WO2013172345A1 - 車両用空調装置のカバー、及びその製造方法 - Google Patents

車両用空調装置のカバー、及びその製造方法 Download PDF

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Publication number
WO2013172345A1
WO2013172345A1 PCT/JP2013/063422 JP2013063422W WO2013172345A1 WO 2013172345 A1 WO2013172345 A1 WO 2013172345A1 JP 2013063422 W JP2013063422 W JP 2013063422W WO 2013172345 A1 WO2013172345 A1 WO 2013172345A1
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WO
WIPO (PCT)
Prior art keywords
core
cover
air conditioner
vehicle air
resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2013/063422
Other languages
English (en)
French (fr)
Inventor
広紀 小林
信介 岡野
晃輔 梅村
竹谷　元
久米　将実
壮平 鮫島
迪斉 松本
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mitsubishi Electric Corp
Original Assignee
Mitsubishi Electric Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mitsubishi Electric Corp filed Critical Mitsubishi Electric Corp
Priority to EP13791701.9A priority Critical patent/EP2851259B1/en
Priority to JP2014515637A priority patent/JP5748909B2/ja
Priority to US14/390,823 priority patent/US9643365B2/en
Publication of WO2013172345A1 publication Critical patent/WO2013172345A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D27/00—Heating, cooling, ventilating, or air-conditioning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/78—Moulding material on one side only of the preformed part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/682—Preformed parts characterised by their structure, e.g. form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B29C70/865—Incorporated in coherent impregnated reinforcing layers, e.g. by winding completely encapsulated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00—Heating, cooling or ventilating devices
    • B60H1/00357—Air-conditioning arrangements specially adapted for particular vehicles
    • B60H1/00371—Air-conditioning arrangements specially adapted for particular vehicles for vehicles carrying large numbers of passengers, e.g. buses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00—Heating, cooling or ventilating devices
    • B60H1/00507—Details, e.g. mounting arrangements, desaeration devices
    • B60H1/00514—Details of air conditioning housings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D23/00—General constructional features
    • F25D23/02—Doors; Covers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/10—Thermosetting resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B29K2105/046—Condition, form or state of moulded material or of the material to be shaped cellular or porous with closed cells
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3041—Trim panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/103—Metal fibres
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    • B32—LAYERED PRODUCTS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
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    • B32—LAYERED PRODUCTS
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Definitions

  • the present invention relates to, for example, a cover for a vehicle air conditioner mounted on a ceiling portion of a railway vehicle, and a method for manufacturing the same.
  • the plate is made of a stainless steel plate, and the reinforcing member is made of an angle material.
  • the overall weight is large, and the reinforcing member is fixed on the upper surface of the plate by welding.
  • On the lower surface of the plate it was necessary to stick a heat insulating material, and there was a problem that productivity was poor.
  • An object of the present invention is to solve such problems, and to obtain a vehicle air conditioner that can be reduced in weight and improved in productivity at low cost, and a method for manufacturing the same. Objective.
  • a cover of a vehicle air conditioner according to the present invention includes a core made of a foam material having heat insulation properties, and a skin member made of a fiber reinforced plastic in which a fiber covering the entire surface of the core is impregnated with a resin. Is elastically deformed into a curved shape.
  • the manufacturing method of the cover of the vehicle air conditioner according to the present invention is as follows: On a curved mold, a saddle process in which a core and fibers having closed cells are supported at two points at both ends and the intermediate part is bent and elastically deformed to form a saddle, An impregnation step of injecting the resin by evacuation into a sealed space formed between the mold and the core, and impregnating the fiber with the resin; And a demolding step of demolding the cover from the mold after the resin is cured.
  • the cover is provided with a core made of a foam material having heat insulating properties and a skin member made of fiber-reinforced plastic covering the entire surface of the core, so that it is lightweight. Productivity is obtained, and a step of attaching a separate heat insulating material is not required, which improves productivity.
  • the core is elastically deformed into a curved shape, compared to a cover in which the core is not elastically deformed, i.e., a cover that has been subjected to thermal deformation, cutting, or deformation using a mold in advance, the core is The repulsive force is large and the load resistance increases.
  • the core is elastically deformed into a curved shape by its own weight, for example, in a saddle type process.
  • a step of deforming into a curved shape by a molding die is not necessary, and productivity is improved at low cost.
  • FIG. 1 It is a top view of the rail vehicle air conditioner which attached the cover of the rail vehicle air conditioner by Embodiment 1 of this invention. It is a perspective view which shows the outdoor cover of FIG. It is arrow sectional drawing along the III-III line of FIG. 2 which shows the outdoor cover of FIG. It is sectional drawing which shows a vertical process among the processes which manufacture the outdoor cover of FIG. 2 by a vacuum impregnation molding method. It is sectional drawing which shows an impregnation process among the processes which manufacture the outdoor cover of FIG. 2 by a vacuum impregnation molding method. It is the figure which showed the relationship between the longitudinal elastic modulus of a core, and the elastic deformation of the core by dead weight.
  • FIG. 1 is a plan view showing a railway vehicle air conditioner equipped with covers 9 and 10 of a railway vehicle air conditioner according to Embodiment 1 of the present invention. However, the right halves of the covers 9 and 10 are notched in the figure.
  • This railway vehicle air conditioner is mounted on the ceiling of a vehicle, and includes an indoor unit portion 1, an outdoor unit portion 2, an indoor unit portion 1 and an outdoor unit portion 2 that communicate with the vehicle interior side. 3 and the indoor unit part 1 and the outdoor unit part 2, respectively, and an indoor cover 9 and an outdoor cover 10 that are exposed to the outside air are provided. As shown in FIG.
  • the indoor cover 9 and the outdoor cover 10 are rectangular and have a curved shape that protrudes upward with a curvature of 1500 mm or more and 2500 mm or less, and make maximum use of space in consideration of vehicle limitations. For this purpose, 1800 mm is suitable.
  • the indoor cover 9 and the outdoor cover 10 cover the air conditioner main body including the indoor unit portion 1 and the outdoor unit portion 2.
  • the indoor unit portion 1 has an indoor blower 4 and an indoor heat exchanger 5.
  • the outdoor unit 2 includes an outdoor blower 6, an outdoor heat exchanger 7, and a compressor 8.
  • the outdoor cover 10 is manufactured by a vacuum impregnation molding method (VaRTM), a core 11 made of a foam material having closed cells having heat insulation properties, and a core 11 elastically deformed into this curved shape.
  • the gel coat 14 is integrated with each other.
  • This FRP is obtained by impregnating a vinyl ester resin, which is a base resin, into a carbon reinforced fiber that is excellent in terms of lightness, mechanical properties, thermal properties, optical properties, and flexibility of molding method.
  • the reinforcing fiber may be glass fiber, aramid fiber, Kevlar fiber, boron fiber, alumina fiber or the like.
  • a thermosetting epoxy resin, an unsaturated polyester resin, a furan resin, a polyurethane resin, or the like may be used instead of the vinyl ester resin.
  • the fibers include short fibers and long fibers, but long fibers are used from the viewpoint of mechanical properties, and woven fibers are used as the form.
  • This core 11 has a longitudinal elastic modulus of 9 to 33 MPa, and a material combustion test for railway vehicles (“Ministerial Ordinance for Establishing Technical Standards for Railways” (December 25, 2001, Ministry of Land, Infrastructure, Transport and Tourism Ordinance No. 151), Article 83. ) Is a closed-cell foamed material of thermosetting resin that has heat insulation properties exceeding the acceptance criteria of flame retardancy.
  • the core 11 is a foamed material of phenol resin.
  • the thickness of the core 11 is set so that necessary heat insulation and bending rigidity can be obtained, but 3 to 30 mm is suitable, and 9 mm is more preferable. If it is 30 mm or more, the occupied volume of the outdoor cover 10 becomes large, which is not desirable. If it is 3 mm or less, the rigidity required for the outdoor cover 10 cannot be obtained.
  • the longitudinal elastic modulus E is set to a range of values obtained by the following equation using the curvature R, length l, thickness t, width b, density ⁇ , atmospheric pressure P, and dimensional tolerance f of a predetermined shape. .
  • Equation (1) is an equation for the maximum deflection ⁇ max of a two-point support beam that has a rectangular cross section and receives its own weight (2)
  • Figure 6 shows the result of placing a 9mm thick core on a mold with a curvature of 1800mm and testing whether or not the core 11 deformed by its own weight follows the mold, and the core 11 is covered with a bagging film and vacuumed.
  • the results of testing whether or not the change in the plate thickness is within 0.1 mm of the normal allowable dimensional difference of the fine grade are indicated by ⁇ and ⁇ .
  • the core 11 having a longitudinal elastic modulus E of 9 MPa or more and 33 MPa or less follows the curvature of 1800 mm by its own weight without passing through the thermal and cutting process, and the normal allowable dimensional difference that the deformation at atmospheric pressure is fine. It was confirmed that it can be suppressed within.
  • the resin diffusion medium 13 is formed with a mesh-like flow path, and a vinyl ester resin, which is a base resin, circulates through the flow path and is impregnated with carbon reinforcing fibers.
  • This material is made of carbon fiber from a thermal and mechanical viewpoint.
  • the material of the resin diffusion medium 13 is glass fiber, aramid fiber, Kevlar fiber, boron fiber, alumina fiber, thermosetting epoxy resin, unsaturated polyester resin, vinyl ester resin, furan resin, polyurethane resin, thermoplastic resin. Nylon, PBT, ABS or the like may be used.
  • the gel coat 14 is made of an unsaturated polyester resin that is flame retardant by bromination from the viewpoint of flame retardance in order to prevent adverse effects such as light, water, heat, etc. from entering the interior of the outdoor cover 10. .
  • the material of the gel coat 14 may be a thermosetting epoxy resin, vinyl ester resin, furan resin, polyurethane resin, or the like.
  • the configuration of the indoor cover 9 is also the same as that of the outdoor cover 10, and the description thereof is omitted.
  • a method for manufacturing the outdoor cover 10 of the railway vehicle air conditioner according to Embodiment 1 of the present invention will be described.
  • a gel coat resin is applied on a mold 15 that has been subjected to a release treatment with a Teflon (registered trademark) coating using a spray gun to form a gel coat 14.
  • a predetermined number of fabric fibers 16 are laminated on the gel coat 14 in a predetermined direction.
  • the resin diffusion medium 13 is laminated.
  • the resin diffusion medium 13 may be laminated between the fabric fiber 16 and the gel coat 14 or between the fabric fibers, but is disposed between the fabric fiber 16 and the core 11 in terms of design.
  • the core 11 is placed on the resin diffusion medium 13.
  • the core 11 is formed into the mold 15 having a curvature of 1800 mm by its own weight as shown in FIG. Deforms along.
  • a predetermined number of fabric fibers 16 are laminated in a predetermined direction.
  • the peel ply 17 is laminated thereon, and the resin diffusion medium 13 is disposed thereon.
  • an air suction port 18 of a vacuum pump and a resin injection port 19 to be injected from a resin tank (not shown) are respectively attached to the molding die 15 and covered with a bagging film 20 so that air does not leak.
  • the periphery of the bagging film 20 is adhered to the mold 15 with the sealant 21.
  • the inside including the woven fiber 16 covered with the bagging film 20 is evacuated using a vacuum pump, and then the valve is released to inject the resin.
  • the inside covered with the bagging film 20 is in a vacuum state, and the resin passes through the two resin diffusion media 13 and diffuses throughout the fibers while being impregnated in the thickness direction of the woven fibers 16 (impregnation step). After this impregnation step, the valve is closed to cure the resin.
  • the bagging film 20, the upper one resin diffusion medium 13, and the peel ply 17 are removed, and finally the entire surface of the core 11 is covered with the skin member 12 made of FRP from the molding die 15.
  • the outdoor cover 10 is removed.
  • the indoor cover 9 is also manufactured by the same method as the outdoor cover 10.
  • the covers 9 and 10 of the railway vehicle air conditioner cover the core 11 made of a foam material having heat insulating properties and the entire surface of the core 11. Since the skin member 12 made of FRP in which a fiber is impregnated with a resin is provided, light weight can be obtained, and a process of attaching a separate heat insulating material is unnecessary, and productivity is improved. Further, since the core 11 is deformed into a curved shape by elastic deformation due to its own weight, a cover in which the core is not elastically deformed, that is, a cover that has been subjected to thermal deformation, cutting, or deformation by a molding die in advance. In comparison, the repulsive force is greater than the external force, and the load resistance increases.
  • the core 11 is made of a foam material and has closed cells, the vacuum impregnation molding method can be applied when manufacturing the covers 9 and 10 without impregnating the resin inside the core 11.
  • the core 11 is a closed-cell foamed material having a longitudinal elastic modulus of 9 MPa to 33 MPa and a thickness of 3 mm to 30 mm.
  • the core 11 is supported at two points at both ends before being covered with the skin member 12. Therefore, the cover 9, 10 can realize a curved surface having a curvature of 1600 mm or more and 2000 mm or less by its own weight, eliminating the need for thermal and cutting, and improving productivity.
  • the covers 9 and 10 can be reduced in weight.
  • the covers 9 and 10 are ensured to be flame retardant for rail vehicle vehicles.
  • the core 11 is made of a phenol resin which is a thermosetting resin, the covers 9 and 10 having excellent mechanical characteristics and heat resistance can be obtained.
  • the core 11 made of the closed cell foam material is used when the covers 9 and 10 are manufactured in the vacuum impregnation molding method.
  • the core 11 is not impregnated with resin.
  • the core 11 is deformed into a curved shape by its own weight at room temperature, and when the core 11 is deformed, no thermal processing or cutting process is required.
  • Productivity of 9, 10 is improved, and it is formed in a curved shape without using a molding die having a curved shape with a high die cost, and is produced at low cost.
  • the core 11 is bent and deformed by its own weight.
  • the core 11 may be bent and deformed by an external force by a weight.
  • a weight When a weight is used, a material that does not break even if it is deformed to a target curvature may be used.
  • the core 11 When the weight is used, the core 11 is deformed into a curved shape in a short time as compared with the case of its own weight, and the productivity of the covers 9 and 11 is improved accordingly.
  • the external force has been described by taking the weight as an example here, it can also be realized by using an external force such as a vacuum, an autoclave or the like, a pressure, a magnetic force, an adhesive force and the like.
  • the cover of the railway vehicle air conditioner and the method for manufacturing the same have been described.
  • the present invention is of course not limited to this, and the present invention can be applied to, for example, a tram, a bus air conditioner. It can also be applied to the cover.

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Abstract

　この鉄道車両用空調装置のカバー１０は、空気調和機本体を覆う、車両用空調装置のカバーであって、カバー１０は、断熱性を有する発泡材からなるコア１１と、このコア１１の全面を覆った繊維強化プラスチックからなる表皮部材１２とを備え、コア１１は、弾性変形により湾曲状に変形されている。

Description

車両用空調装置のカバー、及びその製造方法
　この発明は、例えば、鉄道車両の天井部に搭載される車両用空調装置のカバー、及びその製造方法に関する。
　従来、車両用空調装置のカバーとして、アーチ状のプレートと、このプレートの外側に設けた補強部材と、プレートの内側に設けた断熱材とから構成されたものが知られている（例えば、特許文献１参照）。
　一方で、発泡材をコアとするＦＲＰ（繊維強化プラスチック）サンドイッチパネルは、剛性を保ちつつ軽量化が可能であり、かつ断熱性に優れていることが知られている（例えば、特許文献２参照）。
特開平６-７２３２６号公報 特開２００６-１３０８７３号公報
　しかしながら、特許文献１に記載のカバーでは、プレートはステンレス板で構成され、また補強部材はアングル材で構成されており、全体重量が大きく、またこのプレートの上面では補強部材を溶接で固定し、プレートの下面では断熱材を貼着する必要があり、生産性が悪いという問題点があった。
　また、特許文献２に記載のＦＲＰサンドイッチパネルでは、車両用空調装置のカバーに必要な曲面形状を得るために、心材に予め熱的、または切削加工を施す必要があり、生産性が悪く、また成型金型を用いた場合には、金型コストが高い曲面形状を有する金型を用いなければならすコストが嵩むという問題点があった。
　この発明は、かかる問題点を解決することを課題とするものであって、軽量化を図ることができるとともに、低コストで生産性が向上した車両用空調装置、及びその製造方法を得ることを目的とする。
　この発明に係る車両用空調装置のカバーは、断熱性を有する発泡材からなるコアと、このコアの全面を覆った繊維に樹脂が含浸した繊維強化プラスチックからなる表皮部材と、を備え、前記コアは、湾曲形状に弾性変形されている。
　また、この発明に係る車両用空調装置のカバーの製造方法は、
　湾曲形状の成形型上に、独立気泡を有するコア及び繊維を両端部で２点支持された状態で中間部が撓んで弾性変形させて腑型する腑型工程と、
　前記成形型と前記コアとの間に形成された密閉空間に真空引きにより前記樹脂を注入し、前記繊維に樹脂を含浸させる含浸工程と、
　前記樹脂を硬化後、前記成形型から前記カバーを脱型する脱型工程と、を備えている。
　この発明に係る車両用空調装置のカバーによれば、カバーは、断熱性を有する発泡材からなるコアと、このコアの全面を覆った繊維強化プラスチックからなる表皮部材とを備えているので、軽量性が得られるとともに、別途断熱材を貼付する工程が不要であり、生産性が向上する。
　また、コアは、湾曲形状に弾性変形されているので、コアが弾性変形していないカバー、即ちコアを予め熱的変形、切削加工または成型金型による変形を施したカバーと比べ、外力に対して反発力が大であり、耐荷重が増大する。
　また、この発明に係る車両用空調装置のカバーの製造方法によれば、コアは、腑型工程で、例えば自重により湾曲形状に弾性変形させるようになっているので、コアを熱的、切削あるいは成型金型により湾曲形状に変形する工程が不要となり、低コストで生産性が向上する。
この発明の実施の形態１による鉄道車両用空調装置のカバーを装着した鉄道車両用空調装置の平面図である。 図１の室外カバーを示す斜視図である。 図２の室外カバーを示す図２のＩＩＩ-ＩＩＩ線に沿った矢視断面図である。 図２の室外カバーを真空含浸成形法により製造する工程のうち、腑型工程を示す断面図である。 図２の室外カバーを真空含浸成形法により製造する工程のうち、含浸工程を示す断面図である。 コアの縦弾性率と自重によるコアの弾性変形との関係を示した図である。
　以下、実施の形態について図に基づいて説明するが、各図において、同一、または相当部材、部位については同一符号を付して説明する。
　実施の形態１．
　図１はこの発明の実施の形態１による鉄道車両用空調装置のカバー９，１０を装着した鉄道車両用空調装置を示す平面図である。但し、図においてカバー９，１０の右半分は切り欠かれている。
　この鉄道車両用空調装置は、車両の天井部に搭載されており、車両室内側と連通した室内ユニット部１と、室外ユニット部２と、室内ユニット部１及び室外ユニット部２を収納した筐体３と、室内ユニット部１及び室外ユニット部２をそれぞれ覆い、外気に晒された、室内カバー９及び室外カバー１０を備えている。
　室内カバー９及び室外カバー１０は、図２に示すように、矩形状であって上方に曲率１５００mm以上２５００mm以下で突出した曲面を有する湾曲形状であり、車両限界を考慮すると空間を最大限利用するためには１８００mmが適している。
　この室内カバー９及び室外カバー１０は、室内ユニット部１及び室外ユニット部２からなる空気調和機本体を覆っている。
　室内ユニット部１は、室内送風機４及び室内熱交換器５を有している。
　室外ユニット部２は、室外送風機６、室外熱交換器７、圧縮機８を有している。
　図３は図２のＩＩＩ-ＩＩＩ線に沿った矢視断面図である。
　室外カバー１０は、真空含浸成形法（VaRTM：Vacuum assist Resin Transfer Molding）で製造されており、断熱性を有する独立気泡を有する発泡材からなるコア１１と、この湾曲形状に弾性変形されたコア１１の全面を覆った繊維強化プラスチック（ＦＲＰ　以後ＦＲＰと呼ぶ。）からなる表皮部材１２と、コア１１の上面と表皮部材１２との間に介在した樹脂拡散媒体１３と、表皮部材１２の上面を被覆したゲルコート１４とからなり、それぞれは一体化されている。
　このＦＲＰは、軽量性、機械的特性、熱的特性、光的特性、成形方法の自由度の点で優れた炭素強化繊維に母材樹脂であるビニルエステル樹脂が含浸されたものである。
　なお、強化繊維として、ガラス繊維、アラミド繊維、ケブラー繊維、ボロン繊維、アルミナ繊維等であってもよい。
　また、母材樹脂として、ビニルエステル樹脂の代りに、熱硬化性のエポキシ樹脂、不飽和ポリエステル樹脂、フラン樹脂、ポリウレタン樹脂等であってもよい。
　繊維は、短繊維、長繊維等があるが、機械的特性の観点から長繊維が用いられ、形態としては織物繊維が用いられている。
　このコア１１は、縦弾性率が９～３３ＭＰａ、鉄道車両用材料燃焼試験（「鉄道に関する技術上の基準を定める省令」（平成１３年１２月２５日国土交通省令 第１５１号）の第８３条）における難燃性の合格基準を超えた断熱性を有し、熱硬化性樹脂の独立気泡の発泡材である。具体的には、コア１１は、フェノール樹脂の発泡材である。
　コア１１の厚さは、必要な断熱性と曲げ剛性が得られるように設定するが、３～３０ｍｍが適しており、９mmがより好ましい。３０ｍｍ以上では室外カバー１０の占有体積が大きくなるので望ましくなく、３ｍｍ以下では室外カバー１０として必要とする剛性が得られない。
　コア１１の縦弾性率は、後述する製造工程で受ける大気圧での変形を許容範囲に抑えることができ、かつコア１１を所定の曲率に変形できるようなものを採用する。
　変形は真空引きした際にコア１１が受ける大気圧や錘等の外力を用いてもよいが、より好ましくは自重により所定の曲率の湾曲形状に変形するものがよい。
　具体的には縦弾性率Eを所定形状の曲率R、長さｌ、厚さt、幅ｂ、密度ρ、大気圧P、寸法許容差fを用いて下式で得られる値の範囲とする。
Figure JPOXMLDOC01-appb-M000002
　(１)式は長方形断面を持ち自重を受ける２点支持梁の最大撓み量δmaxの式（２）
Figure JPOXMLDOC01-appb-M000003
から求められる撓み量が、曲率R、長さlを持つ曲面の最大深さＤ
Figure JPOXMLDOC01-appb-M000004
を上回り、かつ大気圧Ｐでの板厚変化
Figure JPOXMLDOC01-appb-M000005
が許容される変形量f内に収まることから導出される。
　最も好ましい条件として、t=９mm、f=０．１mm(精級の普通許容寸法差)、R=１８００mm、l=１８００mm、ρ=０.０００００００４kg/mm3を式(1)に代入すると、縦弾性率Eは９MPa以上３３MPa以下で最良の形態を実現できる。
　図６は実際に曲率１８００mmの成形型に厚さ９mmのコアを置き、自重で変形したコア１１が成形型に沿うか否かを試験した結果と、そのコア１１をバギングフィルムで覆い、真空引きしたときの板厚変化が精級の普通許容寸法差０．１mm以内か否かを試験した結果を○、×で示したものである。
　この結果から、９MPa以上３３MPa以下の縦弾性率Eを持つコア１１は熱的、切削加工工程を経ることなく自重で１８００mmの曲率に沿い、かつ大気圧での変形が精級の普通許容寸法差内に抑えられることを確認した。
　樹脂拡散媒体１３は、網目状の流路が形成されており、この流路に母材樹脂であるビニルエステル樹脂が流通し、炭素強化繊維に含浸するようになっている。
　この材質は、熱的、機械的な観点から炭素繊維が用いられている。
　なお、樹脂拡散媒体１３の材質は、ガラス繊維、アラミド繊維、ケブラー繊維、ボロン繊維、アルミナ繊維、熱硬化性のエポキシ樹脂、不飽和ポリエステル樹脂、ビニルエステル樹脂、フラン樹脂、ポリウレタン樹脂、熱可塑性のナイロン、ＰＢＴ，ＡＢＳ等であってもよい。
　ゲルコート１４は、室外カバー１０の内部に光、水、熱等の悪影響が及ぶのを防止するために、難燃性の観点から臭素化により難燃性である不飽和ポリエステル樹脂が用いられている。
　なお、ゲルコート１４の材質は、熱硬化性のエポキシ樹脂、ビニルエステル樹脂、フラン樹脂、ポリウレタン樹脂等でもよい。
　なお、室内カバー９の構成も、室外カバー１０と同じであり、その説明は省略する。
　次に、この発明の実施の形態１による鉄道車両用空調装置の室外カバー１０の製造方法について説明する。
　先ず、テフロン（登録商標）コーティングで離型処理された成形型１５の上にゲルコート樹脂を、スプレーガンを用いて塗布してゲルコート１４を形成する。
　次に、ゲルコート１４の上に織物繊維１６を所定の方向に所定の枚数、積層する。
　この後、樹脂拡散媒体１３を積層する。この樹脂拡散媒体１３は、織物繊維１６とゲルコート１４の間や織物繊維間に積層してもよいが、意匠性の点から織物繊維１６とコア１１との間に配置する。
　次に、樹脂拡散媒体１３上にコア１１を載置する。
　こうして、成形型１５上に、織物繊維１６、樹脂拡散媒体１３及びコア１１を順に腑型する腑型工程では、図４に示すように、コア１１は、自重により１８００mmの曲率の成形型１５に沿うように変形する。
　次に、図５に示すように、織物繊維１６を所定の方向に所定の枚数、積層する。
　その上にピールプライ１７を積層し、その上に樹脂拡散媒体１３を配置する。
　次に、真空ポンプの空気の吸引口１８と樹脂タンク（図示せず）からの注入される樹脂の注入口１９をそれぞれ成形型１５に取り付け、全体をバギングフィルム２０で覆い、空気が漏れないようにバギングフィルム２０の周囲を、シーラント２１で成形型１５に接着させる。
　この後、真空ポンプを用いてバギングフィルム２０で覆われた織物繊維１６を含めた内部を、真空状態にしたのち、バルブを解放して樹脂を注入する。
　バギングフィルム２０で覆われた内部は真空状態となり、樹脂は、２つの樹脂拡散媒体１３を通り、織物繊維１６の厚さ方向に含浸されながら繊維全体に拡散する（含浸工程）。
　この含浸工程の後、バルブを閉口し樹脂を硬化させる。
　樹脂の硬化後、バギングフィルム２０、上側の一方の樹脂拡散媒体１３、ピールプライ１７を取り外し、最後に成形型１５から、コア１１の全面がＦＲＰからなる表皮部材１２で覆われた鉄道車両用空調装置の室外カバー１０を脱型する。
　なお、室内カバー９についても、室外カバー１０と同じ方法で製造される。
　以上説明したように、この実施の形態による鉄道車両用空調装置のカバー９，１０では、カバー９，１０は、断熱性を有する発泡材からなるコア１１と、このコア１１の全面を覆った、繊維に樹脂が含浸したＦＲＰからなる表皮部材１２と、を備えているので、軽量性が得られるとともに、別途断熱材を貼付する工程が不要であり、生産性が向上する。
　また、コア１１は、自重による弾性変形で湾曲形状に変形されているので、コアが弾性変形していないカバー、即ちコアを予め熱的変形、切削加工または成型金型による変形を施したカバーと比べ、外力に対して反発力が大であり、耐荷重が増大する。
　また、コア１１は、発泡材で構成され、独立気泡であるので、コア１１の内部に樹脂が含浸することなく、カバー９，１０を製造する場合に真空含浸成形法を適用できる。
　また、コア１１は、縦弾性率９MPa以上３３MPa以下、厚さ３mm以上３０mm以下の独立気泡の発泡材であって、表皮部材１２で覆われる前では両端部で２点支持された状態で中間部が撓み変形するようになっているので、カバー９，１０が曲率１６００mm以上２０００mm以下の曲面を自重により実現でき、熱的、切削加工が不要となり、生産性が向上する。
　また、繊維は、比強度、比剛性の高い炭素繊維であるので、カバー９，１０は、軽量化を図ることができる。
　また、表皮部材１２及びコア１１は、鉄道車両用材料燃焼試験における難燃性の合格基準を超えているので、カバー９，１０は、鉄道車両用車両用としての難燃性が確保される。
　また、コア１１は、熱硬化性樹脂であるフェノール樹脂で構成されているので、機械的特性及び耐熱性に優れたカバー９，１０を得ることができる。
　また、この実施の形態による車両用空調装置のカバー９，１０の製造方法によれば、独立気泡の発泡材で構成されたコア１１は、真空含浸成形法においてカバー９，１０を製造する際に、コア１１内に樹脂が含浸することはない。
　また、成形型１５上に、コア１１を腑型する腑型工程では、コア１１は、常温で、自重により湾曲に変形され、コア１１を変形するに際して熱的加工、切削工程が不要となり、カバー９，１０の生産性が向上し、また金型コストが高い曲面形状を有する成型金型を用いずに湾曲形状に形成されており、低コストで生産される。
　なお、上記実施の形態では、コア１１を自重により湾曲変形させたが、錘による外力でコア１１を湾曲変形させるようにしてもよい。
　錘を用いた場合には、目的の曲率まで変形させても破損しない材料を用いればよい。
　なお、錘を用いた場合には、自重の場合と比較して、コア１１は短時間で湾曲形状に変形され、それだけカバー９，１１の生産性が向上する。
　また、ここでは錘を例に外力を説明したが、真空引きやオートクレーブ等の圧力、磁力、粘着力などの外力を用いても実現できる。
　なお、上記実施の形態では、鉄道用車両用空調装置のカバー、及びその製造方法について説明したが、勿論このものに限定されるものではなく、この発明は、例えば路面電車、バス用の空調装置のカバーにも適用することができる。
　１　室内ユニット部、２　室外ユニット部、３　筐体、４　室内送風機、５　室内熱交換器、６　室外送風機、７　室外熱交換器、８　圧縮機、９　室内カバー、１０　室外カバー、１１　コア、１２　表皮部材、１３　樹脂拡散媒体、１４　ゲルコート、１５　成形型、１６　織物繊維、１７　ピールプライ、１８　吸引口、１９　注入口、２０　バギングフィルム、２１　シーラント。

Claims (11)

  1. 　車両の天井部に搭載される、室内ユニット部及び室外ユニット部からなる空気調和機本体を覆う、車両用空調装置のカバーであって、
    　前記カバーは、断熱性を有する発泡材からなるコアと、このコアの全面を覆った繊維に樹脂が含浸した繊維強化プラスチックからなる表皮部材と、を備え、
    　前記コアは、弾性変形で湾曲形状に変形されている車両用空調装置のカバー。
  2. 　前記繊維は、炭素繊維である請求項１に記載の車両用空調装置のカバー。
  3. 　前記表皮部材及び前記コアは、難燃性である請求項１または２に記載の車両用空調装置のカバー。
  4. 　前記コアは、熱硬化性樹脂で構成されている請求項１～３の何れか１項に記載の車両用空調装置のカバー。
  5. 　前記車両用空調装置は、鉄道車両用空調装置である請求項１～４の何れか１項に記載の車両用空調装置のカバー。
  6. 　前記表皮部材及び前記コアは、鉄道車両用材料燃焼試験における難燃性の合格基準を超えている請求項５に記載の車両用空調装置のカバー。
  7. 　請求項１に記載の車両用空調装置のカバーを製造する製造方法であって、
    　湾曲形状の成形型上に、独立気泡を有する前記コア及び前記繊維を両端部で２点支持された状態で中間部が撓んで弾性変形させて腑型する腑型工程と、
    　前記成形型と前記コアとの間に形成された密閉空間に真空引きにより前記樹脂を注入し、前記繊維に樹脂を含浸させる含浸工程と、
    　前記樹脂を硬化後、前記成形型から前記カバーを脱型する脱型工程と、を備えている車両用空調装置のカバーの製造方法。
  8. 　前記腑型工程において、前記コアを常温で、自重により弾性変形させる請求項７に記載の車両用空調装置のカバーの製造方法。
  9. 　前記コアは、その縦弾性率Eが曲率R、長さｌ、厚さt、密度ρ、大気圧P、普通寸法許容差fからなる以下の式から算出される請求項８に記載の車両用空調装置のカバーの製造方法。
    Figure JPOXMLDOC01-appb-M000001
  10. 　前記腑型工程において、前記コアを常温で、外力により弾性変形させる請求項７に記載の車両用空調装置のカバーの製造方法。
  11. 　前記コアは、その縦弾性率が９～３３MPaである請求項９に記載の車両用空調装置のカバーの製造方法。
PCT/JP2013/063422 2012-05-14 2013-05-14 車両用空調装置のカバー、及びその製造方法 Ceased WO2013172345A1 (ja)

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