CN105415455A - 一种轨道车辆底板用纤维复合板及其制造方法 - Google Patents

一种轨道车辆底板用纤维复合板及其制造方法 Download PDF

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CN105415455A
CN105415455A CN201510948107.3A CN201510948107A CN105415455A CN 105415455 A CN105415455 A CN 105415455A CN 201510948107 A CN201510948107 A CN 201510948107A CN 105415455 A CN105415455 A CN 105415455A
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composite
layers
layer
rail vehicle
composite felt
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李延军
许斌
程大莉
何文
梁星宇
张晓冬
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Nanjing Forestry University
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Nanjing Forestry University
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    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27D—WORKING VENEER OR PLYWOOD
    • B27D1/00—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring
    • B27D1/04—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring to produce plywood or articles made therefrom; Plywood sheets
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Abstract

本发明是一种轨道车辆底板用纤维复合板及其制造方法，其结构是三层全为竹纤维束与化纤的复合毡，或以上下表层材料采用一层纵向纹理薄竹帘或一层木质单板，利用可持续且弹性模量高的竹纤维束和化纤复合而成，并采用高强化纤细线的上下穿插缝纫，可以大大提高复合底板的内结合强度、力学强度和耐疲劳性。通过采用三层分别加热、热粘合和冷却成型三段制造工艺，可通过固定压机生产连续长的轨道用车厢底板，具有内结合强度高、耐老化性能好、防腐性能好、耐疲劳性能好等优点，其各项性能指标符合轨道车辆工业的技术要求。

Description

一种轨道车辆底板用纤维复合板及其制造方法
技术领域
本发明涉及的是以多层复合纤维毡，来生产轨道车辆用底板及其制造方法，属木材工业中的人造板制造技术领域。
背景技术
车厢底板为车辆的主要承载体，轨道车辆要求底板具有较高的力学性能和抗冲击性能，外观美观并具有防腐性能、隔音性能和耐老化性能。现有的轨道车辆底板主要为桦木胶合板底板和铝蜂窝板，桦木胶合板车厢底板存在防腐性能差、隔音效果差和阻燃效果不佳的缺点，车辆制造厂难以接受；铝蜂窝板存在内层蜂窝与表层板之间的胶合面少，易剪切变形和凹陷等缺陷。本发明利用特制的竹纤维束和化纤，通过采用特殊的制造工艺，可制得轨道用车厢底板，具有内结合强度高、耐老化性能好、防腐性能好、耐疲劳性能好等优点，且可利用我国资源丰富的可持续竹纤维束，拓宽了底板用材的来源，具有深远的现实意义。
发明内容
本发明的目的是提供一种以多层复合纤维来生产轨道车辆底板及制造方法。利用弹性模量高的竹纤维束和化纤复合而成，通过采用高强化纤细线的上下穿插缝纫，可以大大提高复合底板的内结合强度、力学强度和耐疲劳性。且可通过固定压机生产连续长的板材。为了表层美观，可在纤维复合板外层覆贴一层PVC地板革，或铝合金板材。
本发明的技术解决方案：一轨道车辆底板用纤维复合板，其特征是由三层复合毡1构成，每层复合毡1由占总重量40～60%的竹纤维束与60～40%的化纤-聚丙烯纤维PP并在复合毡上用聚丙烯纤维PP细线进行上下穿插缝纫而成。
其制造方法，包括如下工艺步骤：
a、木质单板、薄竹帘分选和整理，木质单板含水率≤10%，根据所需单面涂胶，涂胶量160～180g/m2，陈化或低温干燥；并将薄竹帘干至含水率12%以下，经单面喷涂酚醛胶并经低温干燥到含水率18%以下；
b、复合毡的制造，将竹纤维束（40～60%）与化纤-聚丙烯纤维（PP）（60～40%）等制造为纤维毡，并将其用PP细线在毡上进行上下穿插缝纫好；
c、组坯和成型，将三层复合毡单独使用，三层复合毡在三块压板的最高温度分别为170～210℃、40～100℃、20～70℃，最高压力分别为0.5MPa、4.0MPa、4.0MPa的压力下分段进行连续加热、热粘合和冷却成型加工工序，每段的时间为3～12分钟，然后出来已成型的连续板材，按所需长度进行截断。如将三层复合毡和木质单板、薄竹帘等材料复合使用时，三层复合毡先在第一块的最高温度为170～210℃的热压板中加热，然后将三层复合毡和热风加热过的竹帘或单板组坯后，一起趁热将其放进第二块压板中热粘合和固化，温度和压力以及以后步骤同上。
本发明的优点：可有效地利用我国具有生长快、周期短、年年可择伐、持续利用时间长的竹材资源-竹纤维束，以及化纤、竹帘、单板等。将这些材料单独或复合使用，经科学的设计和合理的组合，可解决大批量生产出符合高速轨道车辆工业技术要求的新型底板的技术难题。以三层全为竹纤维束与化纤的复合毡；或以上下表层材料各采用一层纵向纹理薄竹帘、中间为三层竹纤维和化纤的复合毡，该纵向纹理薄竹帘的背面喷涂酚醛胶；或以上下表层材料各采用一层纵向纹理单板、中间为三层竹纤维和化纤的复合毡，该纵向纹理单板背面喷涂酚醛胶。为了表层美观，可在纤维复合板外层覆贴一层PVC地板革，或铝合金板，或环氧玻璃纤维板等。其强度、内结合强度、弹性模量等各项性能指标，都能完全符合轨道车辆厂底板的技术要求。
附图说明
附图1是轨道车辆底板用纤维复合板结构（实施例1）示意图。
附图2是轨道车辆底板用纤维复合板结构（实施例2）示意图。
附图3是轨道车辆底板用纤维复合板结构（实施例3）示意图。
附图4是一种轨道车辆底板用纤维复合板连续生产示意图。
图中：1是复合毡，复合毡为竹纤维束（40～60%）与化纤-聚丙烯纤维（PP）（60～40%）组成，并将其用PP细线在毡上进行上下穿插缝纫好,复合毡的厚度为8～30mm；2是纵向纹理薄竹帘，厚度为0.8～1.8mm，该纵向纹理薄竹帘与复合毡结合的一面喷涂酚醛胶；3是纵向纹理木质单板，厚度为0.8～1.8mm，该木质单板与复合毡结合的一面喷涂或辊涂酚醛胶。；4是定型压板；5是冷却压板；6是成型板材；7是加热板；8是油缸。
具体实施方式
对照附图1，其结构是由三层复合毡1构成，每层复合毡1由总重量40～60%的竹纤维束与60～40%的化纤-聚丙烯纤维PP，并用聚丙烯纤维PP细线在毡上进行上下穿插缝纫而成。
对照附图2，其结构是三层复合毡的上表层、下表层为纵向纹理薄竹帘2，所述的纵向纹理薄竹帘2与上表层、下表层上的复合毡的结合面喷涂酚醛胶，喷涂胶量为200g/m2，喷涂后经低温干燥到含水率12～18%；
对照附图3，其结构是三层复合毡的上表层、下表层为两层纵向纹理木质单板3，所述的纵向纹理木质单板3与上表层、下表层上的两层纵向纹理木质单板3与复合毡的结合面涂酚醛胶，胶量为180g/m2，涂胶后经低温干燥到含水率12～18%；
实施例1：
如图1所示，
轨道车辆底板用纤维复合板的制造方法如下：
a、复合毡，将竹纤维束45%与化纤-聚丙烯纤维（PP）55%制造为12mm纤维毡，并将其用PP细线在毡上进行上下穿插缝纫好；
b、组坯和成型，将三层复合毡在三块压板的最高温度分别为190℃、60℃、50℃，最高压力为0.2MPa、3.0MPa、3.0MPa的压力下分段进行连续加热、热粘合和冷却成型加工工序，每段的时间均为9分钟，然后出来已成型的连续板材，按所需长度进行截断。
经常规后期加工后，即可得到成品为18mm轨道车辆底板用纤维复合板，其物理力学性能如下：
MOR∥：≥25MPa
MOR⊥：≥25MPa
MOE∥：≥3000MPa
MOE⊥：≥3000MPa
密度：0.70～0.85g/cm3。
实施例2：
如图2所示，
轨道车辆底板用纤维复合板的制造方法如下：
a、竹帘分选和整理，将1.2mm厚的薄竹帘干至含水率10%以下，经单面喷涂酚醛胶并经低温干燥到含水率18%以下；
b、复合毡，将竹纤维束50%与化纤-聚丙烯纤维（PP）50%制造为10mm纤维毡，并将其用PP细线在毡上进行上下穿插缝纫好；
c、组坯和成型，将三层复合毡经过200℃第一道加热板7进行加热8分钟，在进入第二块定型压板4时，将已经经过热风加热到80℃的薄竹帘放置于三层复合毡的上下表面，与芯层接触的一面有酚醛胶，然后一同进入第二块定型压板4，在3MPa的压力下，在芯层复合毡的热量下，将表层竹帘和复合毡牢固地结合在一起，同时三层复合毡也在融熔状态下经过8分钟结合在一起；然后设备的上压板同时抬起，板坯共同进入第三块冷却压板5，在第三块冷却压板的温度30℃，最高压力为3.0MPa的压力下冷却成型，经过8分钟的冷却定型，设备冷却上压板抬起，此时出来的已是成型的连续板材6，按所需长度进行截断。
经常规后期加工后，即可得到成品为18mm轨道车辆底板用纤维复合板，其物理力学性能如下：
MOR∥：≥60MPa
MOR⊥：≥25MPa
MOE∥：≥5000MPa
MOE⊥：≥2500MPa
密度：0.75～0.90g/cm3。
实施例3，
轨道车辆底板用纤维复合板的结构如图3，
轨道车辆底板用纤维复合板的制造方法如下：
a、木质单板分选和整理，木质单板含水率≤10%，单面涂胶，涂胶量160～180g/m2，陈化或低温干燥至表干；
b、复合毡，将竹纤维束50%与化纤-聚丙烯纤维（PP）50%制造为10mm纤维毡，并将其用PP细线在毡上进行上下穿插缝纫好；
c、组坯和成型，将三层复合毡经过200℃第一道加热板7进行加热8分钟，在进入第二块定型压板4时，将已经经过热风加热到80℃的木质单板放置于三层复合毡的上下表面，与芯层接触的一面有酚醛胶，然后一同进入第二块定型压板4，在3MPa的压力下，在芯层复合毡的热量下，将表层单板和复合毡牢固地结合在一起，同时三层复合毡也在融熔状态下经过8分钟结合在一起；然后设备的上压板同时抬起，板坯共同进入第三块冷却压板5，在第三块冷却压板5的冷却水温度40℃以下，最高压力为3.0MPa的压力下冷却成型，经过8分钟的冷却定型，设备上压板抬起，此时出来的已是成型的连续板材6，按所需长度进行截断。
经常规后期加工后，即可得到成品为18mm轨道车辆底板用纤维复合板，其物理力学性能如下：
MOR∥：≥45MPa
MOR⊥：≥25MPa
MOE∥：≥5000MPa
MOE⊥：≥2500MPa
密度：0.75～0.90g/cm3。

Claims (9)

1.轨道车辆底板用纤维复合板，其特征是由三层复合毡构成，每层复合毡1由占总重量40～60%的竹纤维束与60～40%的化纤-聚丙烯纤维PP构成，并在复合毡上用聚丙烯纤维PP细线进行上下穿插缝纫而成。
2.根据权利要求1所述的轨道车辆底板用纤维复合板，其特征是所述的三层复合毡的上表层、下表层为纵向纹理薄竹帘，该纵向纹理薄竹帘与上表层、下表层上的复合毡的结合面喷涂酚醛胶，喷涂胶量为200g/m2，喷涂后经低温干燥到含水率12～18%。
3.根据权利要求1所述的轨道车辆底板用纤维复合板，其特征是所述的三层复合毡的上表层、下表层为两层纵向纹理木质单板，所述纵向纹理木质单板与上表层、下表层上的两层纵向纹理木质单板与复合毡的结合面喷涂酚醛胶，胶量为180g/m2，涂胶后经低温干燥到含水率12～18%。
4.根据权利要求1～3所述的轨道车辆底板用纤维复合板，其特征是所述的纤维复合板的上下各覆贴一层薄竹帘，或一层PVC地板革，或一层铝合金板面层。
5.根据权利要求1～3所述的轨道车辆底板用纤维复合板，其特征是所述的复合毡的厚度为8～30mm。
6.根据权利要求2所述的轨道车辆底板用纤维复合板，其特征是所述的纵向纹理薄竹帘，厚度为0.8～1.8mm。
7.根据权利要求3所述的轨道车辆底板用纤维复合板，其特征是所述的纵向纹理木质单板，厚度为0.8～1.8mm。
8.根据权利要求1所述的轨道车辆底板用纤维复合板，其特征是所述的竹纤维束可换成麻纤维，聚丙烯纤维也可是丙纶、涤纶。
9.如权利要求1～3的轨道车辆底板用纤维复合板的制造方法，其特征是该方法包括如下工艺步骤：
a）木质单板、薄竹帘分选和整理，木质单板含水率≤10%，根据所需单面涂胶，涂胶量160～180g/m2，陈化或低温干燥；并将薄竹帘干至含水率10%以下，经单面喷涂酚醛胶并经低温干燥到含水率18%以下；
b）复合毡，将竹纤维束（40～60%）与化纤-聚丙烯纤维（PP）（60～40%）经开松、混合铺装以及上下针刺成纤维毡，并用PP细线将纤维毡进行上下穿插缝纫；
c）组坯和成型，将三层复合毡单独使用，三层复合毡在三块压板的温度分别为170～210℃、40～100℃、20～70℃，力分别为0.5MPa、4.0MPa、4.0MPa的压力下分段进行连续加热、热粘合和冷却成型，每段的时间为3～12分钟，成型后的连续板材，按所需长度进行截断；
d)三层复合毡和木质单板、薄竹帘材料复合使用时，三层复合毡先在第一块的温度为170～210℃的热压板中加热，然后将三层复合毡和热风加热过的竹帘或单板组坯后，一起放进第二块压板中热粘合和固化，重复步骤c）至n块压板,n=3。
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