fix it on the flat mold, with the side of the prismatic core parallel to the flat mold. S3. Fill the angle between the bottom adhesive material and the bolt connection material with unidirectional fiber bundles; S4. Fiber prepreg is laid on the bottom adhesive material, bolt connection material and the outside of the unidirectional fiber bundle to become the surface material, and then cured by autoclave molding process. S5. After removing the prismatic core mold, a through groove opening is machined to obtain the composite material slide groove.

5. The method for preparing the composite material groove as described in claim 4, characterized in that, In S1, prepreg twill fabric is first laid on the flat mold, and then multiple layers of prepreg unidirectional tape are laid in the set manner; Alternatively, in S1, a prepreg twill fabric is first laid on the surface of the prismatic core mold, and then multiple layers of prepreg unidirectional tape are laid in a set manner. Alternatively, in S4, first lay multiple layers of prepreg unidirectional tape according to the set method, so that it is in firm contact with the prepreg unidirectional tape of the bottom adhesive part and the bolt connection part, and then lay the prepreg twill fabric on the outermost side.

6. The method for preparing the composite material groove as described in claim 4, characterized in that, In S2, the prismatic core mold is connected to both ends of the prepreg by a positioning mounting base. Then, the positioning mounting base is installed on the flat mold, and the distance between the prismatic core mold and the flat mold is adjusted.

7. The method for preparing the composite material groove as described in claim 4, characterized in that, In S3, the length direction of the unidirectional fiber bundle is consistent with the axial direction of the prismatic core mold, filling the gap between the bottom adhesive part, the bolt connection part and the surface layer laying part.

8. The method for preparing the composite material groove as described in claim 4, characterized in that, In S4, during the autoclave molding process, the unidirectional fiber bundles are completely impregnated by the surrounding flowing resin material.

9. The method for preparing the composite material groove as described in claim 4, characterized in that, In S5, through holes are machined on both sides of the through groove, penetrating the bottom bonding part and the surface layer laying part respectively.

10. A rail vehicle, comprising a chute, characterized in that, The chute is a composite material chute as described in any one of claims 1-3.

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