Heat Resistant Rail Floor Assembly with Composite Fire Panel
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Solution Overview
Problem
Existing rail vehicle floor structures, often made of metallic materials like aluminum, fail to withstand high temperatures due to melting at around 660°C, necessitating the need for heat-resistant floor assemblies that can endure temperatures up to 850°C as per regulatory requirements.
Innovation Solution
A heat-resistant floor assembly for rail vehicles comprising a floor structure with a fire protection panel made of composite material, including a resin and woven fiber reinforcement layer, an insulation layer, and attachment assemblies with intumescent tape for enhanced fire resistance, where the composite material incorporates polyester resin, woven basalt fibers, and rock wool for improved thermal insulation and fire protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metallic floor structures (aluminum) are used, then the floor structure is lightweight and easy to manufacture, but it melts at around 660°C and cannot withstand temperatures as high as 850°C
Solution Approach 1:
The patent applies composite materials by combining a metallic floor structure with a fire protection panel made of composite material comprising resin and woven fiber reinforcement layer. This composite construction provides heat resistance up to 850°C while maintaining structural integrity, resolving the contradiction between temperature resistance and manufacturing ease.
Solution Approach 2:
The fire protection panel is nested underneath the metallic floor structure, creating a layered assembly where the metal floor provides structural support and the composite panel provides thermal protection. This nesting approach allows both materials to contribute their strengths without requiring complete replacement of the existing metallic structure.
2Temperature
If a fire protection panel made of composite material is added underneath the floor structure, then heat resistance is improved, but the device complexity and number of components increase
Solution Approach 1:
The fire protection panel is divided into a plurality of sub-panels that can be manufactured and installed separately. Each sub-panel is equipped with attachment assemblies that include threaded studs, nuts, and washers, allowing for modular installation underneath the floor structure. This segmentation reduces the complexity of handling and installing large single-piece panels.
Solution Approach 2:
The attachment assemblies are pre-installed on the sub-panels during manufacturing, with threaded studs protruding from the rear surface. This preliminary action allows for quick installation by simply fastening the pre-prepared sub-panels to the floor structure, reducing on-site assembly complexity.
3Ease of manufacture
If sub-panels are used to form the fire protection panel, then manufacturing and installation flexibility is improved, but gaps between adjacent sub-panels may compromise fire resistance
Solution Approach 1:
An intumescent tape is introduced as an intermediary material between adjacent sub-panels in overlapping regions. This tape serves as a sealant that prevents fire and smoke penetration through gaps. The intumescent property allows the tape to expand when exposed to heat, maintaining seal integrity even as the panel structure experiences thermal expansion.
Solution Approach 2:
The intumescent tape undergoes parameter change by expanding in volume when exposed to high temperatures. This expansion fills any gaps or voids that may develop between sub-panels during thermal events, maintaining the continuity of the fire protection barrier and ensuring reliable fire resistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides rail vehicles with effective heat-resistant properties, ensuring structural integrity and safety by maintaining integrity at high temperatures and preventing fire spread through the use of intumescent tape and composite materials with high fiber content.
Implementation Method 1
an intumescent tape interfaces between two adjacent sub-panels in the overlapping region
Implementation Method 2
a fire protection panel made of a composite material connected underneath the floor structure. The composite material may comprise: a resin; and a woven fiber reinforcement layer embedded within the resin
Implementation Method 3
The composite material may further comprise a woven basalt fiber layer
Implementation Method 4
The insulation layer may comprise rock wool
Data Source
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AI summary
The present document describes a heat resistant floor assembly 10 for a rail vehicle. The heat resistant floor assembly 10 comprising: a floor structure 12 and a fire protection panel 14 made of a composite material connected underneath the floor structure 12.