轨道客车用低成本阻燃复合材料裙板制造技术

Manufacturing Technology of Low-Cost Flame-Retardant Composite Apron for Railway Vehicles

为推进新型阻燃蜂窝夹层结构复合材料在轨道交通领域低成本高效制备,采用有限元仿真设计了一款全高度蜂窝夹层结构复合材料裙板,评估了不同克重国产化阻燃玻纤增强环氧树脂预浸料制备的蜂窝夹层结构裙板性能和直接成本、成型方式对成型裙板质量的影响、胶膜对蜂窝夹层结构复合材料阻燃性能的影响。结果表明:综合制造周期、模具成本、人工成本和设备成本,相比于模压工艺、真空袋压工艺成本较低。通过使用阻燃胶膜制备的夹层复合材料的燃烧热释放较普通胶膜得到显著延迟,改善复合材料的阻燃性能并减少燃烧有毒气体的释放。使用大克重的预浸料(EW600),会对复合材料的拉伸弹性模量产生约20%的劣化,但其压缩及层间剪切性能得到提高;裙板的单件质量为8.57 kg,较传统片状模塑料(SMC)工艺制备得到复合材料裙板实现了33.01%的减重,制造成本相当;裙板的直接成本为1033.37元/m^(2),较EW300的1208.4元/m^(2)降低了14.5%,在满足使用要求的基础上大克重预浸料的使用有助于进一步降低复合材料裙板的制造成本。总的来看,采用真空袋压工艺并选用大克重阻燃玻纤增强环氧树脂预浸料和阻燃胶膜,有助于轨道交通用蜂窝夹层结构复合材料的降本增效。

To promote the low-cost and efficient preparation of new flame retardant honeycomb sandwich structure composite materials in the field of rail transit,a kind of full-height honeycomb sandwich structure composite apron was designed by adopting finite element simulation.It was evaluated that the performance and direct cost of honeycomb sandwich structure composite apron prepared with domestic flame-retardant glass fiber reinforced epoxy resin prepreg with different weight,the influence of molding methods on the quality of molded apron and the effect of adhesive film on the flame retardancy of honeycomb sandwich structure composite.The results show that compared to the molding process,the vacuum bag pressing process has lower costs due to its comprehensive manufacturing cycle,mold cost,labor cost,and equipment cost.The combustion heat release of sandwich composite prepared by using flame-retardant adhesive film is significantly delayed compared to the ordinary adhesive film,improving the flame retardancy of the composite and reducing the release of toxic gases during combustion.The use of large-weight prepreg(EW600)can degrade the tensile modulus of the composite by about 20%,but compression and interlayer shear properties are improved.The single piece weight of the apron is 8.57 kg,which achieves a weight reduction of 33.01%compared to the composite apron prepared by traditional sheet molding compound(SMC)process,but the manufacturing cost is equivalent.The direct cost of the skirt board is 1033.37 RMB/m^(2),which is 14.5%lower than the 1208.4 RMB/m^(2)of EW300.On the basis of meeting the usage requirements,the use of large-weight prepreg can further reduce the manufacturing cost of composite apron.Overall,the use of vacuum bag pressing process,large-weight flame-retardant glass fiber reinforced epoxy resin prepreg and flame-retardant adhesive film can contribute to reduce costs and increase efficiency of honeycomb sandwich structure composite for rail transit.