Lightweight wagon body fireproof floor structure

Abstract

A fire protection floor structure for a wagon body, comprising a sandwich plate 5 made of a metal upper layer 10, a metal lower layer 20, a core layer 30 therebetween and a metal edge profile 40. The core layer 30 is completely surrounded by the metal upper layer 10, the metal lower layer 20 and the edge profile 40. The floor structure has a mineral coolant layer 60 on the side of the lower layer 20 facing away from the core layer 30, the mineral coolant layer 60 being covered on the side facing away from the core layer 30 with a fireproof layer 70. The core layer 30 is made from structural foam, in particular PET foam, or from balsa wood or contains at least 95% by weight of PET or balsa wood.

Description

[Technical field]

[0001] The present invention relates to a fire-protected floor structure of a wagon body for a rail or road transport vehicle of lightweight construction. [Background technology]

[0002] ASTM E119 standard is often required for floor structures of rail transport vehicles or road transport vehicles, i.e. in case of fire with temperatures up to 840-860°C, the surface temperature on the upper layer of the floor structure must not exceed an average temperature of 140°C for 30 minutes and must not exceed 400 kg / m 2 The floor structure under this load must not collapse within 30 minutes.

[0003] Fireproof underframe floor structures for railway vehicles are known per se from the state of the art. Thus, Chinese Patent No. 110641491(A) describes a method for manufacturing an underframe fireproof floor structure for railway vehicles, comprising a floor load-bearing frame and a floor placed on the floor load-bearing frame, the floor load-bearing frame being welded together by using carbon steel and having a rectangular outer frame and a number of cross members. A hat-shaped fireproof plate with an upper side facing downwards is placed between two adjacent cross members, and the side walls of the hat-shaped fireproof plate are clamped between the two adjacent cross members. The two edges of the hat-shaped fireproof plate are correspondingly and integrally connected to the upper upper surfaces of the upper sides of the two adjacent cross members. The floor is connected to each cross member by using an adhesive, and a cold-resistant heat-insulating material made of ceramic fibers is placed between the floor and the hat-shaped fireproof plate.

[0004] China Patent No. 210454809(A) describes a floor structure for a railway vehicle, the floor structure comprising a layer made of stainless steel sheet, and a heat insulating layer is arranged on the stainless steel layer. An aluminium profile floor frame is arranged on the heat insulating layer.

[0005] US 2018 / 0215398 A1 describes a floor structure with an underframe that is part of a wagon body, the underframe extending along a longitudinal axis that coincides with the feed axis of such a vehicle and having a number of longitudinal mounting rails arranged on the area of ​​the underside of the underframe, the mounting rails projecting downwards to define between them a number of compartments into which plates with insulating material are inserted to form a fire protection system.

[0006] EP 0806539(A1) describes a laminated composite floor for a railway wagon having internal cavities, at least one of which is filled with an intumescent material. When exposed to fire, such an article will delay or prevent the breakthrough of the fire into an adjacent compartment or room for a sufficient time to enable its passengers to evacuate the adjacent compartment or to extinguish the fire. The fire-resistant material meets the requirements of ASTM E152.

[0007] No. 6,114,003 describes a fire and heat resistant insulation plate used to protect the hull, bulkheads, ceilings, and passenger compartments of ships, aircraft, tank cars, and tank trucks. The insulation plate has an inner core air cell fabricated from metal with a first side for receiving a first composite material and a second side for receiving a second composite material. The composite material has an inner layer formed from a metal foil, a ceramic based intermediate layer, and an outer layer of a fire resistant flame retardant coating on a fiberglass sheet.

[0008] A problem in the manufacture of fire-resistant floor structures for rail or road vehicle wagon bodies is that floor structures known from the state of the art which meet the fire protection requirements according to ASTM E119 are heavy. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Chinese Patent No. 110641491(A) [Patent Document 2] Chinese Patent No. 210454809(A) [Patent Document 3] US Patent Application Publication No. 2018 / 0215398(A1) [Patent Document 4] European Patent No. 0806539(A1) [Patent Document 5] U.S. Patent No. 6,114,003 Summary of the Invention [Problem to be solved by the invention]

[0010] The object of the present invention is to provide a fire-resistant floor structure in a wagon body for a rail or road transport vehicle of light construction, which meets the requirements of the ASTM E119 test protocol. This floor structure must therefore provide a barrier against fire on the protected side of the floor structure, i.e. the inside of the wagon, and sufficient structural integrity to maintain the load-bearing capacity of the floor structure even in the event of a fire. A further object of the present invention relates to the easy installation of the floor structure in the wagon body. [Means for solving the problem]

[0011] These objects are met by a fire-resistant floor construction as defined in claim 1. Preferred embodiments of the floor construction are defined in the claims which depend directly or indirectly on independent claim 1.

[0012] The fireproof floor structure according to the invention for a wagon body for a rail vehicle or road vehicle, which includes a connection profile, has a sandwich plate made of a metal upper layer, a metal lower layer and, between them, a layer made of a core layer of a non-fireproof material, as well as a metal edge profile, where the edge profile is configured in such a way that the core layer is completely surrounded by the metal upper layer, the metal lower layer and the edge profile. The floor structure has, on the side of the lower layer facing away from the core layer, a mineral coolant layer and a fireproof hard-layer plate in the area for attaching the connection profile, the inner area of ​​the side of the hard-layer plate facing away from the sandwich plate in each case has a fireproof adhesive layer area. Thus, either the fireproof hard-layer plate or the mineral coolant layer is located on the lower layer, i.e. the mineral coolant layer surrounds the fireproof hard-layer plate, so that the side of the lower layer facing away from the core layer is covered over the entire surface by the mineral coolant layer and the fireproof hard-layer plate. The side of the inorganic coolant layer facing away from the sandwich plate as well as at least one edge area of ​​the area of ​​the hard layer plate not covered with fire-resistant adhesive are covered with a fire-resistant layer, and the connection profile is glued in the inner area of ​​the side of the fire-resistant adhesive layer facing away from the sandwich plate, respectively.

[0013] The non-refractory material of the core layer specifically means that it can react with oxygen in the air to release radiant energy or heat, and after ignition, will continue to burn even if the ignition source is removed.

[0014] According to the invention, the core layer made of a non-fire-resistant material is a core layer made of structural foam, in particular a core layer made of PET foam, or a core layer made of balsa wood, in particular balsa wood end grain board. In this context, structural foam means a foam with a cellular structure. Core layers containing at least 95% by weight of PET or balsa wood are also preferred.

[0015] Refractory materials expand when exposed to heat, i.e., they increase in volume and correspondingly decrease in density when exposed to heat. The increase in volume of refractory materials is conveniently up to 20 times the original material volume.

[0016] Rail vehicles for application of the floor structure are in particular rail, metro, suburban and underground trains as well as trams. Preferred applications of the floor structure according to the invention in road vehicles are in particular bus wagon bodies and other non-rail public transport vehicles. Particularly preferred applications concern battery-powered vehicles (e-mobility). The metal top and bottom layers as well as the edge profiles of the sandwich plates are preferably manufactured from aluminum.

[0017] The inorganic coolant layer is preferably adhered to the entire bottom layer surface, except for the areas having the fire resistant hard layer plate, preferably with a two component polyurethane or epoxy resin adhesive.

[0018] The inorganic coolant layer is preferably made from a layer of cemented calcium silicate. The cooling effect is based on the endothermic evaporation of hydrated minerals. The inorganic coolant layer is expediently 1mm to 3mm thick. Preferably the commercial product ENEX is used. ENEX is an inorganic coolant made from metal hydrates and which absorbs large amounts of heat when heated above a threshold temperature. The effect is based on the evaporation of hydrated minerals.

[0019] The fire-resistant layer is preferably glued over the entire surface of the inorganic coolant layer, except for the areas of the hard-layer plate that are covered with a fire-resistant adhesive, and in each case onto the edge areas of the fire-resistant hard-layer plate. Preferably, a two-component polyurethane adhesive is used.

[0020] The fire-resistant layer is preferably made from a fire-resistant fleece, which in turn is preferably made from silicate fibers. The fire-resistant layer expediently has a thickness of 0.7-3 mm. Preferably, the product PYRO-SAFE is used for the fire-resistant layer.

[0021] The floor structure has a substantially rectangular structure in top view, with a width expediently between 1.5m and 4m, preferably between 2m and 3m, and a length expediently between 6m and 25m, preferably between 10m and 20m.

[0022] The floor structure is preferably arranged to be self-supporting and the sandwich plate expediently has a thickness of from 30mm to 80mm, preferably from 50mm to 70mm.

[0023] The upper and lower layers of the sandwich preferably have a thickness of 1.0 to 2.0 mm.

[0024] The fire-resistant hard-layer plate is preferably made from a graphite-based plate material. Since the connection profile cannot be reliably bonded to the fire-resistant layer, a fire-resistant hard-layer plate is required in each case to attach the profile.

[0025] The fire-resistant hard layer plate is preferably produced from a fire-resistant fleece which is pressed under high pressure, for example as explained above.

[0026] Connecting profiles, preferably C-rails for receiving pipes or conduits, are located on the exposed surface areas of the fire-resistant hardlayer plates, these connecting profiles being preferably attached to the fire-resistant hardlayer plates by means of a fire-resistant adhesive.

[0027] The floor structure according to the invention is preferably connected to the wall of the wagon body via the edge profiles of the sandwich by fastening means, which can be achieved for example by welding or by screws, rivets or adhesive.

[0028] The invention will be further described with reference to the following illustrative drawings. [Brief description of the drawings]

[0029] [Figure 1] FIG. 2 shows a schematic cross-section of a floor structure according to the invention of a wagon body with a connecting profile. [Diagram 2] FIG. 2 shows a perspective view of a section through a floor structure according to the invention of a wagon body of a rail or road vehicle with a connecting profile, seen from the vehicle floor. [Diagram 3] FIG. 2 shows another perspective view of a section through a floor structure according to the invention of a wagon body of a rail or road vehicle with a connecting profile, seen from the vehicle floor. [Figure 4] FIG. 2 shows a perspective view of the surface of a floor structure according to the invention. [Diagram 5] FIG. 2 shows a perspective view of the underside of a floor structure according to the invention with multiple connection profiles. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] 1 shows a schematic cross-section of a floor structure according to the invention for a wagon body with a connection profile. The floor structure comprises a sandwich plate 5 which comprises a metal upper layer 10, a metal lower layer 20 and between them a layer made of a core layer 30 of a non-fireproof material as well as a metal edge profile 40, which is configured in such a way that the core layer 30 is completely surrounded by the metal upper layer 10, the metal lower layer 20 and the edge profile 40. The floor structure comprises either an inorganic coolant layer 60 on the side of the lower layer 20 facing away from the core layer 30 or a fire-resistant hard layer plate 80 in an area for attaching a connection profile 90, such that the side of the lower layer 20 facing away from the core layer 30 is completely covered with either an inorganic coolant layer 60 or a fire-resistant hard layer plate 80. The inner area of ​​the hard layer plate 80 on the side facing away from the sandwich plate 5 comprises a fire-resistant adhesive layer area 85. In this context, the term "inner area" is understood as the inner area of ​​the hard layer plate when viewed from the top side of the hard layer plate. The side of the inorganic coolant layer 60 facing away from the sandwich plate 5 as well as the area of ​​the hard layer plate 80 not covered with the fire-resistant adhesive 85 are covered with the fire-resistant layer 70. The fire-resistant layer 70 therefore covers the entire inorganic coolant layer 60 and overlaps the part of the hard layer plate 80 not covered with the fire-resistant adhesive layer 85. The connection profile 90 is glued to the side of the fire-resistant adhesive layer 85 facing away from the sandwich plate 5, the connection profile being located in the inner area of ​​the fire-resistant adhesive layer 85 such that there is a gap between the connection profile 90 and the outer edge of the fire-resistant adhesive layer 85. The inner area of ​​the fire-resistant adhesive layer again refers to the inner area when viewed from the top side of the fire-resistant adhesive layer. The connection profile is a C-rail, with "C" referring to the cross section of the longitudinal rail. In a top view of the underside of the floor structure, the fire-resistant adhesive layer 85 can have any shape, in particular it can be circular, oval or rectangular.

[0031] 2 shows a perspective view of a section of a floor structure according to the invention of a rail or road vehicle wagon body with a connection profile, seen from the vehicle floor. When the floor structure according to the invention is mounted on the wagon body, the fixing elements, in this case a single C-rail or the like, are either oriented towards the floor of the vehicle or towards the wheels.

[0032] In the lower part, FIG. 2 shows the sandwich 5 with the upper layer 10 and the lower layer 20 surrounding the core layer 30 made of a non-fireproof material. On the side of the lower layer 20 facing away from the core layer 30, the inorganic coolant layer 60 is visible, and in the area for attaching the connection profile 90, the fireproof hard layer plate 80 is visible. The inner area of ​​the side facing away from the core layer 30 of the hard layer plate 80 has a fireproof adhesive layer 85. The side of the inorganic coolant layer 60 facing away from the core layer 30, as well as the area of ​​the hard layer plate 80 not covered with the fireproof adhesive layer 85, is covered with a fireproof layer 70. The fireproof layer 70 thus covers the entire inorganic coolant layer 60 and overlaps at least the edge area of ​​the part of the hard layer plate 80 not covered with the fireproof adhesive layer area 85. The C-rail 90 is glued to the side of the fireproof adhesive layer 85 facing away from the core layer 30. The fire-resistant hard layer plate 80 has a rectangular shape, the edge area of ​​which is shown in Figure 2 by rectangular lines on the surface of the fire-resistant layer 70. The fire-resistant adhesive layer 85 also has a rectangular surface shape, the extension of which is located within the fire-resistant hard layer plate 80.

[0033] Figure 3 shows another perspective view of a section of a floor structure according to the invention of a rail or road wagon body with a connecting profile, seen from the vehicle floor. Figure 3 shows a floor structure with edge profiles 40 and the outer surface of the fireproof layer 70. C-rails 90 protrude from the fireproof layer 70.

[0034] Figure 4 shows a perspective view of the surface of a floor structure according to the invention, the surface being formed by a metallic top layer 10. Furthermore, Figure 4 shows the peripheral edge profile 40 of the sandwich plate 5.

[0035] Figure 5 shows a perspective view of the underside of a floor construction according to the invention with a number of connection profiles attached to it, the underside being formed by a fire-resistant layer 70 and a number of C-rails protruding from the surface of the fire-resistant layer 70. Furthermore, Figure 5 shows the peripheral edge profile 40 of the sandwich plate 5.

[0036] Below we briefly describe two fire tests performed according to ISO 834-1 based on ASTM E119.

[0037] Test 1: 0.35m 2 A load of 1470 Newtons was applied to a square floor plate with a surface of 1 mm. The floor plate was manufactured from an aluminum upper layer and an aluminum lower layer, each with a thickness of 1 mm, a core layer made of PET foam between them, and a metal edge profile made of aluminum. The edge profile was designed in such a way that the core layer was completely surrounded by the metal upper layer, the metal lower layer and the edge profile. On the side of the lower layer facing away from the core layer, the floor plate had a mineral coolant layer with a thickness of 2 mm made from ENEX and, in the area for mounting the C-shaped connecting rail, a fire-resistant hard layer plate made from PYRO-SAFE, a fire-resistant fleece pressed under high pressure. The inner area of ​​the hard layer plate facing away from the core layer had a fire-resistant adhesive layer area, and the side of the inorganic coolant layer made from ENEX facing away from the core layer, as well as at least one edge area of ​​the area of ​​the hard layer plate not covered with fire-resistant adhesive, was covered with a 2.2 mm thick fire-resistant layer of PYRO-SAFE. A connection profile was glued in the inner area of ​​the fire-resistant adhesive layer area facing away from the core layer.

[0038] The floor plate was then placed in a furnace and tested according to ISO 834-1 in accordance with the standard temperature curve according to DIN EN 1363-1. The test procedure according to ISO 834-1 corresponds in part to the ASTM E119 test. Temperature measurements were carried out on the top layer in the center of the floor plate, where the top layer of the floor plate was heated from 20°C to 862°C over a time period of 35 minutes according to Table 1 below, with the structure of the floor plate still intact after 35 minutes. [Table 1]

[0039] Test 2: As a comparison test, an equivalent floor plate with the same structure as in the first test but without the inorganic coolant layer was tested according to the ISO 834-1 guidelines, using as fire-resistant layer a 2 mm thick layer made from Sika Unitherm Platinum, a solvent-free 2K fire-resistant coating based on epoxy resin with 100% solids volume.

[0040] The base plate was again placed in the furnace and tested according to ISO 834-1 in accordance with the standard temperature curve according to DIN EN 1363-1, however the test had to be stopped after 18 minutes as the permissible temperature-time curve according to DIN EN 1363-1 was exceeded and the base plate burned.

Claims

1. A fireproof floor structure for a wagon body, said floor structure comprising a sandwich plate (5) made of a metal upper layer (10), a metal lower layer (20), a core layer (30) therebetween, and a metal edge profile (40), said edge profile (40) being configured in such a way that said core layer (30) is completely surrounded by said metal upper layer (10), said metal lower layer (20) and said edge profile (40), said floor structure comprising an inorganic coolant layer (60) on a side of said lower layer (20) facing away from said core layer (30), said inorganic coolant layer (60) being covered on a side facing away from said core layer (30) with a fire-resistant layer (70), The core layer (30) is made from structural foam, in particular PET foam, or from balsa wood, in particular balsa wood end grain board, or contains at least 95% by weight of PET or balsa wood. This is a fireproof floor structure for a wagon body.

2. 2. A fire protection floor structure according to claim 1, characterized in that the metal upper layer (10) and the metal lower layer (20) of the sandwich plate (5) and the edge profile (40) are made from aluminum.

3. 2. A fire protection floor structure according to claim 1, characterized in that the inorganic coolant layer (60) is glued onto the entire surface of the lower layer (20), preferably with a two-component polyurethane adhesive.

4. The floor structure comprises a connection profile (90) arranged on the side of the lower layer (20) facing away from the core layer (30), the floor structure has a fire-resistant hard layer plate (80) on the side of the lower layer (20) facing away from the core layer (30) in an area for attaching the connection profile (90), the inner area of the hard layer plate (80) facing away from the sandwich plate in each case being a fire-resistant adhesive layer area.

3. A fireproof floor structure according to claim 1 or 2, characterized in that the inorganic coolant layer (60) has a side facing away from the core layer (30) and at least one edge area of the area of the hard layer plate (80) that is not covered with the fireproof adhesive (85) is covered with the fireproof layer (70), and the connecting profile (90) is glued into the inner area of the fireproof adhesive layer area (85) on the side facing away from the core layer (30).

5. 5. A fireproof floor structure according to claim 4, characterized in that, outside the area of the lower layer (20) having the fire-resistant hard layer plate (80), the inorganic coolant layer (60) is glued onto the entire surface of the lower layer (20), preferably with a two-component polyurethane adhesive.

6. 5. A fire protection floor structure according to claim 4, characterized in that the fire-resistant layer (70) is glued onto the entire surface of the inorganic coolant layer (60) and in each case onto the edge areas of the fire-resistant hard layer plates, preferably with a two-component polyurethane adhesive.

7. 4. A fire protection floor structure according to any one of claims 1 to 3, characterized in that the mineral coolant layer (60) is made from a layer made from cement-bound calcium silicate.

8. A fire protection floor structure according to claim 7, characterized in that the inorganic coolant layer (60) has a thickness of 1 mm to 3 mm.

9. 4. A fire protection floor construction according to any one of claims 1 to 3, characterized in that the fire-resistant layer (70) is made from a fire-resistant fleece, the fleece preferably being made from silicate fibers.

10. The fireproof floor structure according to claim 9, characterized in that the fireproof layer (70) has a thickness of 0.7 mm to 3.0 mm.

11. 4. A fire-rated floor structure according to any one of claims 1 to 3, characterized in that the floor structure has a substantially rectangular structure in top view, with a width expediently between 1.5m and 4m, preferably between 2m and 3m, and a length expediently between 6m and 25m, preferably between 10m and 20m.

12. 4. A fire protection floor structure according to any one of claims 1 to 3, characterized in that the floor structure is configured to be self-supporting and the sandwich plate (5) expediently has a thickness of 30 mm to 80 mm, preferably 50 mm to 70 mm.

13. A fire protection floor structure according to any one of claims 1 to 3, characterized in that the upper layer (10) and the lower layer (20) of the sandwich (5) have a thickness of between 1.0 mm and 2.0 mm.

14. 5. A fire protection floor structure according to claim 4, characterized in that said fire-resistant hard layer plate (80) is made from a graphite-based plate material.

15. 5. A fire floor structure according to claim 4, characterized in that the exposed surface of the fire-resistant hard layer plate (80) has at least one C-profile (90) for receiving a pipe or conduit, the at least one C-profile (90) being attached to the fire-resistant hard layer plate (80) by a fire-resistant adhesive.

16. 4. A fire-resistant floor structure according to any one of claims 1 to 3, characterized in that the floor structure is attached to the wall of the wagon body via the edge profiles of the sandwich plates (5) by fixing means.

17. 4. A fire protection floor arrangement according to any one of claims 1 to 3, characterized in that the wagon body is a wagon body for a road vehicle or a rail vehicle.

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