Railroad vehicle and production method thereof

Abstract

To provide a railroad vehicle and a production method thereof in which an air-conditioning duct provided above a ceiling can be reduced in weight, quietness in a vehicle cabin can be improved, and installation work to a roof structure can be simplified.SOLUTION: A railroad vehicle 10, in which an air conditioner KT is provided in a roof structure YK, comprises an air-conditioning duct KD above a ceiling, including: a ceiling panel 2 where an air outlet 21 is formed for blowing a conditioned air supplied from the air conditioner into a vehicle cabin 1; and a hat-shaped upper duct section 3 disposed above the ceiling panel. The upper duct section composed of a lightweight material KS, inside which air spaces 31 are distributed, is constructed with the hat-shaped cross section by a pair of vertical wall sections 3T and a horizontal wall section 3Y extendedly arranged between the vertical wall sections. The horizontal wall section is fixed with one inner bone YK1 on a roof structure at the top in a middle section 3Y1 in the vehicle width direction. The vertical wall section is separately fixed with another inner bone YK2 on the ceiling panel of the roof structure at the bottom.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a railway vehicle and a method for manufacturing the same, and more particularly, to a railway vehicle having an air-conditioning duct in the ceiling space and a method for manufacturing the same.

Background Art

[0002] Conventionally, as an air-conditioning duct provided in the ceiling space of a railway vehicle, a ceiling duct unit in which a ceiling panel and an upper duct portion formed in a hat cross-section and disposed above the ceiling panel are integrally connected is known. Since this ceiling duct unit has a length of about 2 to 3 m, for example, it is necessary to ensure a predetermined rigidity during attachment to the roof structure of the railway vehicle and during transportation. Generally, a reinforcing plate is attached to the upper duct portion. However, the ceiling duct unit with the reinforcing plate has an increased vehicle weight by the weight of the reinforcing plate, which goes against the needs for weight reduction and low center of gravity of the railway vehicle.

[0003] In this regard, for example, Patent Document 1 discloses a railway vehicle 100 including a ceiling duct unit 100Y without a reinforcing plate. As shown in FIG. 9, the ceiling duct unit 100Y has a structure in which an upper plate 104 of a hat cross-section made of reinforced plastic is attached to the back surface of a ceiling plate 101 made of reinforced plastic. A plurality of cold air outlet holes 102 and a plurality of protrusions 103 are provided on the back surface of the ceiling plate 101, and a cold air duct 107, a cold air extraction hole 108, and a cold air reservoir 109 are formed between the upper plate 104 and the ceiling plate 101. Further, at the upper end of the upper plate 104, a mounting seat 105 that protrudes laterally from both side surfaces and is attached to the framework 106 of the roof structure is provided, and both end portions of the ceiling plate 101 are sandwiched between curtain plates 111 and fixed to another framework 112. In addition, lighting fixtures 110 are attached near both end portions of the ceiling plate 101.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, the ceiling duct unit 100Y of the railway vehicle 100 in Patent Document 1 described above had the following problems. That is, since the ceiling duct unit 100Y has a hollow cross-section structure in which the upper plate 104 with a hat cross-section is attached to the back surface of the ceiling plate 101, the middle part of the upper plate 104 in the vehicle width direction cannot be fixed to the framework 106 of the roof structure, and there is a possibility of sagging and vibration noise in the middle part. Therefore, there was a problem that it was not preferable for weight reduction of the upper plate 104 and quietness in the vehicle interior. In addition, since both ends of the ceiling plate 101 are sandwiched between the curtain plates 111 and fixed to other frameworks 112, when attaching the mounting seat 105 of the upper plate 104 to the framework 106 of the roof structure, both ends of the ceiling plate 101 located below get in the way, and there is a problem that the attachment work becomes complicated.

[0006] The present invention has been made to solve such problems, and an object thereof is to provide a railway vehicle and a manufacturing method thereof that can reduce the weight of an air-conditioning duct provided on the ceiling, improve the quietness in the vehicle interior, and simplify the attachment work to the roof structure.

Means for Solving the Problems

[0007] In order to achieve the above object, the railway vehicle and its manufacturing method according to the present invention have the following configurations. (1) A railway vehicle provided with an air-conditioning duct on the ceiling back, the air-conditioning duct having a ceiling panel provided with an air conditioner on a roof structure and having an air outlet for blowing conditioned air supplied from the air conditioner into the vehicle interior, and an upper duct portion with a hat cross-section disposed above it, The upper duct portion is formed of a lightweight material in which air layers are dispersedly arranged inside, and a hat cross-section is formed by a pair of vertical wall portions and a horizontal wall portion extending between the vertical wall portions, The horizontal wall portion is fixed to one inner bone of the roof structure at the middle part in the vehicle width direction, The vertical wall portion and the ceiling panel are separately fixed to the other inner bone of the roof structure, one above the other.

[0008] In the present invention, the upper duct portion is formed of a lightweight material in which air layers are dispersedly arranged inside, and a hat cross-section is formed by a pair of vertical wall portions and a horizontal wall portion extending between the vertical wall portions. Therefore, while ensuring the required rigidity, the weight reduction can be improved. Further, since the middle portion in the vehicle width direction of the horizontal wall portion is fixed to one of the inner frames of the roof structure, the sagging, vibration, and noise of the middle portion can be suppressed. Further, since the air layers are dispersedly arranged inside the upper duct portion, the noise transmitted through the air-conditioning duct can be absorbed by the dispersedly arranged air layers, and the heat transmitted from the roof structure can be effectively blocked. Therefore, the quietness in the vehicle interior can be enhanced and a comfortable room temperature can be maintained.

[0009] Further, the horizontal wall portion is fixed to one of the inner frames of the roof structure at the middle portion in the vehicle width direction, and the vertical wall portion and the ceiling panel are separately fixed to the other inner frame of the roof structure, above and below. Therefore, after fixing the upper duct portion to one of the inner frames and the other inner frame of the roof structure, the ceiling panel can be fixed to the other inner frame of the roof structure. Therefore, when fixing the upper duct portion to one of the inner frames and the other inner frame of the roof structure, there is no interference from the ceiling panel, and the installation work of the air-conditioning duct to the roof structure can be simplified.

[0010] Therefore, according to the present invention, it is possible to provide a railway vehicle that can reduce the weight of the air-conditioning duct provided in the ceiling space, improve the quietness in the vehicle interior, and simplify the installation work to the roof structure.

[0011] (2) In the railway vehicle described in (1), the lightweight material is characterized in that it is a material in which a glass wool material obtained by laminating and fixing glass fibers to a predetermined thickness is coated with a metal foil.

[0012] In the present invention, the lightweight material is a material in which a glass wool material obtained by laminating and fixing glass fibers to a predetermined thickness is coated with a metal foil. Therefore, in the upper duct portion, while ensuring the required rigidity, the weight can be reduced, and the sound absorption and heat insulation properties can be further improved. Further, by coating the glass wool material with a metal foil, the penetration of moisture into the glass wool material can be prevented, and the generation of mold and the like can be suppressed. Furthermore, the flame retardancy of the upper duct portion can be improved, and a railway vehicle with higher safety can be provided.

[0013] (3) In the railway vehicle according to (1) or (2), the other inner bone is formed in a hat cross-section with a horizontal flange portion at the lower end, the lower end portion of the vertical wall portion is airtightly adhered to the upper surface of the flange portion via a first seal member, and the ceiling panel is airtightly adhered to the lower surface of the flange portion via a second seal member.

[0014] In the present invention, the other inner bone is formed in a hat cross-section with a horizontal flange portion at the lower end. The lower end portion of the vertical wall portion is airtightly adhered to the upper surface of the flange portion via a first seal member, and the ceiling panel is airtightly adhered to the lower surface of the flange portion via a second seal member. Therefore, the upper duct portion and the ceiling panel, which are divided vertically, can be airtightly adhered to each other with the flange portion of the other inner bone interposed therebetween. Therefore, while enhancing the sealing performance of the air-conditioning duct, the installation work on the roof structure can be simplified.

[0015] (4) In the railway vehicle according to any one of (1) to (3), the upper duct portion is formed in a hat cross-section of the same shape and has a predetermined length, and is formed so as to be connectable in series in the longitudinal direction of the vehicle.

[0016] In the present invention, since the upper duct portion is formed with a predetermined length having the same hat cross-section and is formed to be connectable in series in the vehicle longitudinal direction, by preparing a plurality of upper duct portions of the same type, it is possible to correspond to railway vehicles equipped with vehicle compartments of various lengths. Therefore, while contributing to cost reduction, it is possible to reduce the weight of the air-conditioning duct, improve the quietness in the vehicle compartment, and simplify the attachment work to the roof structure.

[0017] (5) A method for manufacturing a railway vehicle having an air-conditioning duct provided in the ceiling space, the air-conditioning duct including a ceiling panel formed with an air outlet for blowing conditioned air supplied from an air conditioner provided in a roof structure into a vehicle compartment, and an upper duct portion having a hat cross-section disposed above the ceiling panel, The upper duct portion is formed of a lightweight material in which air layers are dispersedly arranged inside, and a hat cross-section is formed by a pair of vertical wall portions and a horizontal wall portion extending between the vertical wall portions. An upper duct fixing step of fixing an intermediate portion in the vehicle width direction of the horizontal wall portion to one inner bone of the roof structure and fixing the vertical wall portions to other inner bones, After the upper duct fixing step, a ceiling panel fixing step of fixing the ceiling panel to the other inner bones, characterized by comprising the above.

[0018] In the present invention, since the upper duct portion is formed of a lightweight material in which air layers are dispersedly arranged inside, and a hat cross-section is formed by a pair of vertical wall portions and a horizontal wall portion extending between the vertical wall portions, it is possible to improve weight reduction while ensuring required rigidity. Further, in the upper duct fixing step S1, since the intermediate portion in the vehicle width direction of the horizontal wall portion is fixed to one inner bone of the roof structure, it is possible to suppress the sagging and vibration noise of the intermediate portion. Further, since the air layers are dispersedly arranged inside the upper duct portion, the noise transmitted through the air-conditioning duct can be absorbed by the dispersedly arranged air layers, and the heat transmitted from the roof structure can be effectively blocked. Therefore, the quietness in the vehicle compartment can be enhanced and a comfortable room temperature can be maintained.

[0019] Also, after the upper duct fixing step of fixing the middle part in the vehicle width direction of the transverse wall part to one inner bone of the roof structure and fixing the longitudinal wall part to the other inner bone, in the ceiling panel fixing step, the ceiling panel is fixed to the other inner bone. Therefore, when fixing the upper duct part to one inner bone and the other inner bone of the roof structure, it is not obstructed by the ceiling panel, and the installation work of the air conditioning duct to the roof structure can be simplified.

[0020] Therefore, according to the present invention, it is possible to provide a manufacturing method of a railway vehicle that can reduce the weight of the air conditioning duct provided in the ceiling, improve the quietness in the vehicle interior, and simplify the installation work to the roof structure.

Effects of the Invention

[0021] According to the present invention, it is possible to provide a railway vehicle and a manufacturing method thereof that can reduce the weight of the air conditioning duct provided in the ceiling, improve the quietness in the vehicle interior, and simplify the installation work to the roof structure.

Brief Description of the Drawings

[0022]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Modes for Carrying Out the Invention

[0023] <Configuration of the Railway Vehicle> Next, a railway vehicle according to an aspect of an embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 shows a schematic side view of a railway vehicle according to an aspect of an embodiment of the present invention. FIG. 2 shows a sectional view taken along line A-A shown in FIG. 1. FIG. 3 shows a sectional view taken along line B-B shown in FIG. 2. FIG. 4 shows an enlarged view of part C shown in FIG. 3. FIG. 5 shows an enlarged view of part D shown in FIG. 2. FIG. 6 shows a sectional view taken along line E-E shown in FIG. 5. FIG. 7 shows a sectional view taken along line F-F shown in FIG. 5.

[0024] As shown in FIG. 1, the railway vehicle 10 includes a underframe DW supported by a pair of front and rear bogies DS running on a rail RL, gable structures TK standing at the front end and the rear end of the underframe DW, side structures GK standing at both side ends of the underframe DW, and a roof structure YK connected to the upper ends of the gable structures TK and the side structures GK. Further, on the side structure GK, side windows GM of various sizes, a passenger side door GT1 for passengers to get on and off, and a crew side door GT2 for drivers and the like to get on and off are formed. Underfloor equipment KZ is mounted on the underframe DW. An air conditioner KT is mounted on the roof structure YK. Here, one air conditioner KT is mounted near the center in the vehicle longitudinal direction of the roof structure YK, but a plurality of air conditioners may be mounted.

[0025] Also, as shown in FIGS. 1 to 3, the railway vehicle 10 includes a ceiling panel 2 formed with an air outlet 21 for blowing conditioned air CA supplied from an air conditioner KT provided in a roof structure YK into the vehicle compartment 1, and an upper duct portion 3 having a hat cross-section disposed above the ceiling panel 2. The air-conditioning duct KD is provided in the ceiling space. The ceiling panel 2 is made of a resin material or the like and is shaped into a predetermined shape at the center of the ceiling. Further, on the ceiling panel 2, an upwardly curved portion 2H protruding upward in an arc shape and a downwardly curved portion 2T protruding downward in an arc shape are formed at different positions in the vehicle longitudinal direction from both ends in the vehicle width direction where the air outlet 21 is formed, enhancing the rigidity of the intermediate portion in the vehicle width direction of the ceiling panel 2. Therefore, the intermediate portion in the vehicle width direction of the ceiling panel 2 is not connected to one of the inner frames YK 1 of the roof structure YK. Note that the ceiling panel 2 does not necessarily have to have the upwardly curved portion 2H and the downwardly curved portion 2T and may be formed in a flat shape. Further, a heat insulating material 25 is adhered to the back surface side of the ceiling panel 2. The heat insulating material 25 can also serve as a sound absorbing material. Further, on the end side in the vehicle width direction of the ceiling panel 2, an interior lighting plate 6 equipped with a lighting fixture (not shown) is attached, and on the end side in the vehicle width direction of the interior lighting plate 6, a side ceiling plate 5 joined to the interior plate of the side structure GK is attached.

[0026] Also, as shown in FIG. 2, the supply ports KT 1 for the conditioned air CA supplied from the air conditioner KT are provided in two locations each in the front and rear of the vehicle with a return port RG for returning the air in the vehicle compartment 1 to the air conditioner KT interposed therebetween. The supply ports KT 1 for the conditioned air CA are connected to an air-conditioning duct KD constituted by the ceiling panel 2 and the upper duct portion 3 having a hat cross-section disposed above it via a connecting duct 3S made of, for example, an aluminum alloy. The connecting duct 3S is formed in a special trapezoidal shape in which the width dimension is expanded while bending from the two supply ports KT 1 toward one air-conditioning duct KD. Note that the two supply ports KT 1 may be integrated into one. Further, the return port RG may be disposed outside the vehicle width direction of the supply port KT 1.

[0027] Further, as shown in FIGS. 3 to 7, the upper duct portion 3 is formed of a lightweight material KS in which air layers 31 are dispersedly arranged inside, and constitutes a hat cross-section with a pair of vertical wall portions 3T and a horizontal wall portion 3Y extending between upper end portions 3T1 of the vertical wall portions 3T. Here, as the lightweight material KS, a fiber-based lightweight material formed by fixing glass fiber, carbon fiber, chemical fiber, plant fiber, etc. with an adhesive or the like, or a foam-based lightweight material formed of rigid foam urethane, foamed aluminum, etc. can be used. Here, the lightweight material KS is covered on the front and back surfaces of the fiber-based lightweight material by a metal skin material 32, and is shaped so as to constitute a hat cross-section with a pair of vertical wall portions 3T and a horizontal wall portion 3Y. The thickness of the metal skin material 32 may be about several tens of microns to several hundreds of microns. Note that the air layers 31 are dispersedly arranged in the gaps between the fibers when the lightweight material KS is a fiber-based lightweight material, and are dispersedly arranged as bubbles when the lightweight material KS is a foam-based lightweight material.

[0028] As described above, since the upper duct portion 3 is formed of the lightweight material KS covered with the metal skin material 32 and having the air layers 31 dispersedly arranged inside, and constitutes a hat cross-section with a pair of vertical wall portions 3T and a horizontal wall portion 3Y extending between the vertical wall portions 3T, weight reduction can be improved while ensuring required rigidity.

[0029] Also, as shown in FIGS. 3 and 5, an intermediate portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y is fixed to one inner bone YK1 of the roof structure YK. Here, one inner bone YK1 is arranged at the center in the vehicle width direction of the roof structure YK and extends in the vehicle longitudinal direction. And the intermediate portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y is fixed to the one inner bone YK1 at a plurality of locations in the vehicle longitudinal direction. Two screw members 381 are inserted from below through a patch 382 and a collar member 384 with a flange into the intermediate portion (central portion) 3Y1 in the vehicle width direction of the horizontal wall portion 3Y, and the tip portions of the screw members 381 are engaged with screw seats 383 of the one inner bone YK1. Note that since the collar member 384 with a flange is interposed, fastening can be performed without strongly pressing the lightweight material KS, and even if the thickness of the lightweight material KS changes due to secular change, loosening of the screw members 381 can be prevented. Further, as the engaging member, a rivet member or the like may be used, but a screw member 381 or the like that can easily reduce the deformation of the lightweight material KS by adjusting the tightening amount is preferable.

[0030] As described above, since the intermediate portion 3Y1 in the vehicle width direction of the transverse wall portion 3Y is fixed to one of the inner frames YK1 of the roof structure YK, it is possible to suppress the sagging, vibration, and noise of the intermediate portion 3Y1 in the vehicle width direction of the transverse wall portion 3Y. Further, since the upper duct portion 3 has air layers 31 dispersedly arranged therein, the noise transmitted through the air-conditioning duct KD can be absorbed by the dispersedly arranged air layers 31, and the heat transmitted from the roof structure YK can be effectively blocked. Therefore, the quietness in the vehicle compartment 1 can be enhanced, and a comfortable room temperature can be maintained.

[0031] Further, as shown in FIGS. 3 to 5, the transverse wall portion 3Y of the upper duct portion 3 is fixed to one of the inner frames YK1 of the roof structure YK at the intermediate portion 3Y1 in the vehicle width direction, and the longitudinal wall portion 3T of the upper duct portion 3 and the ceiling panel 2 are separately fixed above and below to another inner frame YK2 of the roof structure YK. Here, the other inner frame YK2 is arranged outward in the vehicle width direction from the one inner frame YK1, and includes a horizontal flange portion YK21, a side wall portion YK22, and a zenith portion YK23. The longitudinal wall portion 3T of the upper duct portion 3 and the ceiling panel 2 are separately fixed above and below to the flange portion YK21 of the other inner frame YK2.

[0032] Specifically, the longitudinal wall portion 3T of the upper duct portion 3 is fixed to the upper surface of the flange portion YK21 of the other inner frame YK2 via an L-shaped fitting 36 attached to the outer surface of the longitudinal wall portion 3T using a pad 371 that abuts against the inner surface of the longitudinal wall portion 3T and a screw member 372 inserted from the inner surface, etc. A plurality of L-shaped fittings 36 are attached to the outer surface of the longitudinal wall portion 3T at predetermined intervals in the vehicle longitudinal direction. A spacer member 363 is inserted between the L-shaped fitting 36 and the flange portion YK21. Then, a screw member 361 is inserted through the spacer member 363 from below the flange portion YK21, and the tip of the screw member 361 is engaged with a screw seat 362 fixed to the L-shaped fitting 36. Further, on the upper surface of the flange portion YK21 of the other inner frame YK2, a screw seat 242 for fastening the ceiling panel 2 is fixed at the same position in the vehicle width direction as the screw seat 362 fixed to the L-shaped fitting 36 and at different positions in the vehicle longitudinal direction.

[0033] In addition, the ceiling panel 2 is fixed from below to the flange portion YK21 of another inner frame YK2 via a stepped fitting 23 having a lower step portion 231 fixed to the inner surface near the air outlet 21. The upper step portion 232 of the stepped fitting 23 is fixed to the flange portion YK21 of the other inner frame YK2 by engaging the tip of a screw member 241 inserted from below with a screw seat 242 of the flange portion YK21.

[0034] Therefore, after fixing the upper duct portion 3 to one inner frame YK1 and the other inner frame YK2 of the roof structure YK, the ceiling panel 2 can be fixed to the other inner frame YK2 of the roof structure YK. As a result, when fixing the upper duct portion 3 to one inner frame YK1 and the other inner frame YK2 of the roof structure YK, it is not obstructed by the ceiling panel 2, and the installation work of the air-conditioning duct KD to the roof structure YK can be simplified.

[0035] Therefore, according to this railway vehicle 10, the weight of the air-conditioning duct KD provided in the ceiling can be reduced, the quietness in the vehicle compartment 1 can be improved, and the installation work of the air-conditioning duct KD to the roof structure YK can be simplified.

[0036] As shown in FIG. 4, an air volume adjustment plate 22 for adjusting the air volume of the conditioned air CA blown from the air outlet 21 into the vehicle compartment 1 is fixed to the upper step portion 232 of the stepped fitting 23 attached near the air outlet 21 of the ceiling panel 2. The air volume adjustment plate 22 includes a vertical plate 22T that stands vertically and a bent plate 22K that is connected to the vertical plate 22T and bends at a right angle, forming two upper and lower air reservoirs. An air volume adjustment hole 221 of an appropriate size is formed in the horizontal portion of the bent plate 22K. In addition, a second air volume adjustment plate 233 having punching holes of an appropriate size formed therein is screwed from below to the upper step portion 232 of the stepped fitting 23. The second air volume adjustment plate 233 can be easily attached and replaced, and the air volume can be adjusted in the vehicle. In this way, by forming two upper and lower air reservoirs and making the air volume adjustable in two upper and lower stages, the air volume of the conditioned air CA blown from the air outlet 21 into the vehicle compartment 1 can be adjusted more subtly. As a result, the comfort in the vehicle compartment 1 can be further improved.

[0037] Also, in this railway vehicle 10, as shown in FIG. 6, it is preferable that the lightweight material KS constituting the upper duct portion 3 is a material in which glass wool material GW obtained by laminating and fixing glass fibers GS to a predetermined thickness is coated with a metal foil 32a. As the metal foil 32a, for example, an aluminum foil or the like can be used. In this case, in the upper duct portion 3, while ensuring the required rigidity, the weight can be further reduced, and the sound absorption and heat insulation properties can be further improved. Further, by coating the glass wool material GW with the metal foil 32a, penetration of moisture into the glass wool material GW can be prevented, and generation of mold or the like can be suppressed. Furthermore, the flame retardancy of the upper duct portion 3 can be improved, and a railway vehicle 10 with even higher safety can be provided.

[0038] Also, in this railway vehicle 10, as shown in FIGS. 3 and 4, the other inner frame YK2 is formed in a hat cross section with a flange having a horizontal flange portion YK21 at the lower end. On the upper surface of the flange portion YK21, the lower end portion 3T2 of the vertical wall portion 3T is airtightly adhered via a first seal member 41, and on the lower surface of the flange portion YK21, the ceiling panel 2 is airtightly adhered via a second seal member 42, which is preferable. As the first seal member 41 and the second seal member 42, for example, a foamed seal material made of a strip-shaped ethylene propylene rubber or the like can be used. Here, the second seal member 42 is adhered to the upper step portion 232 of the stepped fitting 23 attached near the outlet 21 of the ceiling panel 2, and the ceiling panel 2 is airtightly adhered to the lower surface of the flange portion YK21 via the second seal member 42. In this case, the upper duct portion 3 and the ceiling panel 2 divided vertically can be airtightly adhered to each other with the flange portion YK21 of the other inner frame YK2 interposed therebetween. Therefore, while enhancing the sealing performance of the air-conditioning duct KD, simplification of the mounting work when mounting the air-conditioning duct KD to the roof structure YK can be achieved.

[0039] In addition, in this railway vehicle 10, as shown in FIGS. 2, 5 to 7, it is preferable that the upper duct portion 3 is formed with a predetermined length L1, L2 in the same hat cross section and is formed so as to be connectable in series in the vehicle longitudinal direction. Here, as shown in FIGS. 2 and 5, the lengths L1, L2 of the upper duct portions 3, 3 connected in series in the vehicle longitudinal direction are the same, but they may be formed with different lengths. In this case, by preparing a plurality of the same type of upper duct portions 3, it is possible to correspond to the railway vehicle 10 provided with the vehicle compartments 1 of various lengths. Therefore, while contributing to cost reduction, it is possible to reduce the weight of the air-conditioning duct KD, improve the quietness in the vehicle compartment 1, and simplify the attachment work to the roof structure YK.

[0040] In addition, when connecting a plurality of upper duct portions 3, 3 in series in the vehicle longitudinal direction, as shown in FIG. 6, the longitudinal ends of both in the vehicle longitudinal direction are connected by a seal adhesive 34, and a receiving plate 35 that abuts on the outer surface of the other upper duct portion 3 is preferably attached in advance to the longitudinal end of one upper duct portion 3 in the vehicle longitudinal direction. In this case, after fixing the other upper duct portion 3 to the other inner frame YK2, when fixing one upper duct portion 3 to the other inner frame YK2, the longitudinal end of the other upper duct portion 3 is pressed by the receiving plate 35 attached to one upper duct portion 3, and the floating of the other upper duct portion 3 can be prevented. Thereby, a plurality of upper duct portions 3, 3 can be more stably connected in series in the vehicle longitudinal direction.

[0041] In addition, when connecting a plurality of upper duct portions 3, 3 in series in the vehicle longitudinal direction, as shown in FIG. 7, it is preferable to connect the intermediate portions 3Y1, 3Y1 in the vehicle width direction of the transverse wall portions 3Y, 3Y with a metal tape 33. Here, the metal tape 33 is attached to the upper and lower surfaces of the intermediate portions 3Y1, 3Y1 in the vehicle width direction of the transverse wall portions 3Y, 3Y, but the metal tape 33 may be attached to either one. Thereby, the sagging, vibration and noise of the intermediate portion 3Y1 in the vehicle width direction of the transverse wall portion 3Y can be further suppressed. In addition, when connecting the upper duct portion 3 in series in the vehicle longitudinal direction with another member (for example, the connecting duct 3S), as shown in FIG. 5, it is also preferable to connect the intermediate portion 3Y1 in the vehicle width direction of the transverse wall portion 3Y and the other member with a metal tape 33.

[0042] <Method for manufacturing a railway vehicle> Next, a method for manufacturing a railway vehicle according to another embodiment of the present invention will be described in detail with reference to the drawings. FIG. 8 shows a flowchart diagram in the method for manufacturing a railway vehicle according to this other embodiment.

[0043] As shown in FIGS. 1 to 8, the method for manufacturing the railway vehicle 10 includes a ceiling panel 2 provided with an air conditioner KT on a roof structure YK and having an air outlet 21 for blowing conditioned air CA supplied from the air conditioner KT into the vehicle compartment 1, and an upper duct portion 3 having a hat cross-section disposed above the ceiling panel 2. The method for manufacturing the railway vehicle 10 includes an upper duct fixing step S1 in which the upper duct portion 3 is formed of a lightweight material KS in which air layers 31 are dispersedly arranged, and a hat cross-section is formed by a pair of vertical wall portions 3T and a horizontal wall portion 3Y extending between the vertical wall portions 3T. The middle portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y is fixed to one inner bone YK1 of the roof structure YK, and the vertical wall portions 3T are fixed to the other inner bone YK2. After the upper duct fixing step S1, there is a ceiling panel fixing step S2 of fixing the ceiling panel 2 to the other inner bone YK2. Since each component of the railway vehicle 10 is common to the content already described in detail, here, except when necessary, it is omitted as a rule.

[0044] [[ID=I3]]In the method for manufacturing the railway vehicle 10, since the upper duct portion 3 is formed of a lightweight material KS in which air layers 31 are dispersedly arranged, and a hat cross-section is formed by a pair of vertical wall portions 3T and a horizontal wall portion 3Y extending between the vertical wall portions 3T, weight reduction can be improved while ensuring required rigidity. Further, in the upper duct fixing step S1, since the middle portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y is fixed to one inner bone YK1 of the roof structure YK, sagging, vibration, and noise of the middle portion 3Y1 can be suppressed. Further, since the air layers 31 are dispersedly arranged inside the upper duct portion 3, the noise transmitted through the air conditioning duct KD can be absorbed by the dispersedly arranged air layers 31, and the heat transmitted from the roof structure YK can be effectively blocked. Therefore, the quietness in the vehicle compartment 1 can be enhanced, and a comfortable room temperature can be maintained.

[0045] Also, after the upper duct fixing step S1 of fixing the intermediate portion 3Y1 in the vehicle width direction of the transverse wall portion 3Y to one inner frame YK1 of the roof structure YK and fixing the longitudinal wall portion 3T to the other inner frame YK2, in the ceiling panel fixing step S2, the ceiling panel 2 is fixed to the other inner frame YK2. Therefore, when fixing the upper duct portion 3 to one inner frame YK1 and the other inner frame YK2 of the roof structure YK, it is not obstructed by the ceiling panel 2, and the installation work of the air-conditioning duct KD to the roof structure YK can be simplified. Thus, according to the manufacturing method of the railway vehicle 10, the weight of the air-conditioning duct KD provided in the ceiling can be reduced, the quietness in the vehicle compartment 1 can be improved, and the installation work of the air-conditioning duct KD to the roof structure YK can be simplified. Needless to say, the railway vehicle 10 and its manufacturing method can be changed into various forms without changing the gist of the present invention.

[0046] <Operational effects> As described in detail above, according to the railway vehicle 10 according to the present embodiment, the upper duct portion 3 is formed of a lightweight material KS in which the air layers 31 are dispersedly arranged inside, and the hat cross section is formed by a pair of longitudinal wall portions 3T and a transverse wall portion 3Y extending between the longitudinal wall portions 3T. Therefore, while ensuring the required rigidity, the weight reduction can be improved. Further, since the intermediate portion 3Y1 in the vehicle width direction of the transverse wall portion 3Y is fixed to one inner frame YK1 of the roof structure YK, the sagging, vibration, and noise of the intermediate portion 3Y1 can be suppressed. Further, since the air layers 31 are dispersedly arranged inside the upper duct portion 3, the noise transmitted through the air-conditioning duct KD can be absorbed by the dispersedly arranged air layers 31, and the heat transmitted from the roof structure YK can be effectively blocked. Therefore, the quietness in the vehicle compartment 1 can be enhanced, and a comfortable room temperature can be maintained.

[0047] Further, the transverse wall portion 3Y is fixed to one inner frame YK1 of the roof structure YK at the intermediate portion 3Y1 in the vehicle width direction, and the longitudinal wall portion 3T and the ceiling panel 2 are separately fixed to the other inner frame YK2 of the roof structure YK in the vertical direction. Therefore, after fixing the upper duct portion 3 to one inner frame YK1 and the other inner frame YK2 of the roof structure YK, the ceiling panel 2 can be fixed to the other inner frame YK2 of the roof structure YK. Therefore, when fixing the upper duct portion 3 to one inner frame YK1 and the other inner frame YK2 of the roof structure YK, it is not obstructed by the ceiling panel 2, and the installation work of the air-conditioning duct KD to the roof structure YK can be simplified.

[0048] Therefore, according to the present embodiment, it is possible to provide a railway vehicle 10 that can reduce the weight of the air-conditioning duct KD provided in the ceiling space, improve the quietness in the vehicle compartment 1, and simplify the installation work of the air-conditioning duct KD to the roof structure YK.

[0049] Further, according to the present embodiment, the lightweight material KS is a material in which a glass wool material GW in which glass fibers GS are laminated and fixed to a predetermined thickness is covered with a metal foil 32a. Therefore, in the upper duct portion 3, while ensuring the required rigidity, the weight can be reduced, the sound absorption performance, and the heat insulation performance can be further improved. Further, by covering the glass wool material GW with the metal foil 32a, the penetration of moisture into the glass wool material GW can be prevented, and the generation of mold and the like can be suppressed. Furthermore, the flame retardancy of the upper duct portion 3 can be improved, and a railway vehicle 10 with higher safety can be provided.

[0050] Further, according to the present embodiment, the other inner frame YK2 is formed in a hat cross section with a flange portion YK21 at the lower end, and on the upper surface of the flange portion YK21, the lower end portion 3T2 of the longitudinal wall portion 3T is airtightly adhered via the first seal member 41, and on the lower surface of the flange portion YK21, the ceiling panel 2 is airtightly adhered via the second seal member 42. Therefore, the upper duct portion 3 and the ceiling panel 2 divided into upper and lower parts can be airtightly adhered with the flange portion YK21 of the other inner frame YK2 interposed therebetween. Therefore, while enhancing the sealing performance of the air-conditioning duct KD, the installation work to the roof structure YK can be simplified.

[0051] Further, according to the present embodiment, since the upper duct portion 3 is formed with a predetermined length L1 and L2 in the same hat cross section and is formed so as to be connectable in series in the vehicle longitudinal direction, by preparing a plurality of the same type of upper duct portions 3, it is possible to correspond to railway vehicles 10 having vehicle compartments 1 of various lengths. Therefore, while contributing to cost reduction, it is possible to reduce the weight of the air-conditioning duct KD, improve the quietness in the vehicle compartment 1, and simplify the attachment work to the roof structure YK.

[0052] Further, according to another embodiment of the manufacturing method of the present railway vehicle 10, the upper duct portion 3 is formed of a lightweight material KS in which air layers 31 are dispersedly arranged inside, and a hat cross section is formed by a pair of vertical wall portions 3T and a horizontal wall portion 3Y extending between the vertical wall portions 3T. Therefore, while ensuring the required rigidity, it is possible to improve the weight reduction. Further, in the upper duct fixing step S1, since the intermediate portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y is fixed to one inner bone YK1 of the roof structure YK, it is possible to suppress the sagging and vibration noise of the intermediate portion 3Y1. Further, since the air layers 31 are dispersedly arranged inside the upper duct portion 3, the noise transmitted through the air-conditioning duct KD can be absorbed by the dispersedly arranged air layers 31, and the heat transmitted from the roof structure YK can be effectively blocked. Therefore, the quietness in the vehicle compartment 1 can be enhanced and a comfortable room temperature can be maintained.

[0053] Further, after the upper duct fixing step S1 of fixing the intermediate portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y to one inner bone YK1 of the roof structure YK and fixing the vertical wall portion 3T to the other inner bone YK2, in the ceiling panel fixing step S2, since the ceiling panel 2 is fixed to the other inner bone YK2, when the upper duct portion 3 is fixed to one inner bone YK1 and the other inner bone YK2 of the roof structure YK, it is not obstructed by the ceiling panel 2, and the attachment work of the air-conditioning duct KD to the roof structure YK can be simplified.

[0054] Therefore, according to this other embodiment, it is possible to provide a manufacturing method of a railway vehicle 10 that can reduce the weight of the air-conditioning duct KD provided in the ceiling space, improve the quietness in the vehicle compartment 1, and simplify the attachment work to the roof structure YK.

Industrial Applicability

[0055] The present invention can be used as a railway vehicle equipped with an air-conditioning duct in the ceiling space and a method for manufacturing the same.

Explanation of Signs

[0056] 1 Vehicle compartment 2 Ceiling panel 3 Upper duct part 3T Vertical wall part 3T2 Lower end part 3Y Horizontal wall part 3Y1 Intermediate part 10 Railway vehicle 21 Air outlet 31 Air layer 32a Metal foil 41 First seal member 42 Second seal member CA Conditioned air [[ID=G37]]GS Glass fiber GW Glass wool material KD Air-conditioning duct KS Lightweight material KT Air conditioner S1 Upper duct fixing process S2 Ceiling panel fixing process YK Roof structure YK1, YK2 Inner frame [[ID=5,4]] YK21 Flange part

Claims

1. A railway vehicle having an air-conditioning duct provided in a ceiling space, the air-conditioning duct including a ceiling panel formed with an air outlet for blowing conditioned air supplied from an air conditioner into a vehicle interior, and an upper duct portion having a hat-shaped cross section disposed above the ceiling panel, wherein: the upper duct portion is formed of a lightweight material in which air layers are dispersedly arranged therein, and has a hat-shaped cross section formed by a pair of vertical wall portions and a horizontal wall portion extending between the vertical wall portions; the horizontal wall portion is fixed to one inner frame of the roof structure at an intermediate portion in the vehicle width direction; the vertical wall portion and the ceiling panel are separately fixed to another inner frame of the roof structure, one above the other.

2. The railway vehicle according to claim 1, wherein: the lightweight material is a material in which a glass wool material obtained by laminating and fixing glass fibers to a predetermined thickness is covered with a metal foil.

3. The railway vehicle according to claim 1, wherein: the other inner frame is formed in a hat-shaped cross section with a horizontal flange portion at a lower end; a lower end portion of the vertical wall portion is airtightly adhered to an upper surface of the flange portion via a first seal member; the ceiling panel is airtightly adhered to a lower surface of the flange portion via a second seal member.

4. The railway vehicle according to any one of claims 1 to 3, wherein: the upper duct portion is formed to have a predetermined length with the same hat-shaped cross section, and is formed to be connectable in series in the vehicle longitudinal direction.

5. A method for manufacturing a railway vehicle having an air-conditioning duct provided in a ceiling space, the air-conditioning duct including a ceiling panel formed with an air outlet for blowing conditioned air supplied from an air conditioner into a vehicle interior, and an upper duct portion having a hat-shaped cross section disposed above the ceiling panel, the method including: an upper duct forming step of forming the upper duct portion with a lightweight material in which air layers are dispersedly arranged therein, the upper duct portion having a hat-shaped cross section formed by a pair of vertical wall portions and a horizontal wall portion extending between the vertical wall portions; an upper duct fixing step of fixing an intermediate portion in the vehicle width direction of the horizontal wall portion to one inner frame of the roof structure, and fixing the vertical wall portion to another inner frame; and a ceiling panel fixing step of fixing the ceiling panel to the other inner frame after the upper duct fixing step.

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