FR3036364B1 - TRANSPORT VEHICLE CASE WITH A SANDWICH STRUCTURE PROVIDED WITH AN EXTENSION COMPRISING A COMPLEMENTARY STRUCTURE - Google Patents

Abstract

The object of the invention is a transport vehicle body having lateral flanks (F1, F2) and a roof (P) and whose side flanks and roof are made by means of composite panels for which at least one of the composite panels (111, 112, 113, 300) consists of a composite structure (110, 111, 112, 113, 114) comprising a composite sandwich panel (1) consisting of a first skin (10) and a second skin (11) on either side of a core (12) and having at least one extension of an edge of the composite sandwich panel formed by a monolithic part forming a single wall (101, 102, 103, 104, 105, 106) extending the composite sandwich panel said single wall forming a complementary panel of reduced thickness relative to the composite sandwich panel (1).

Description

TRANSPORT VEHICLE CASE WITH A SANDWICH STRUCTURE PROVIDED WITH AN EXTENSION COMPRISING A COMPLEMENTARY STRUCTURE

Field of the invention

The present invention relates to crates of transport vehicles with sandwich structures and proposes the realization of a box using at least one structure such as a panel having an extension adapted to be used as a base to form an additional structure to the panel and in particular to constitute a complementary panel of reduced thickness.

A sandwich structure such as a sandwich composite panel is a structure comprising a first skin, a core constituted by a plate of generally low density material such as a foam, a honeycomb and a second skin, said first and second skins being solidarized to the soul on both sides of the soul. There are also sandwich structures for which the skins are a material such as a cardboard and the soul a plasterboard.

Sandwich structures of the composite panel type are sandwich structures comprising skins made of a bonding material called a matrix and a reinforcing material in general in the form of fibers which sandwich a core of lightweight filler material, foam, material alveolar, material neither bee or other and which are attached to this soul.

The matrix retains the geometrical arrangement of the fibers and transmits them the stresses to which the panel is subjected. The material obtained is thus light, has good fatigue strength and has good mechanical properties in the direction of the fibers.

The edges of the composite sandwich structures may be straight and in this case, the core is apparent on these edges or be terminated by a return to the skin constituted by the covering of one skin by the other skin one or both skins covering the thickness of the soul at the edge of the panel.

Technological background

The present invention is in the case where at least one of the edges of the structure or panel comprises such a return to the skin constituting a border at this edge, this border being extended beyond.

It is known in particular from the patent application FR15 51573 filed February 24, 2015 incorporated herein by reference provides to use the return to the skin as a fastening edge of the structure or panel to another structure or panel.

The present invention is in the case where at least one of the edges of the structure or panel comprises such a return to the skin constituting a border at this edge, the panel being extended beyond the fixing edge of the panel.

An interesting point when replacing metal structures by composite sandwich structures is to give the latter additional possible functions because of their design and their constitution which enhances their use in addition to the weight gain they bring compared to metal structures.

Indeed, some manufacturing processes of composite material parts are well suited to the manufacture of very complex parts, both in terms of geometry but also in terms of constitution variation: this is the case for processes using molds for create composite parts with a complex shape, which makes it possible to envisage new ways of integrating equipment, supports and composite parts.

Brief description of the invention

The present invention aims to enhance the structures such as composite panels and in particular to produce a semi-product comprising a panel of sandwich-type material and an extension made according to the invention by a monolithic portion for producing a wall extending the structural part.

The sandwich portion may in particular be intended to produce walls, for example body walls of a vehicle, whether it be a chassis, a floor, a face or the roof of such a vehicle. and the monolithic portion intended to constitute all or part of an integrated equipment.

The monolithic part is mainly one of the skins of the sandwich which is extended and its thickness can be variable according to the expected efforts.

Alternatively, it is possible to extend two skins of the sandwich and to join them, which thus makes it possible to obtain a self-rigid monolithic structure in panel or structure termination.

In this case, the return to the panel edge skin is used as the basis for producing complementary structures and in this case, the structure comprises a composite sandwich panel provided with skins made of composite material and at least one edge of the panel comprises a return to the skin consisting of an extension of the skins beyond the edge of the soul, the skins being applied to one another and secured to one another to produce a monolithic complementary panel in that it does not has no soul between the skins.

In this context, the present invention proposes a transport vehicle body having lateral flanks and a roof and whose side flanks and roof are made by means of composite panels, characterized in that at least one of said composite panels consists of a composite structure comprising a sandwich composite panel consisting of a first skin and a second skin on either side of a core and having at least one extension of an edge of the sandwich composite panel made by a portion monolithic forming a single wall extending the sandwich composite panel said single wall forming a complementary panel of reduced thickness relative to the composite sandwich panel.

According to a first embodiment, at least one of the flanks consists of a said composite structure and comprises an extension along a part of the roof to form with said flag a longitudinal duct in the body and / or a longitudinal gutter cable passage or conduits.

According to a second embodiment, the horn and the flanks consist of composite structures comprising at least one extension of an edge of the composite sandwich panel made by a monolithic part forming a single wall extending the composite sandwich panel and forming between the roof and flanks of single-walled ducts.

The flag is advantageously a composite structure comprising two single walls extending the sandwich composite panel of the flag on its sides facing the flanks to achieve the roof of the box.

The sandwich panels of the roof and flanks may comprise edges with return to the skin provided with profiles, facing each other, the fixing between the sidewalls and the roof being formed at the level of the profiles.

At least one of said sandwich panels advantageously comprises longitudinal inserts for fixing the single wall of a said composite structure.

The flag may include longitudinal inserts for suspension of a ceiling or ceiling element of the body. The invention applies in particular to a train car comprising a body according to the invention.

BRIEF DESCRIPTION OF THE DRAWINGS Other features and advantages of the invention will become apparent on reading the following description of a nonlimiting exemplary embodiment of the invention with reference to the drawings which represent: in FIG. 1: a schematic view performing a structure of the invention; in Figure 2: a schematic cross-sectional view of a first application of the invention; in Figure 3: a detail of a box of the prior art; in FIG. 4: a detail of FIG. 2 according to the invention; in Figure 5: a schematic cross-sectional view of a second application of the invention; in Figures 6 to 8: cross-sectional views of the variants of a third application of the invention; in Figure 9: a general schematic view of the components of a vehicle body according to several aspects of the invention. in Figure 10: another example of application of the invention in cross section.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As seen above, the object of the present invention is to make it possible to take advantage of the replacement of metal panels by composite sandwich structures in order to use the latter as a basis for providing additional functions that are possible because of their design and constitution in order to increase their valuation beyond the gain in mass they bring compared to metal structures.

This is made possible in the context of the molding of composite parts which makes it possible, for example, to have portions of the core discontinuously on a first skin and then to deposit a second skin both on the parts of the souls and on the first skin where deprived of said soul parts.

FIG. 1 illustrates an exemplary embodiment of a composite structure according to the principle of the invention for which a core 12 is positioned on a portion of a first skin 11 draped or arranged on a first mold portion 1000 defining zones d Thin thickness 1001, 1003 and greater thickness 1002 of the structure.

A second skin 10 is then deposited by layering or otherwise on the core in the thick zone 1002 and on the first skin in the areas 1001, 1003 of thin thickness.

The areas of thin thickness are areas where the structure has no core between the skins 10,11 and is a monolithic panel portion.

As shown, this monolithic portion may not be flat and produce a variable shape piece providing a particular function as in the example shown and explained later where the part allows for a conditioned air duct or cable routing duct or pipes for example.

A closing part of the mold 1004 is applied to the second skin and the molding is done in a conventional manner by vacuum polymerization for example.

A first application of the invention as represented in FIG. 2 may especially be the production of a structure such as a floor 110 comprising a sandwich composite panel 1 consisting of a first skin 10 and a second skin 11 on the one hand. and other a core 12 which comprises at least one extension of an edge of the composite sandwich panel made by the monolithic portion forming a single wall 101 extending the sandwich composite panel laterally and in the example forming a conduit for example.

The single wall then forms a complementary panel of reduced thickness with respect to the sandwich composite panel and in continuity of one face of this sandwich panel.

Compared to a prior art for which a duct is made by a CA sheet fixed to a side panel Pai and a ply floor as shown in FIG. 3, the present invention has the advantage of providing continuity between the duct and the floor and of perform in one operation the laying of the floor and his or her ducts.

FIG. 4 represents an enlarged detail of FIG. 2 at the level of the duct 202 made by the curved monolithic wall 101 which extends the upper face of the composite panel 1 constituted by the skins 10, 11 and the core 12.

In this example, the monolithic portion is made by an extension of the two skins 10,11 of the sandwich composite panel joined together.

The extension is derived from a return to the skin 17 panel edge, the skins 10, 11 being applied to one another and secured to each other to serve as a basis for the realization of said wall simple 101.

The top of the duct made by the single wall is fixed on the side panel 400, which is here a second composite panel, with fastening means 120 adapted, for example blind rivets.

The side panel 400 and the floor 110 are fixed on a longitudinal structural profile or beam-shaped angle 500 and include returns to the skin reinforced by the panel termination profiles 13 at the edge of the composite sandwich panel.

The two structural profiles 500 present on both sides of the body may in particular be constituted by longitudinal structural elements of the chassis such as stretcher to the right of the bogie.

The profiles 13 receive a row of fixing means 120a, 120d fitted between the panels and a first wing of the longitudinal structural profile while a second row of fasteners is made between the monolithic parts back to the skin and a second wing on a box portion of said profile.

For its part, the composite part of the panel 1 comprises longitudinal inserts 6 reinforcement or accessories attachment or in the case of a floor of a rail car body or bus seat fasteners for example.

With particular regard to the floors of the train cars in particular, air ducts are often installed there when a blowing of air conditioning is provided at the bottom of the sides of the crates. These inserts long type metal reported are used to feed ejecto-convectors located at the right of each bay or window. A particularly bonded floor covering covers and dresses these sheaths provided with inspection and blowing grids. These long-pan sheaths can also sometimes serve as a seat support, since their internal structure can ensure the required mechanical strength. Classically, and in direct connection with the metal architecture of structures, these equipment and fittings are reported on the structure of metal crates by removable links or not. All these assembly operations must take into account many requirements, which can affect the costs of implementation, maintenance, and complicate the industrialization of production.

In the example of Figure 2, the ducts 201 fulfill the function of air ducts to distribute the air conditioning of the car.

Another example of a composite structure according to the invention is shown in FIG. 5 for which a junction 130 between two returns to the head-end skin of two panels 1, 1 'is made with fixing means 120, one of the panels comprising a extension 111 extending the return to the skin to make a monolithic wall here making a housing 212 or a stiffener.

In this example, the wall-forming extension is formed by one of the skins 11 of the sandwich composite panel which extends beyond the edge of the composite sandwich panel while the second skin 10 of this panel stops at the return to the skin of the sandwich panel. fixing said panel.

In the cases of FIGS. 4 and 5, the return to the skin 17 also forms a support and / or fixation border of the structure which is extended to form said simple wall. The example of Figure 6 provides a connection of the type of Figure 5 for which a panel 300 is curved. According to this example, the curved panel is a structural pavilion vehicle body without extension while the panel 111 has an extension. This extension comprises a first portion 106 away from the roof panel and then returns to apply on this panel to allow for a conduit 203 such as an air conditioning duct. It comprises at the end of the first part a second portion 105 shaped cable receiving gutter or pipe extending longitudinally in the vehicle body. Other applications are possible for extensions that will be shaped accordingly.

In the example of Figure 7 at least two composite structures 113,114 is here the flag and the sides of a vehicle body called body faces in the railway field are each provided with a sandwich composite panel 1 and a single wall 103, 104 extending a first skin 10 of said composite sandwich panel. The single wall of each of the first and second structures is applied to the second skin 11 of the sandwich composite panel of the other structures and attach thereto which solidarises the structures together.

In this way the composite parts of the structures are kept at a distance and a box 201 is made between the ends of said composite sandwich panels and said single walls.

In the case of Figure 8, the monolithic panel of one of the structure is extended by a gutter 107. Alternatively, the gutter can be reported and attach with the free end of the monolithic panel 102 on the opposite structure.

At least the sandwich composite panel of a first of said structures comprises at least one insert 6, 13 between its skins 10, 11, the single wall of a second of said composite structures being fixed on said insert through the second skin 11 said first of said composite structures.

In the case of FIGS. 6 to 8 in particular, the inserts are, on the one hand, profiles 13 at the level of the returns to the skin and profiles 6 in the heart of panels.

For Figure 6, the single wall 106 of a first structure 111 is applied on one face 11 of the other 300 of the structures away from a junction portion between said structures.

The second 300 of the structures comprises a sandwich composite panel provided with at least one profile 6, said single wall being fixed on said profile through a skin of the composite sandwich panel of the second of the structures. The invention is particularly applicable to a transport vehicle body shown diagrammatically in FIG. 9 and having lateral faces F1, F2 and a flag P and whose side flanks and flag are made by means of composite panels for which at least one one of said composite panels consists of a composite structure according to the invention as in the case of FIGS. 6 to 8.

In this case, at least one of the faces 111, 112, 113 consists of a said composite structure and comprises an extension 105, 106 along a part of the roof to form with said pavilion a longitudinal duct C, 201, 203 in the box and / or a longitudinal gutter 105 for the passage of cables or ducts.

It is thus possible to form between the flag and the faces of the single-walled conduits 201 as in FIG. 7 or ducts whose one wall is a composite panel portion 300 and the other wall a single wall 106 as in FIG.

In the case of Figures 7 and 8, the flag of the vehicle body is a composite structure 114 having two single walls 104 extending the sandwich composite panel of the flag on its sides facing the sidewalls or faces to achieve the roof of the box.

The roof sandwich panels and the faces or flanks have edges with return to the skin provided with profiles 13, facing each other, the fixing between the side flanks and the roof being formed at the level of the profiles.

The flag of the transport vehicle body according to Figures 6 to 8 further comprises longitudinal inserts 6 supporting a ceiling or ceiling element 310 of the body.

A transport vehicle body, such as a train car, can combine a floor 110, longitudinal members 500 called in the railroad sector longitudinal or side support rails of the floor, sidewalls or side faces 111, 112, 113 and a roof 114, 300 according to the examples shown in Figures 2 and 6 to 8 to form the car body of Figure 9 pre-equipped with its ventilation ducts, technical boxes and cable supports and pipes.

The floor is then made with at least one composite sandwich panel 1 extending laterally to the longitudinal members forming the stretchers or longitudinal members 500 and consisting of an upper skin 10 and a lower skin 11 on either side of a soul 12.

The sandwich composite panel comprises at least one extension 101 with double curvature formed by a monolithic portion forming a single wall. This simple wall has a reduced thickness compared to the sandwich composite panel and extends the upper face of the composite sandwich panel.

Said single wall forms with a lower part of a side face the walls of a side box 202 inside the body.

The present invention is part of a search for optimization of the mass of the elements constituting a train car or other railway-type vehicle, to reduce the number of elementary parts, to make the solutions flexible, modular and standardized. , to facilitate the realization of pre-equipped subassemblies, to guarantee a good resistance to aging and corrosion of the equipment. to manufacture the car, the floor structure is made in one piece of composite material, in the form of a sandwich material, but possibly in monolithic stiffened form, all or part of the sides of the vehicle body are made of sandwich composite material, but optionally in monolithic form optionally stiffened, one or two of the skins of the floor sandwich composite material is extended so as to achieve a form capable of performing the function of aeraulic duct on the side of the floor, the equipment is finalized by fasteners as much as necessary optionally, the floor is given a sound and heat insulation capacity by choosing a suitable core for the sandwich material.

In doing so, it reduces the number of parts constituting the body structure and equipment, facilitating their assembly, their cost and associated logistics and maintenance costs, and also allowing the pre-equipment floor, thus ensuring the possibility of integrate peripheral functions such as ventilation ducts, floor coverings, equipment supports (seats, shelves, etc.). On the other hand, the user cost of the vehicle is improved over the entire life of the vehicle. product life thanks in particular to easier maintenance operations.

In the context of the above, the examples of Figures 2, 6-8 and 10 illustrate the case where sandwich panels have extensions of at least one of their skins to create a box able to receive the air conditioning of the car and which circulates at a speed of about 6 m / s. The panels thus provide the aeraulic function of the car while also being able to perform other functions such as thermal insulation, acoustic insulation and the support of on-board equipment (seats, tablets facing each other, support columns , transverse partitions, ...).

In the case of Figure 2, the structural floor 6 is for example made of a sandwich of 50 mm thick composite material consisting of longitudinal monolithic banks 10,11 with a thickness of 6 mm ensuring the aeraulic function.

This floor also incorporates reinforcements 6 themselves composite of a tubular section of about 45 x 45 mm and a core material 12 thermal and acoustic insulation, for example PET foam.

The reinforcements 6 allow to receive fastenings of interior arrangements such as seats, shelves vis-à-vis, holding columns, transverse partitions, caissons, platforms and the mechanical interface with the primary body structure. The entire floor is mechanically fixed to the support members 500, the assembly possibly forming part of a multi-material box.

The floor covering 600, for example made of elastomeric tiles, made of thermo-welded PVC or carpet, is attached or removably attached in the case of a carpet to the skin 10 here by covering the single-walled pipe portions 101. The watertightness of this flooring is ensured by means of a product adapted to railway maintenance requirements, for example the resistance to detergents based on dilute oxalic acid is for example. The tightness of the connections at the source, especially in the case of discontinuous flooring such as elastomeric tiles is preferred, as well as at all potential infiltration source interfaces, for example seat fasteners. The air-tightness of the circuit is also ensured by the interposition of hydrophobic product such as a closed-cell foam or allowing drainage of the condensation at the interface during mounting at the box, for example a product known under the reference "F800 FR ALG". -01 drain "of the company CELLOFOAM having also an excellent classification Fire / Smoke / Toxicity according to the standards EN 45.545-2 (classification HL3-R1), FMVSS 302, DIN 75 200, ISO 3795 (burning speed" 100 mm / mn ).

In the case of FIGS. 6 to 8, the ducts 201, 203 conduct the air blown by a conventional air-conditioning device in the train cars and distribute this air in the car through air vents 731 arranged in place in the ceiling 310 of the box and connected to the conduits 201, 203 by reported tubular conduits 320 inserted in openings made in the skin 106 of the ducts 201, 203.

The ceiling of the body is according to these examples suspended from the flag 114, 300 by rods 311 fixed on reinforcements 6 integrated in the flag.

FIG. 10 shows another example of application of the invention to the air-flow function and concerns the case of an intermediate floor of a two-level train box.

According to this example, the intermediate floor 700 consists of a sandwich panel 710, 711, 712, the extension of the two skins 710, 711 to create the air flow 730 of the upper level passenger hall.

In this example a third skin 713 is shaped to achieve the ceiling of the lower level passenger room and the upper lateral ducts 721 of this room and to integrate a complementary function related to the lower room air ducts air conditioning blowing, shutters or others.

In the example shown, the skin 713 covers the entire width of the panel 700 and is for example molded directly with the panel. It is possible, however, in the context of the invention to bring this skin back and stop on the edges of the panel for example by covering only the fastening area with the rivets 120d.

As for the configuration example defined in FIG. 2, this type of solution makes it possible to minimize the number of rooms and the integration of the ventilation function by simultaneously treating the interiors of the intermediate floor, Ceiling of the lower room, and central lighting. , reading lights reported on the air conditioning ducts of the lower room as well as the functions of thermal insulation, sound insulation, support the floor covering 600 of the upper room, receive a ceiling covering of the lower room 601.

The composition of the structural floor 700 is constituted for example by a sandwich of 50 mm thick composite material with high performance comprising skins 710, 711 of 3 mm to achieve monolithic longitudinal banks of a thickness of 6 mm ensuring the function ventilation. The sandwich incorporates reinforcements 6, 13 themselves composite of a tubular section of approximately (45 x 45 mm).

The core material 712 thermal and acoustic insulator is for example a PET foam such as the foam commercially known under the name Armaform AC80 (W) from the company Armacell.

The flooring is here also made of elastomeric tiles, strips of heat-welded PVC or carpet is reported glued or removably attached in the case of a carpet of vehicles of 1 ° class for example. The sealing principles can be achieved through the use of products already referenced for the example of Figure 2 previously described. The whole of this floor incorporating the treated air ducts is mechanically fixed on longitudinal banks formed by longitudinal members 800 forming stretchers or sills intermediate the lower stage and the upper floor of the sides of the body and serving as waistline on which the upper and lower panels 810, 811 of the faces are fixed as for the previous examples in their returns to the skin.

Air vents 730 are arranged in place along conduits 720 in openings of said ducts to distribute air into the car.

In this example, vertical openings 802 in the duct 720 make it possible to distribute the conditioned air between cover panels 801 inside the box, for example to open air along the windows of the car.

Under the intermediate floor of the second ceiling ducts 721 distribute the conditioned air by second air vents 730 from place to place along the second ducts.

A ceiling covering 601 covers the underside of the intermediate floor.

The method of assembly of the body structure is compatible with the definition of such subassemblies so as to allow the pre-assembly of the intermediate floor before completing the assembly of the 2nd face of the vehicle. The air-tightness of the circuit is moreover ensured by the interposition of products similar to those already described in the example of FIG.

Furthermore, and taking into account the connection node of this intermediate floor integrating the aeraulic circuits, a particularly neat sealing is achieved via in particular the application at the interface of a sealant adapted to the most severe operating conditions (temperature, hygrometry). differential expansion, electrolytic torque aluminum / carbon skins for example).

According to these conditions of use in commercial service, several types of mastic can be potentially used, for example the following families: MS Polymer (eg ISR 70-03 from Bostik)

Polyurethane (Sikaflex 265) or other waterproof sealant. The set is eventually part of a multi-material crate. The invention is not limited to the examples shown and in particular the profiles 6 between the skins adapted to receive one or more fastening members of a complementary structural element may also serve as fastening means for interior trim or equipment or even seat supports in the case of the floor of Figure 2 and the intermediate floor of Figure 10.

The air flow is in the upper duct 720 which supplies air vents 730 which here comprise upwardly directed air slats and passages 811 to ejecto-convectors under windows of the upper floor and in the lower duct 721 which feeds high air vents 730 provided with slats directing the airflow down into the low floor.

The ducts formed between the single wall and another structure may be sealed conduits and may also incorporate thermal and / or acoustic insulation functions by their constitution. The invention, which is particularly applicable to the production of passenger cars, subways, trams or other vehicles in combination with a lower chassis that interfaces with bogies, is not limited to the example shown and is but can be used to make an upper fuselage of an aircraft, a bus, boxes of caravans or mobile homes (mobile home in English). In these applications the longitudinal members 500 may be part of a vehicle body reinforcement belt.

Claims (4)

1 - Transport vehicle body having side flanks (Fl, F2) and a roof (P) and whose side flanks and roof are made by means of composite panels characterized in that at least one of said composite panels (111, 112, 113, 300) consists of a composite structure (110, 111, 112, 113, 114) comprising a composite sandwich panel (1) consisting of a first skin (10) and a second skin (11). ) on either side of a core (12) and having at least one extension of an edge of the composite sandwich panel formed by a monolithic portion forming a single parai (101, 102, 103, 104, 105, 105) extending the composite sandwich panel said single wall forming a complementary panel of reduced thickness relative to the composite sandwich panel (1). said single wall consisting of one or both skins of the sandwich composite panel, the sandwich panels of the roof and flanks have edges with return to the skin provided with profiles (13), facing each other, the fixing between the flanks and the flag being made at the level of the profiles. 2 - Transport vehicle body according to claim 1 wherein at least one of the flanks (111, 112, 113) consists of a said composite structure and comprises an extension (105, 106) along a portion of the roof to form with said, flag a longitudinal duct (C, 201, 203) in the box and / or a longitudinal gutter (105) for passage of cables or ducts. 3 - Transport vehicle body according to claim 1 for which the roof and the sidewalls consist of composite structures (112, 113, 114) comprising at least one extension of an edge of the sandwich composite panel made by a monolithic portion forming a single wall (101, 102, 103, 104, 105, 1.06) extending the sandwich composite panel and forming between the roof and the flanks of the single walled conduits (201). 4- transport vehicle case according to claim 3 for which the roof is a composite structure (114) having two single walls (104) extending the sandwich composite panel of the flag on its sides facing the sides to achieve the roof of the body . 5- transport vehicle body according to any one of claims 1 to 4 wherein at least one of said sandwich panels comprises longitudinal inserts (6) for fixing the single wall of said composite structure. 6- transport vehicle case according to any one of claims 1 to 5 for which the flag comprises longitudinal inserts (6) for suspending a ceiling or ceiling element (310) of the body. 7 - Train car comprising a body according to any one of claims 1 to 6.