CN108609054A - Compound ceiling of bus and preparation method thereof - Google Patents

Abstract

The invention discloses a bus composite ceiling and a preparation method thereof. The bus composite ceiling comprises: an outer skin, an inner core, an inner skin and an aluminum alloy edge sealing, wherein the outer skin, the inner core and the inner skin are sequentially arranged from top to bottom The outer skin, the inner core and the inner skin are all rectangular, and the edge banding wraps the four sides of the outer skin, the inner core and the inner skin. Compared with the common metal bus roof, the invention has the characteristics of low weight, good anti-corrosion performance, low manufacturing cost and the like. Compared with the traditional FRP structure, the material has no small molecule overflow under high temperature, and the invention has the characteristics of flame retardancy, environmental protection and no peculiar smell.

Description

Composite roof for bus and preparation method thereof

technical field

The invention relates to a bus composite roof and a preparation method thereof.

Background technique

Currently, bus roofs are generally welded by steel square tubes or aluminum profiles, filled with insulation materials and decorative materials. The structure is complex and the number of parts is large, which makes the overall weight of the bus remain high, and leads to many assembly processes and long assembly hours. Therefore, there is a need to improve the technology of the bus roof.

Contents of the invention

In order to solve the above technical problems, the present invention provides a bus composite roof and a preparation method thereof.

To achieve the above object, the present invention is achieved through the following technical solutions:

A bus composite roof, comprising: an outer skin, an inner core, an inner skin and an aluminum alloy edge banding, wherein the outer skin, the inner core and the inner skin are sequentially arranged from top to bottom and connected to each other, the outer skin, the inner Both the core and the inner skin are rectangular, and the edge banding wraps the four sides of the outer skin, the inner core and the inner skin.

According to one embodiment of the present invention, the outer skin and the inner skin are flame-retardant composite materials.

According to one embodiment of the present invention, the inner core is a honeycomb structure made of flame-retardant continuous fiber composite material. The continuous refers to the preparation of the whole board.

According to an embodiment of the present invention, the outer surface of the inner skin is provided with a first decorative film, and the outer surface of the outer skin is provided with a second decorative film.

According to an embodiment of the present invention, the first decorative film is made of flame-retardant PVC material, and the second decorative film is made of anti-ultraviolet and anti-aging material.

According to one embodiment of the present invention, the flame-retardant composite material and the flame-retardant continuous fiber composite material are composites of modified phenolic resin and fiber-reinforced composite material or composites of epoxy resin and fiber-reinforced composite material.

According to one embodiment of the present invention, the outer skin, the inner core and the inner skin are curved in the width direction to form an arc.

According to an embodiment of the present invention, the ceiling is provided with an air conditioner installation hole and a roof window installation hole, and the air conditioner installation hole and the roof window installation hole run through the inner skin, the inner core and the outer skin.

According to one embodiment of the present invention, the closure is an aluminum profile.

According to one embodiment of the present invention, the interconnection method of the outer skin, the inner core and the inner skin is cementing.

According to one embodiment of the present invention, the roof and the vehicle body are cemented.

A method for preparing the above-mentioned composite roof for buses, comprising the following steps: step 1, using autoclave molding to make an outer skin and an inner skin; step 2, placing the outer skin on a self-heating forming mold, and One end face is connected with the outer skin, and the inner skin is connected with the other end face of the inner core; step 3, using a sealing bag to seal the self-heating forming mold with the outer skin, inner core and inner skin therein, then heating the mold, and Vacuuming and pressing make the outer skin, the inner core and the inner skin tightly formed.

According to one embodiment of the present invention, the preparation method of the inner core includes the following steps: step 1, setting a mold, and setting a plurality of grooves at equal intervals on the mold, the grooves are in the shape of the lower half of a hexagon; step 2, placing The whole piece of flame-retardant fiber composite material is laid on the mold, and a hexagonal first pressing piece is set at the position corresponding to the groove, so that the whole piece of flame-retardant fiber composite material fits with the inner surface of the groove to form a semi-hexagonal shape; Step 3 1. Lay another whole layer of flame-retardant fiber composite material on the top of the first pressing piece, set a second pressing piece with the same shape as the first pressing piece at the gap between the first pressing pieces, and place the first pressing piece above the first pressing piece The entire flame-retardant fiber composite material is pressed into a half-hexagonal shape, which is combined with the half-hexagonal shape of the entire flame-retardant fiber composite material below to form a complete hexagonal shape; Step 4: Fix the two flame-retardant fiber composite materials to form an inner core .

According to one embodiment of the present invention, the connection between the inner core and the outer skin and between the inner core and the inner skin is realized by bonding.

According to one embodiment of the present invention, the four sides of the fastened outer skin, the inner core and the inner skin are bonded and sealed.

The present invention sets a three-layer structure so that the structure of the bus roof becomes simple. The material of the outer skin, the inner core and the inner skin is a composite of modified phenolic resin and fiber reinforced composite material, which can reduce the total weight of the bus roof. The first decorative film It plays the role of flame retardant, and the second decorative film plays the role of anti-ultraviolet and anti-aging. The air conditioner, escape window, battery pack module, monitoring probe, driver's electric fan, air conditioning duct, lighting and other components can be preset on the ceiling. The installation position saves the time and process of the final assembly. The roof is cemented on the car body with high-strength and high-elastic structural glue, which has high water leakage resistance, high shock absorption and noise reduction performance, and at the same time reduces the frequency and frequency of vehicle maintenance. The invention has the characteristics of light weight, flame retardancy, heat insulation, sound insulation, good rigidity, overall molding and environmental protection, no small molecule overflow, etc. Compared with the ordinary metal bus roof, the invention has low weight, good anti-corrosion performance and low manufacturing cost Features. Due to the use of internal and external flame-retardant composite skins and flame-retardant continuous fiber composite honeycomb cores, compared with the traditional glass fiber reinforced plastic structure, the material does not overflow small molecules at high temperatures, and the invention has the characteristics of flame retardancy, environmental protection and no peculiar smell.

Description of drawings

Fig. 1 is a structural diagram of the present invention;

Fig. 2 is a sectional view of the present invention;

Fig. 3 is an enlarged view of part P of Fig. 2;

Fig. 4 is the top view of Fig. 1;

Fig. 5 is the mold structure diagram of the preparation method of embodiment 2 inner core;

Fig. 6 is a schematic diagram of the preparation method of the inner core in Example 2.

Detailed ways

The present invention is described in detail below in conjunction with accompanying drawing:

Example 1

As shown in FIGS. 1 to 4 , the bus composite roof in this embodiment includes: an outer skin 1 , an inner core 2 , an inner skin 3 and an edge band 4 . Wherein, the outer skin 1, the inner core 2 and the inner skin 3 are arranged from top to bottom in turn, and are connected to each other, the outer skin 1, the inner core 2 and the inner skin 3 are all rectangular, and the edge banding 4 wraps the outer skin 1, The four sides of inner core 2 and inner skin 3. The outer surface of the inner skin 3 is provided with a first decorative film 5 , and the outer surface of the outer skin 1 is provided with a second decorative film 6 . The side connecting the inner skin 3 and the inner core 2 is the inner surface, and the other side is the outer surface; the side connecting the outer skin 1 and the inner core 2 is the inner surface, and the other side is the outer surface. The first decorative film 5 is flame-retardant PVC material, and the second decorative film 6 is anti-ultraviolet and anti-aging material. The material of the outer skin 1 and the inner skin 3 is a flame-retardant composite material. The inner core 2 is a honeycomb structure made of flame-retardant continuous fiber composite material. Flame-retardant composite materials and flame-retardant continuous fiber composite materials are composites of modified phenolic resin and fiber-reinforced composite materials or composites of epoxy resin and fiber-reinforced composite materials. The outer skin 1 , the inner core 2 and the inner skin 3 are curved in the width direction to form an arc. Air conditioner installation holes 7 and roof window installation holes 8 are provided on the ceiling, and the air conditioner installation holes 7 and roof window installation holes 8 run through the inner skin 3 , the inner core 2 and the outer skin 1 . The closure is aluminum profile. The interconnection method of the outer skin 1, the inner core 2 and the inner skin 3 is cementation. The roof and the car body are cemented. Edge sealing 4 can be the structure that also has side eaves above.

When in use, the outer skin 1, the inner core 2 and the inner skin 3 are bonded sequentially from top to bottom, and then the edge banding 4 is wrapped around the four sides of the outer skin 1, the inner core 2 and the inner skin 3, and the inner skin The outer surface of 3 is provided with a first decorative film 5, the outer surface of the outer skin 1 is provided with a second decorative film 6, and an air conditioner installation hole 7 and a roof window installation hole 8 are opened on the ceiling, so that the ceiling and the car body are cemented, Install the air conditioner, escape window, battery pack module, monitoring probe, driver's electric fan, air conditioning duct, lighting and other components on the ceiling.

Example 2

The method for preparing the bus composite roof described in Example 1 in this embodiment includes the following steps: Step 1, using autoclave molding to make the outer skin 1 and the inner skin 3; Step 2, placing the outer skin 1 on the autoclave On the heating forming mold, connect one end surface of the inner core 2 with the outer skin 1, and connect the inner skin 3 with the other end surface of the inner core 2; step 3, use a sealed bag to connect the self-heating forming mold with the outer skin therein 1. The inner core 2 and the inner skin 3 are sealed, and then the mold is heated and vacuumed and pressurized to fasten the outer skin 1, the inner core 2 and the inner skin 3 into shape.

As shown in Fig. 5 and Fig. 6, the preparation method of the inner core 2 includes the following steps: step 1, a mold 9 is set, and several grooves 10 are arranged at equal intervals on the mold 9, and the grooves 10 are the lower half of a hexagon Shape; step 2, laying the entire flame-retardant fiber composite material 11 on the mold 9, and setting a hexagonal first pressing piece 12 corresponding to the position of the groove 10, so that the entire flame-retardant fiber composite material 11 and the groove 10 The inner surfaces are bonded to form a semi-hexagonal shape; step 3, another layer of whole flame-retardant fiber composite material 11 is laid on the top of the first pressing piece 12, and the gap between the first pressing pieces 12 is set corresponding to the first pressing piece 12. The second pressing piece 13 with the same shape as the piece 12 presses the entire flame-retardant fiber composite material 11 above the first pressing piece 12 into a semi-hexagonal shape, and merges with the half-hexagonal shape of the entire flame-retardant fiber composite material 11 below to form A complete hexagonal shape; step 4, fixing two sheets of flame-retardant fiber composite materials 11 to form an inner core. The interval between the grooves 10 is equal to the length of one side of the hexagon. Both the first pressing piece 12 and the second pressing piece 13 are iron rods.

The connection between the inner core 2 and the outer skin 1 and the inner core 2 and the inner skin 3 is realized by bonding. Laminating equipment is used to cover the outer skin 1 with an anti-ultraviolet and anti-aging polymer decorative film, and cover the inner skin 3 with a flame-retardant and environmentally friendly PVC decorative film. The outer skin 1 , the inner core 2 and the inner skin 3 are bonded with edge banding 4 around them. Cut out the air conditioner installation hole 7 and the top window installation hole 8 with a jigsaw. The prepared bus composite roof is bonded to the body frame profile, and the air conditioner, escape window, battery pack module, monitoring probe, driver's electric fan, air conditioning duct, lighting and other components are assembled on the bus composite roof.

The present invention has a three-layer structure so that the structure of the bus roof becomes simple. The material of the outer skin 1, the inner core 2 and the inner skin 3 is a composite of modified phenolic resin and fiber-reinforced composite material, which can reduce the total weight of the bus roof. The decorative film 5 plays the role of flame retardancy, and the second decorative film 6 plays the role of anti-ultraviolet and anti-aging. Air conditioners, escape windows, battery pack modules, monitoring probes, driver electric fans, and air-conditioning ducts can be preset on the ceiling. , lighting and other components, saving the time and process of assembly. The roof is cemented on the car body with high-strength and high-elastic structural glue, which has high water leakage resistance, high shock absorption and noise reduction performance, and at the same time reduces the frequency and frequency of vehicle maintenance. The invention has the characteristics of light weight, heat insulation, sound insulation, good rigidity, etc. Compared with the common all-metal bus roof, the invention can greatly reduce the manufacturing cost and the total weight of the product.

The embodiments in the present invention are only used to illustrate the present invention, and do not constitute a limitation to the scope of the claims. Other substantially equivalent substitutions that can be thought of by those skilled in the art are within the protection scope of the present invention.

Claims (16)

1. A composite roof for buses, characterized in that it comprises: an outer skin, an inner core, an inner skin and an aluminum alloy edge banding, wherein the outer skin, the inner core and the inner skin are arranged successively from top to bottom, and are connected to each other , the outer skin, the inner core and the inner skin are all rectangular, and the edge banding wraps the four sides of the outer skin, the inner core and the inner skin. 2. The bus composite roof according to claim 1, characterized in that, said outer skin and inner skin are flame-retardant composite materials. 3. The bus composite roof according to claim 2, characterized in that, the inner core is a honeycomb structure made of flame-retardant continuous fiber composite material. 4. The bus composite roof according to claim 2, characterized in that, said continuous refers to the preparation of a whole board. 5. The bus composite roof according to claim 1, characterized in that, the outer surface of the inner skin is provided with a first decorative film, and the outer surface of the outer skin is provided with a second decorative film. 6. The bus composite roof according to claim 5, characterized in that, the first decorative film is a flame-retardant PVC material, and the second decorative film is an anti-ultraviolet and anti-aging material. 7. The bus composite roof according to claim 3, characterized in that, the flame-retardant composite material and the flame-retardant continuous fiber composite material are composites of modified phenolic resin and fiber-reinforced composite material or epoxy resin and fiber Composite reinforced composites. 8. The bus composite roof according to claim 7, characterized in that, the outer skin, the inner core and the inner skin are curved in the width direction to form an arc. 9. The bus composite roof according to claim 7, characterized in that, there are air-conditioning installation holes and roof window installation holes on the roof, and the air-conditioning installation holes and roof window installation holes run through the inner skin, the inner core and the outer skin Skin. 10. The bus composite roof according to claim 1, characterized in that, the said closure is an aluminum profile. 11. The bus composite roof according to claim 7, characterized in that the interconnection of the outer skin, the inner core and the inner skin is cemented. 12. The composite roof of the bus according to claim 1, characterized in that, the roof and the vehicle body are cemented. 13. A method for preparing the bus composite ceiling described in any one of claims 1-12, is characterized in that, comprises the following steps: step 1, using autoclave forming method to make outer skin and inner skin; step 2, Place the outer skin on the self-heating forming mold, connect one end surface of the inner core with the outer skin, and connect the inner skin with the other end surface of the inner core; step 3, use a sealed bag to seal the self-heating forming mold with the The outer skin, inner core and inner skin are sealed, and then the mold is heated and vacuumed and pressurized to make the outer skin, inner core and inner skin tightly formed. 14. the method for preparing bus composite ceiling according to claim 13, is characterized in that, the preparation method of described inner core comprises the following steps: step 1, mold is set, and several grooves are set at equal intervals on the mold, groove is The shape of the lower half of the hexagon; step 2, laying the entire flame-retardant fiber composite material on the mold, and setting the first hexagonal pressing piece at the position corresponding to the groove, so that the entire flame-retardant fiber composite material and the groove The inner surfaces are bonded together to form a semi-hexagonal shape; Step 3: lay another whole layer of flame-retardant fiber composite material on top of the first pressing piece, and set the corresponding gap between the first pressing pieces to be the same shape as the first pressing piece The second pressing piece, pressing the entire piece of flame-retardant fiber composite material above the first pressing piece into a half-hexagonal shape, and merging with the half-hexagonal shape of the whole piece of flame-retardant fiber composite material below to form a complete hexagonal shape; Step 4, Two sheets of flame retardant fiber composite material are secured to form the inner core. 15. The method for preparing a bus composite roof according to claim 14, characterized in that, the connection between the inner core and the outer skin and between the inner core and the inner skin is realized by bonding. 16. The method for preparing a bus composite roof according to claim 14, characterized in that, the outer skin, the inner core and the inner skin are bonded and sealed around the fastened and formed outer skin.