Railway vehicle and manufacturing method thereof

Abstract

To provide a railway car and its manufacturing method capable of reducing the weight of an air conditioning duct provided in the ceiling space, improving the quietness in a car cabin, and simplifying the work of mounting the duct to a roof structure. [Solution] A railway car 10 is provided with an air conditioning duct KD in the ceiling space, the air conditioning duct KD having an air conditioning unit KT mounted on a roof structure YK, a ceiling panel 2 formed with an outlet 21 for blowing conditioned air supplied from the air conditioning unit into a vehicle compartment 1, and an upper duct section 3 with a hat-shaped cross section arranged above the ceiling panel. The upper duct section is formed of a lightweight material KS with air layers 31 distributed inside, and the hat-shaped cross section is formed by a pair of vertical wall sections 3T and a horizontal wall section 3Y extending between the vertical wall sections. The horizontal wall section is fixed to one inner frame YK1 of the roof structure at a middle section 3Y1 in the vehicle width direction, and the vertical wall section and the ceiling panel are fixed separately above and below to the other inner frame YK2 of the roof structure.

Description

[Technical field]

[0001] The present invention relates to a railway vehicle and a manufacturing method thereof, and more particularly to a railway vehicle equipped with an air conditioning duct above the ceiling and a manufacturing method thereof. [Background technology]

[0002] Conventionally, a ceiling duct unit has been known for an air conditioning duct installed in the ceiling of a railway vehicle, in which a ceiling panel and an upper duct section formed with a hat cross section are integrally connected to each other. This ceiling duct unit has a length of, for example, about 2 to 3 meters, and therefore it is necessary to ensure a certain rigidity when mounting it on the roof structure of the railway vehicle and when transporting it, and therefore a reinforcing plate is generally attached to the upper duct section. However, a ceiling duct unit with a reinforcing plate attached increases the vehicle weight by the amount of the reinforcing plate, which goes against the needs for reducing the weight and lowering the center of gravity of railway vehicles.

[0003] In this regard, for example, Patent Document 1 discloses a railway vehicle 100 equipped with a ceiling duct unit 100Y without a reinforcing plate. As shown in FIG. 9, the ceiling duct unit 100Y has a structure in which a hat-shaped upper plate 104 made of reinforced plastic is attached to the back surface of a ceiling plate 101 made of reinforced plastic. The ceiling plate 101 has a plurality of cold air outlet holes 102 and a plurality of protrusions 103 on the back surface, and a cold air passage 107, a cold air outlet hole 108, and a cold air reservoir 109 are formed between the upper plate 104 and the ceiling plate 101. The upper end of the upper plate 104 has mounting seats 105 that protrude laterally from both sides and are attached to a framework 106 of the roof structure, and both ends of the ceiling plate 101 are sandwiched between a fascia board 111 and fixed to another framework 112. Lighting fixtures 110 are attached near both ends of the ceiling plate 101. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Utility Model Application Publication No. 7-8143 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the ceiling duct unit 100Y of the railway vehicle 100 of the above-mentioned Patent Document 1 has the following problems. That is, since the above-mentioned ceiling duct unit 100Y has a hollow cross-section structure in which a hat-shaped upper plate 104 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 the middle part sagging or vibration noise. Therefore, there is a problem that it is not preferable for reducing the weight of the upper plate 104 and for quietness in the vehicle cabin. In addition, since the structure is such that both ends of the ceiling plate 101 are sandwiched between the fascia boards 111 and fixed to another framework 112, when the mounting seat 105 of the upper plate 104 is attached to the framework 106 of the roof structure, there is a problem that both ends of the ceiling plate 101 located below get in the way, making the installation work complicated.

[0006] The present invention has been made to solve such problems, and aims to provide a railway vehicle and a manufacturing method thereof that can reduce the weight of air conditioning ducts installed in the ceiling, improve quietness inside the vehicle cabin, and simplify the installation work to the roof structure. [Means for solving the problem]

[0007] In order to achieve the above object, a railway vehicle and a manufacturing method thereof according to the present invention have the following configuration. (1) A railway vehicle having an air conditioner installed in a roof structure, a ceiling panel having an outlet formed therein for blowing conditioned air supplied from the air conditioner into the vehicle cabin, and an air conditioning duct having an upper duct portion with a hat cross section disposed above the ceiling panel, The upper duct portion is formed of a lightweight material with air layers dispersed 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 side wall portion is fixed to one inner frame of the roof structure at a middle portion in a vehicle width direction, The vertical wall portion and the ceiling panel are fixed separately above and below to other inner frames of the roof structure.

[0008] In the present invention, the upper duct portion is formed of a lightweight material with air layers distributed 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, so that the required rigidity can be ensured while improving weight reduction. Also, since the middle portion of the horizontal wall portion in the vehicle width direction is fixed to one inner frame of the roof structure, sagging and vibration noise of the middle portion can be suppressed. Also, since the upper duct portion has air layers distributed therein, the distributed air layers can absorb noise transmitted within the air conditioning duct and can effectively block heat transmitted from the roof structure. As a result, the quietness of the vehicle interior can be increased and a comfortable room temperature can be maintained.

[0009] In addition, since the horizontal wall portion is fixed to one inner frame of the roof structure at its intermediate portion in the vehicle width direction, and the vertical wall portion and the ceiling panel are fixed separately at the top and bottom to the other inner frame of the roof structure, the ceiling panel can be fixed to the other inner frame of the roof structure after the upper duct portion is fixed to the one inner frame and the other inner frame of the roof structure. Therefore, when fixing the upper duct portion to the one inner frame and the other inner frame of the roof structure, it is not hindered by the ceiling panel, and the work of attaching 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 an air conditioning duct installed in the ceiling, improve quietness inside the vehicle cabin, and simplify the installation work to the roof structure.

[0011] (2) In the case of a railway vehicle as described in (1), The lightweight material is characterized in that it is a glass wool material in which glass fibers are laminated and fixed to a predetermined thickness, and is covered with metal foil.

[0012] In the present invention, the lightweight material is a material in which glass wool material, in which glass fibers are laminated and fixed to a predetermined thickness, is covered with metal foil, so that the upper duct portion can be made lighter, and its sound absorption and heat insulation properties can be further improved while ensuring the required rigidity. Also, by covering the glass wool material with metal foil, it is possible to prevent the penetration of moisture into the glass wool material, and to suppress the growth of mold and mildew. Furthermore, it is possible to improve the flame retardancy of the upper duct portion, and it is possible to provide a railway vehicle with even higher safety.

[0013] (3) In the case of a railway vehicle as described in (1) or (2), The other inner rib is formed in a brim-hat cross section having a horizontal brim at a lower end, a lower end 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 the underside of the flange via a second seal member.

[0014] In the present invention, the other inner frame is formed with a brim-shaped hat cross section having a horizontal brim at its lower end, the lower end of the vertical wall portion is airtightly bonded to the upper surface of the brim via a first seal member, and the ceiling panel is airtightly bonded to the lower surface of the brim via a second seal member, so that the upper duct portion, which is divided into upper and lower parts, and the ceiling panel can be airtightly bonded to each other with the brim of the other inner frame in between. This improves the sealing performance of the air conditioning duct while simplifying the installation work to the roof structure.

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

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

[0017] (5) A method for manufacturing a railway vehicle having an air conditioning duct in a ceiling space, the air conditioning duct having an air conditioner installed in a roof structure, a ceiling panel having an outlet formed therein for blowing conditioned air supplied from the air conditioner into a vehicle cabin, 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 with air layers dispersed 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, an upper duct fixing process of fixing an intermediate portion of the horizontal wall portion in a vehicle width direction to one inner frame of the roof structure and fixing the vertical wall portion to another inner frame; The method further comprises a ceiling panel fixing step of fixing the ceiling panel to the other inner frame after the upper duct fixing step.

[0018] In the present invention, the upper duct portion is formed of a lightweight material with air layers distributed 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, so that the required rigidity can be ensured while improving weight reduction. In addition, in the upper duct fixing step S1, the middle portion in the vehicle width direction of the horizontal wall portion is fixed to one inner frame of the roof structure, so that sagging and vibration noise of the middle portion can be suppressed. In addition, since the upper duct portion has air layers distributed therein, the distributed air layers can absorb noise transmitted through the air conditioning duct and can effectively block heat transmitted from the roof structure. As a result, the quietness of the vehicle interior can be increased and the room temperature can be maintained at a comfortable level.

[0019] In addition, after the upper duct fixing process in which the middle portion of the horizontal wall portion in the vehicle width direction is fixed to one inner frame of the roof structure and the vertical wall portion is fixed to the other inner frame, the ceiling panel is fixed to the other inner frame in the ceiling panel fixing process.Therefore, when the upper duct portion is fixed to the one inner frame and the other inner frame of the roof structure, it is not interfered with 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 for a railway vehicle that can reduce the weight of an air conditioning duct installed in the ceiling, improve quietness inside the vehicle cabin, and simplify the installation work to the roof structure. Effect 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 an air conditioning duct installed in the ceiling, improve quietness inside the vehicle cabin, and simplify the installation work to the roof structure. [Brief description of the drawings]

[0022] [Figure 1] 1 is a schematic side view of a railway vehicle according to one embodiment of the present invention. FIG. [Diagram 2] 2 is a cross-sectional view taken along the line AA in FIG. 1. [Diagram 3] 3 is a cross-sectional view of FIG. 2 shown in FIG. [Figure 4] FIG. 4 is an enlarged view of part C shown in FIG. [Diagram 5] FIG. 3 is an enlarged view of part D shown in FIG. [Figure 6] 6 is a cross-sectional view of FIG. 5 shown in E-E. [Figure 7] FIG. 6 is a cross-sectional view of the FF shown in FIG. [Figure 8] FIG. 11 is a flowchart of a method for manufacturing a railway vehicle according to another embodiment of the present invention. [Figure 9] FIG. 1 is a schematic cross-sectional view of a railway vehicle ceiling duct unit described in Patent Document 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] <Configuration of this railway vehicle> Next, a railway vehicle according to 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 embodiment of the present invention. Fig. 2 shows an AA cross-sectional view shown in Fig. 1. Fig. 3 shows a BB cross-sectional view shown in Fig. 2. Fig. 4 shows an enlarged view of C section shown in Fig. 3. Fig. 5 shows an enlarged view of D section shown in Fig. 2. Fig. 6 shows an E-E cross-sectional view shown in Fig. 5. Fig. 7 shows an FF cross-sectional view shown in Fig. 5.

[0024] As shown in Fig. 1, the railway vehicle 10 includes an underframe DW supported by a pair of front and rear bogies DS running on a rail RL, an end structure TK standing at the front and rear ends of the underframe DW, a side structure GK standing at both ends of the underframe DW, and a roof structure YK connected to the upper ends of the end structure TK and the side structure GK. The side structure GK is formed with side windows GM of various sizes, a passenger side door GT1 through which passengers get on and off, and a crew side door GT2 through which the driver and others get on and off. Underfloor equipment KZ is attached to the underframe DW. An air conditioner KT is attached to the roof structure YK. Here, one air conditioner KT is attached to the roof structure YK near the center of the vehicle longitudinal direction, but multiple air conditioners may be attached.

[0025] As shown in Figs. 1 to 3, the railway vehicle 10 is provided with an air conditioning duct KD in the ceiling space, the air conditioning duct KD having a ceiling panel 2 in which an air outlet 21 is formed to blow conditioned air CA from an air conditioner KT provided in the roof structure YK into the vehicle compartment 1, and an upper duct section 3 having a hat cross section, which is disposed above the ceiling panel 2. The ceiling panel 2 is made of a resin material or the like, and is shaped into a predetermined shape in the center of the ceiling. The ceiling panel 2 is also provided with an upwardly curved portion 2H that protrudes upward in an arc shape from both ends in the vehicle width direction where the air outlet 21 is formed, and a downwardly curved portion 2T that protrudes downward in an arc shape, which are formed at different positions in the vehicle longitudinal direction, thereby increasing the rigidity of the middle part of the ceiling panel 2 in the vehicle width direction. Therefore, the middle part of the ceiling panel 2 in the vehicle width direction is not connected to one inner frame YK1 of the roof structure YK. 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. A heat insulating material 25 is attached to the back surface of the ceiling panel 2. The heat insulating material 25 can also serve as a sound absorbing material. A lighting interior panel 6 having lighting fixtures (not shown) attached thereto is attached to the end of the ceiling panel 2 in the vehicle width direction, and a side ceiling panel 5 joined to the interior panel of the side structure GK is attached to the end of the lighting interior panel 6 in the vehicle width direction.

[0026] As shown in FIG. 2, the supply ports KT1 of the conditioned air CA supplied from the air conditioner KT are provided at two locations each at the front and rear of the vehicle, sandwiching a return port RG that returns the air in the vehicle cabin 1 to the air conditioner KT. The supply ports KT1 of the conditioned air CA are connected to the air conditioning duct KD, which is composed of the ceiling panel 2 and the upper duct part 3 with a hat cross section arranged above it, via a connecting duct 3S made of, for example, an aluminum alloy. The connecting duct 3S is formed in a special trapezoid shape in which the width dimension is expanded while bending from the two supply ports KT1 toward one air conditioning duct KD. The two supply ports KT1 may be integrated into one. The return port RG may be arranged outside the supply port KT1 in the vehicle width direction.

[0027] 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 distributed inside, and a hat cross section is formed by a pair of vertical wall portions 3T and a horizontal wall portion 3Y extending between upper ends 3T1 of the vertical wall portions 3T. Here, the lightweight material KS can be a fiber-based lightweight material formed by fixing glass fiber, carbon fiber, chemical fiber, plant fiber, etc. with an adhesive, or a foam-based lightweight material formed from hard foamed urethane, foamed aluminum, etc. Here, the lightweight material KS is shaped so that the front and back surfaces of the fiber-based lightweight material are covered with a metal skin material 32 and the pair of vertical wall portions 3T and the horizontal wall portion 3Y form a hat cross section. The thickness of the metal skin material 32 may be about several tens of microns to several hundreds of microns. When the lightweight material KS is a fiber-based lightweight material, the air layers 31 are distributed in the gaps between the fibers, and when the lightweight material KS is a foam-based lightweight material, the air layers 31 are distributed as bubbles.

[0028] As described above, the upper duct section 3 is formed from a lightweight material KS covered with a metal skin material 32 and has air layers 31 dispersed therein, and has a hat-shaped cross section formed by a pair of vertical wall sections 3T and a horizontal wall section 3Y extending between the vertical wall sections 3T, thereby making it possible to achieve weight reduction while ensuring the required rigidity.

[0029] As shown in Figs. 3 and 5, the intermediate portion 3Y1 of the side wall portion 3Y in the vehicle width direction is fixed to one inner frame YK1 of the roof structure YK. Here, the one inner frame YK1 is disposed in the center of the roof structure YK in the vehicle width direction and extends in the vehicle longitudinal direction. The intermediate portion 3Y1 of the side wall portion 3Y in the vehicle width direction is fixed to the one inner frame YK1 at a plurality of points in the vehicle longitudinal direction. Two screw members 381 are inserted from below into the intermediate portion (center portion) 3Y1 in the vehicle width direction of the side wall portion 3Y via a backing metal 382 and a collar member 384 with a flange, and the tip portion of the screw member 381 is engaged with a screw seat 383 of the one inner frame YK1. Since the collar member 384 with a flange is interposed, the lightweight material KS can be fastened without applying strong pressure, and even if the thickness of the lightweight material KS changes due to aging, the screw member 381 can be prevented from loosening. Although the engaging member may be a rivet member or the like, it is preferable to use a screw member 381 or the like, which can easily reduce deformation of the lightweight material KS by adjusting the amount of fastening.

[0030] As described above, the middle portion 3Y1 of the side wall portion 3Y in the vehicle width direction is fixed to one inner frame YK1 of the roof structure YK, so that sagging and vibration noise of the middle portion 3Y1 of the side wall portion 3Y in the vehicle width direction can be suppressed. In addition, the upper duct portion 3 has air layers 31 distributed inside, so that the distributed air layers 31 can absorb noise transmitted through the air conditioning duct KD and can effectively block heat transmitted from the roof structure YK. This increases the quietness in the vehicle cabin 1 and maintains a comfortable room temperature.

[0031] 3 to 5, the horizontal wall portion 3Y of the upper duct portion 3 is fixed to one inner frame YK1 of the roof structure YK at a middle portion 3Y1 in the vehicle width direction, and the vertical wall portion 3T of the upper duct portion 3 and the ceiling panel 2 are fixed separately at the top and bottom to another inner frame YK2 of the roof structure YK. Here, the other inner frame YK2 is disposed outward in the vehicle width direction from the first inner frame YK1, and includes a horizontal flange portion YK21, a side wall portion YK22, and a zenith portion YK23. The vertical wall portion 3T of the upper duct portion 3 and the ceiling panel 2 are fixed separately at the top and bottom to the flange portion YK21 of the other inner frame YK2.

[0032] Specifically, the vertical 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 metal fitting 36 attached to the outer surface of the vertical wall portion 3T using a backing metal 371 abutting against the inner surface of the vertical wall portion 3T and a screw member 372 inserted from the inner surface. A plurality of L-shaped metal fittings 36 are attached to the outer surface of the vertical wall portion 3T at predetermined intervals in the vehicle longitudinal direction. A spacer member 363 is inserted between the L-shaped metal fitting 36 and the flange portion YK21. 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 metal fitting 36. In addition, a screw seat 242 for fastening the ceiling panel 2 is fixed to the upper surface of the flange portion YK21 of the other inner frame YK2 at the same position in the vehicle width direction as the screw seat 362 fixed to the L-shaped metal fitting 36, but at a different position in the vehicle longitudinal direction.

[0033] The ceiling panel 2 is fixed from below to the flange YK21 of the other inner frame YK2 via a stepped metal fitting 23, the lower step 231 of which is fixed to the rear surface near the air outlet 21. The upper step 232 of the stepped metal fitting 23 is fixed to the flange 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 YK21.

[0034] Therefore, after the upper duct portion 3 is fixed to one inner frame YK1 and another 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 the upper duct portion 3 is fixed to the one inner frame YK1 and another inner frame YK2 of the roof structure YK, it is not hindered 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 the present railway vehicle 10, the weight of the air conditioning duct KD installed in the ceiling can be reduced, the quietness inside 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 airflow adjustment plate 22 for adjusting the volume of conditioned air CA blown from the airflow outlet 21 into the vehicle compartment 1 is fixed to the upper stage 232 of the stepped metal fitting 23 attached near the air outlet 21 of the ceiling panel 2. The airflow adjustment plate 22 is made up of a vertical plate 22T that stands upright and a bent plate 22K that is connected to the vertical plate 22T and bent at a right angle, forming two air pools, one above the other, and an airflow adjustment hole 221 of an appropriate size is formed in the horizontal part of the bent plate 22K. A second airflow adjustment plate 233 having a punched hole of an appropriate size is also screwed from below to the upper stage 232 of the stepped metal fitting 23. The second airflow adjustment plate 233 can be easily attached and replaced, and the airflow can be adjusted on the vehicle. In this way, by forming two air pools, one above and one below, and allowing the air volume to be adjusted in two levels, one above and one below, it is possible to more finely adjust the volume of the conditioned air CA blown into the vehicle cabin 1 from the air outlet 21. This makes it possible to further improve the comfort level inside the vehicle cabin 1.

[0037] In addition, in the present railway vehicle 10, as shown in FIG. 6, the lightweight material KS constituting the upper duct portion 3 is preferably 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. For example, an aluminum foil or the like can be used as the metal foil 32a. In this case, the upper duct portion 3 can be made lighter, and the sound absorbing and heat insulating properties can be further improved while ensuring the required rigidity. Furthermore, by covering the glass wool material GW with the metal foil 32a, it is possible to prevent the penetration of moisture into the glass wool material GW, and to suppress the occurrence of mold and the like. 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] In addition, in the present railway vehicle 10, as shown in Figs. 3 and 4, the other inner frame YK2 is formed in a brim-hat cross section having a horizontal brim YK21 at the lower end, and the lower end 3T2 of the vertical wall portion 3T is airtightly adhered to the upper surface of the brim YK21 via a first seal member 41, and the ceiling panel 2 is airtightly adhered to the lower surface of the brim YK21 via a second seal member 42. For the first seal member 41 and the second seal member 42, for example, a foam seal material made of a strip-shaped ethylene propylene rubber or the like can be used. Here, the second seal member 42 is attached to the upper step portion 232 of the stepped metal fitting 23 attached near the air outlet 21 of the ceiling panel 2, and the ceiling panel 2 is airtightly adhered to the lower surface of the brim YK21 via the second seal member 42. In this case, the upper duct portion 3, which is divided into upper and lower parts, and the ceiling panel 2 can be airtightly bonded to each other by sandwiching the flange portion YK21 of the other inner frame YK2. This improves the sealing performance of the air conditioning duct KD and simplifies the installation work when installing the air conditioning duct KD to the roof structure YK.

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

[0040] In addition, when multiple upper duct parts 3, 3 are connected in series in the vehicle longitudinal direction, it is preferable to connect the ends of both in the vehicle longitudinal direction with a seal adhesive 34 and to attach a support plate 35 that abuts on the outer surface of the other upper duct part 3 to the end of one upper duct part 3 in the vehicle longitudinal direction as shown in Fig. 6. In this case, after the other upper duct part 3 is fixed to the other inner frame YK2, when one upper duct part 3 is fixed to the other inner frame YK2, the end of the other upper duct part 3 in the vehicle longitudinal direction is pressed down by the support plate 35 attached to one upper duct part 3, so that the other upper duct part 3 can be prevented from floating up. This makes it possible to connect multiple upper duct parts 3, 3 in series in the vehicle longitudinal direction more stably.

[0041] In addition, when a plurality of upper duct parts 3, 3 are connected in series in the vehicle longitudinal direction, it is preferable to connect the intermediate parts 3Y1, 3Y1 of the lateral wall parts 3Y, 3Y in the vehicle width direction with a metal tape 33 as shown in FIG. 7. Here, the metal tape 33 is attached to the upper and lower surfaces of the intermediate parts 3Y1, 3Y1 of the lateral wall parts 3Y, 3Y in the vehicle width direction, but the metal tape 33 may be attached to either one of them. This can further suppress the sagging and vibration noise of the intermediate part 3Y1 of the lateral wall part 3Y in the vehicle width direction. Note that, even when the upper duct part 3 is connected in series to another member (for example, a connecting duct 3S) in the vehicle longitudinal direction, it is preferable to connect the intermediate part 3Y1 of the lateral wall part 3Y in the vehicle width direction with the other member with a metal tape 33 as shown in FIG. 5.

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

[0043] As shown in Figures 1 to 8, the manufacturing method for a railway car 10 is a manufacturing method for a railway car 10 in which an air conditioner KT is provided on a roof structure YK, a ceiling panel 2 having an outlet 21 formed therein for blowing conditioned air CA supplied from the air conditioner KT into the vehicle compartment 1, and an air conditioning duct KD disposed above the roof structure YK and having an upper duct portion 3 of a hat cross section, the upper duct portion 3 is formed of a lightweight material KS with an air layer 31 distributed therein, and a hat cross section is formed by a pair of vertical wall portions 3T and a horizontal wall portion 3Y extended between the vertical wall portions 3T, and the manufacturing method includes an upper duct fixing process S1 in which a middle portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y is fixed to one inner frame YK1 of the roof structure YK and the vertical wall portion 3T is fixed to the other inner frame YK2, and a ceiling panel fixing process S2 in which the ceiling panel 2 is fixed to the other inner frame YK2 after the upper duct fixing process S1. Each component of the railway vehicle 10 is the same as that already explained in detail, and therefore will not be described here in principle unless necessary.

[0044] In the manufacturing method of the present railway vehicle 10, the upper duct portion 3 is formed of a lightweight material KS with air layers 31 distributed therein, and a hat-shaped 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, so that the required rigidity can be secured while improving the weight reduction. In addition, in the upper duct fixing step S1, a middle portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y is fixed to one inner frame YK1 of the roof structure YK, so that sagging and vibration noise of the middle portion 3Y1 can be suppressed. In addition, since the upper duct portion 3 has air layers 31 distributed therein, the distributed air layers 31 can absorb noise transmitted through the air conditioning duct KD and can effectively block heat transmitted from the roof structure YK. Therefore, the quietness in the vehicle cabin 1 can be increased and a comfortable room temperature can be maintained.

[0045] In addition, after the upper duct fixing step S1 in which the intermediate portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y is fixed to one inner frame YK1 of the roof structure YK and the vertical wall portion 3T is fixed to the other inner frame YK2, the ceiling panel fixing step S2 fixes the ceiling panel 2 to the other inner frame YK2. Therefore, when the upper duct portion 3 is fixed to the one inner frame YK1 and the other inner frame YK2 of the roof structure YK, it is not hindered by the ceiling panel 2, and the installation work of the air conditioning duct KD to the roof structure YK can be simplified. Therefore, according to the manufacturing method of the present railway vehicle 10, it is possible to reduce the weight of the air conditioning duct KD provided in the ceiling space, improve the quietness in the vehicle cabin 1, and simplify the installation work of the air conditioning duct KD to the roof structure YK. It goes without saying that the present railway vehicle 10 and its manufacturing method can be modified in various ways without changing the gist of the present invention.

[0046] <Action and effect> According to the railway vehicle 10 according to the present embodiment described above in detail, the upper duct section 3 is formed of a lightweight material KS with air layers 31 distributed therein, and a hat-shaped cross section is formed by a pair of vertical wall sections 3T and a horizontal wall section 3Y extending between the vertical wall sections 3T, so that the required rigidity can be secured while improving weight reduction. In addition, since the middle section 3Y1 in the vehicle width direction of the horizontal wall section 3Y is fixed to one inner frame YK1 of the roof structure YK, sagging and vibration noise of the middle section 3Y1 can be suppressed. In addition, since the upper duct section 3 has air layers 31 distributed therein, the distributed air layers 31 can absorb noise transmitted through the air conditioning duct KD and can effectively block heat transmitted from the roof structure YK. Therefore, the quietness in the vehicle cabin 1 can be increased and the room temperature can be maintained at a comfortable level.

[0047] Furthermore, since the horizontal wall portion 3Y is fixed to one inner frame YK1 of the roof structure YK at an intermediate portion 3Y1 in the vehicle width direction, and the vertical wall portion 3T and the ceiling panel 2 are fixed separately at the top and bottom to 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 after the upper duct portion 3 is fixed to the one inner frame YK1 and the other inner frame YK2 of the roof structure YK. Therefore, when fixing the upper duct portion 3 to the one inner frame YK1 and the other inner frame YK2 of the roof structure YK, it is not hindered 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 this embodiment, a railway vehicle 10 can be provided that can reduce the weight of the air conditioning duct KD installed in the ceiling, improve quietness inside the vehicle compartment 1, and simplify the installation work of the air conditioning duct KD to the roof structure YK.

[0049] According to the present embodiment, the lightweight material KS is a material in which the glass wool material GW, in which the glass fibers GS are laminated and fixed to a predetermined thickness, is covered with the metal foil 32a, so that the upper duct portion 3 can be made lighter, and the sound absorbing and heat insulating properties can be further improved while ensuring the required rigidity. Also, by covering the glass wool material GW with the metal foil 32a, it is possible to prevent the penetration of moisture into the glass wool material GW, and to suppress the occurrence of mold and mildew. 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.

[0050] Furthermore, according to this embodiment, the other inner frame YK2 is formed with a brim-shaped hat cross section having a horizontal brim YK21 at its lower end, and the lower end 3T2 of the vertical wall portion 3T is airtightly adhered to the upper surface of the brim YK21 via a first seal member 41, and the ceiling panel 2 is airtightly adhered to the lower surface of the brim YK21 via a second seal member 42, so that the upper duct portion 3, which is divided into upper and lower parts, and the ceiling panel 2 can be airtightly adhered to each other with the brim YK21 of the other inner frame YK2 in between. This improves the sealing performance of the air conditioning duct KD while simplifying the installation work on the roof structure YK.

[0051] Furthermore, according to this embodiment, the upper duct portions 3 are formed with the same hat-shaped cross section and predetermined lengths L1, L2, and are formed so as to be connectable in series in the longitudinal direction of the vehicle, so that by preparing a plurality of the same type of upper duct portions 3, it is possible to accommodate railway vehicles 10 equipped with vehicle compartments 1 of various lengths. This contributes to cost reduction while reducing the weight of the air conditioning duct KD, improving quietness inside the vehicle compartment 1, and simplifying the installation work on the roof structure YK.

[0052] According to another embodiment of the manufacturing method for the railway vehicle 10, the upper duct portion 3 is formed of a lightweight material KS with air layers 31 distributed therein, and a hat-shaped 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, so that the required rigidity can be secured while improving the weight reduction. In addition, in the upper duct fixing step S1, the middle portion 3Y1 in the vehicle width direction of the horizontal wall portion 3Y is fixed to one inner frame YK1 of the roof structure YK, so that sagging and vibration noise of the middle portion 3Y1 can be suppressed. In addition, since the upper duct portion 3 has air layers 31 distributed therein, the distributed air layers 31 can absorb noise transmitted through the air conditioning duct KD and can effectively block heat transmitted from the roof structure YK. Therefore, the quietness in the vehicle cabin 1 can be increased and the room temperature can be maintained at a comfortable level.

[0053] Furthermore, after the upper duct fixing process S1 in which the middle portion 3Y1 of the horizontal wall portion 3Y in the vehicle width direction is fixed to one inner frame YK1 of the roof structure YK and the vertical wall portion 3T is fixed to the other inner frame YK2, the ceiling panel 2 is fixed to the other inner frame YK2 in the ceiling panel fixing process S2.Therefore, when the upper duct portion 3 is fixed to the one inner frame YK1 and the other inner frame YK2 of the roof structure YK, it is not hindered by the ceiling panel 2, and the installation work of the air conditioning duct KD to the roof structure YK can be simplified.

[0054] Therefore, according to this other embodiment, a manufacturing method for a railway vehicle 10 can be provided that can reduce the weight of the air conditioning duct KD installed in the ceiling, improve quietness inside the vehicle compartment 1, and simplify the installation work to the roof structure YK. [Industrial Applicability]

[0055] INDUSTRIAL APPLICABILITY The present invention can be used as a railway vehicle equipped with an air conditioning duct in the ceiling space and a manufacturing method thereof. [Explanation of symbols]

[0056] 1 Vehicle compartment 2 Ceiling Panel 3 Upper duct section 3T vertical wall section 3T2 bottom end 3Y side wall part 3Y1 middle part 10. Railroad cars 21 Air outlet 31 Air Layer 32a metal foil 41 First seal member 42 Second seal member CA Conditioned Air 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 internal bone YK21 Tsubabe

Claims

1. A railway vehicle having an air conditioner installed in a roof structure, a ceiling panel having an outlet formed therein for blowing conditioned air supplied from the air conditioner into a vehicle cabin, and an air conditioning duct having an upper duct portion having a hat cross section and disposed above the ceiling panel, The upper duct portion is formed of a lightweight material with air layers dispersed 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 side wall portion is fixed to one inner frame of the roof structure at a middle portion in a vehicle width direction, The vertical wall portion and the ceiling panel are fixed to other inner frames of the roof structure separately from each other at the top and bottom; The other inner rib is formed in a brim-hat cross section having a horizontal brim at a lower end, a vertical wall portion being fixed to the upper surface of the flange portion via an L-shaped metal fitting attached to its outer surface, and a ceiling panel being fixed to the flange portion from below via a stepped metal fitting having a lower step fixed to the back surface near the air outlet.

2. 2. The railway vehicle according to claim 1, The railway vehicle is characterized in that the lightweight material is a glass wool material made of glass fibers laminated to a predetermined thickness and covered with metal foil.

3. 2. The railway vehicle according to claim 1, 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 railroad vehicle is characterized in that the ceiling panel is airtightly adhered to an underside of the flange via a second seal member.

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

5. A method for manufacturing a railway vehicle having an air conditioning duct in a ceiling space, the air conditioning duct having an air conditioner provided on a roof structure, an air outlet formed in a ceiling panel for blowing conditioned air supplied from the air conditioner into a vehicle cabin, and an upper duct portion having a hat cross section and disposed above the ceiling panel, The upper duct portion is formed of a lightweight material with air layers dispersed 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, an upper duct fixing process of fixing an intermediate portion of the horizontal wall portion in a vehicle width direction 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. The other inner rib is formed in a brim-hat cross section having a horizontal brim at a lower end, a vertical wall portion being fixed to the upper surface of the flange portion via an L-shaped metal fitting attached to its outer surface, and a ceiling panel being fixed to the flange portion from below via a stepped metal fitting having a lower step fixed to the back surface near the air outlet.

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