CN101258193A

CN101258193A - Use of recycled plastics for structural building forms

Info

Publication number: CN101258193A
Application number: CNA2006800254209A
Authority: CN
Inventors: 理查德·W·伦弗瑞（死亡）; 詹尼弗·K·林奇; 汤姆斯·J·诺斯科; 理查德·莱曼; 詹姆斯·D·艾都; 肯尼思·凡尼斯
Original assignee: Rutgers State University of New Jersey
Current assignee: Rutgers State University of New Jersey
Priority date: 2005-05-19
Filing date: 2006-05-19
Publication date: 2008-09-03

Abstract

The present invention provides modular plastic structural composites formed from a mixture of (A) high density polyolefin and one or both of: (B) a thermoplastic-coated fiber material, or (C) polystyrene, poly(methyl methacrylate), or a combination thereof. Composites molded in the form of I-Beams and bridges constructed therefrom are also disclosed.

Description

The purposes of regeneration plastic in the structural construction form

The cross reference of related application

The application's case is a U.S. patent application case the 10/563rd, No. 883 part continuation application, this case is the national applications stage of international application PCT/US03/22893 number, the applying date is on July 21st, 2003, this case requires U. S. application case 60/486 according to 35 U.S.C. § 119 (e), 205 right of priority, the latter's the applying date is on July 8th, 2003, its full content intactly is attached to herein by reference.The application's case also requires the right of priority of No. the 60/683rd, 115, U. S. application case according to 35 U.S.C. § 119 (e), the latter's the applying date is on May 19th, 2005, and its full content intactly is attached to herein by reference.

Technical field

The present invention relates to novel building form with anti-degrading composite manufacturing; Structure by the novel form manufacturing of this class; And the methods involving of making and use this type of form and structure.

Background technology

In the U.S. 500,000 wooden car bridges of surpassing being arranged is to assemble with the timber of chemical treatment.According to estimates, wherein have 40 percent to need repairing or rebuild.

There are some types with chemically treated timber, for example with the timber of creosote processing and the timber of pressure treatment.The manufacturing of this different materials and use are all relatively cheap, and the same with the timber of any other form, extensive use is all arranged, and improved the defensive ability/resistance ability to microbiological deterioration, fungus degrading and water.

Become more and more popular with chemically treated timber, Ren They has recognized that just its some Negative face rings.Chemical treatment timber can consume splendid available, renewable, renewable resources, and brings toxicity.For example, the timber that pressure treatment or CCA handle is to handle with the very big chromated copper arenate of toxicity, and is nonflammable.If think the timber that landfill CCA handled, consider the poisonous chemical diafiltration, this disposal strategy is just improper.The timber that the disposal creosote was handled then needs to use special incinerating apparatus.These material handlings get up more difficult, more expensive than using.But, because these materials were just just felt by people with the economic impact and the environmental influence of chemically treated timber than long work-ing life.

On behalf of chemical treatment, structure regeneration plastic timber cross a kind of possible replacement scheme of timber.No. the 6th, 191,228, United States Patent (USP) case, 5,951, No. 940,5,916, No. 932,5,789, No. 477 and 5,298, structure regeneration plastic Wood composite material is disclosed for No. 214, this material is with consumption back plastics and produces the back plastics and make, wherein polyolefine mixed with polystyrene or thermoplastics coated fibres material (as glass yarn).The railroad tie that these structural composite materials were handled as creosote and the substitute of other rectangular cross section materials have obtained the coml success at present.But the market of structure regeneration plastic timber is limited, and this is because from the installation cost basis, although it has used regeneration type waste plastic, compares the wooden frame of handling, and cost is still too high.

Significant cost variance becomes more obvious in the construction process of bridge structure, wherein substitute the wooden frame that pressure treatment is crossed with structure regeneration plastic wood composite beam.Though structure regeneration type composite beam is the same solid with the timber that CCA handled, composite beam is hard not as the latter, easily sagging or sloughing.Size and the more rectangular beams of use by increasing beam can remedy this point defect.But this can allow compared with the timber of handling originally higher with regard to high material cost and construction cost.

The structural beams of sloughing can not used engineering resin (as polycarbonate or ABS) manufacturing yet.But this is more expensive than the structural composite material made from the regeneration plastic.Compare the timber of handling, on the basis of installation cost, have the structured material of the regeneration plastic manufacturing of cost competitive edge that certain demand is still arranged.

Summary of the invention

Have been found that now United States Patent (USP) case the 6th, 191, No. 228,5,951, No. 940,5,916, No. 932,5,789, No. 477 and 5,298, No. 214 not phase mixed polymer mixes, and can form a kind of structural form, all cost advantage will be arranged more than traditional rectangle regeneration plastic structural beams.Structural form according to the present invention is cast into the object of independent complete shaping, and comprises the pattern of various beams such as I type beam, T type beam, C type beam, and the same axial body of wherein one or more horizontal flanges engages, and axially body is called as wing plate in I type beam field.These pattern cross-sectional areas reduce and mean that the cost in the materials consumption significantly saves, and do not sacrifice mechanical property simultaneously.In application, can further save cost by the molded structure technology that allows.

Therefore, according to an aspect of the present invention, a kind of molded plastic structure matrix material is provided, it has the wing plate parts of arranging along transverse axis, and have at least one and arrange along transverse axis, the edge of a wing parts parallel with the wing plate parts, these edge of a wing parts are by the upper surface or the lower surface engages of monoblock casting one-tenth and wing plate parts, wherein this matrix material be by (A) high density polyolefins and (B) mixture of thermoplasticity coated fibres material, polystyrene or its combination constitute.High density polyolefins is high density polyethylene(HDPE) (HDPE) preferably.Thermoplasticity coated fibres material is the carbon fiber or the glass fibre (for example glass yarn) of thermoplasticity coating preferably.

A kind of molded plastic structure matrix material also is provided, it comprises the wing plate parts of arranging along transverse axis, and have at least one and arrange along transverse axis, the edge of a wing parts parallel with the wing plate parts, these edge of a wing parts are by the upper surface or the lower surface engages of monoblock casting one-tenth and wing plate parts, and wherein this matrix material is to be made of the mixture of (A) high density polyolefins with (B) thermoplasticity coated fibres material polymethylmethacrylate or its combination.

Edge of a wing size with respect to the wing plate part dimension can not be too big, in order to avoid edge of a wing parts bend under load.The vertical dimension of edge of a wing parts (thickness) preferably wing plate parts vertical dimension (not containing edge of a wing parts) about 1/10th to about 1/2nd, the width of the whole edge of a wing parts of measuring perpendicular to edge of a wing parts transverse axis is perpendicular to extremely about ten times of about twices of the width that wing plate parts transverse axis measures.

Other resulting structure forms according to the present invention comprise the tongue trough plate, and it constitutes the interlocking external member.It is found that the interlocking external member has reduced the thickness of required plate, this is because due to the mode of external member load diversity between interlock board.Same this means that also material uses the important economy that goes up cost, does not sacrifice mechanical property simultaneously.In application, can further save cost by the molded structure technology that allows.

So, according to a further aspect in the invention, a kind of flat substantially molded plastic structure matrix material is provided, it has a groove face and a cast-in-block ligulate face, each face is all perpendicular with the composite wood charge level, wherein this matrix material is according to (A) high density polyolefins and (B) thermoplasticity coated fibres material, the mixture of polystyrene or its combination constitutes, wherein this groove face has defined a groove, and the size of ligulate face will make it engage with a groove interlocking, the size of this groove is defined by groove face, and the size of this groove face and ligulate face will allow a plurality of flat substantially molded plastic structure matrix materials interlocking assemble, to disperse the some loads that is born in all component.

In this respect another embodiment according to the present invention provides a kind of molded structure matrix material, wherein with poly-(methyl methacrylate) (PMMA) replace polystyrene.Preferably, substituting at least 90% polystyrene with poly-(methyl methacrylate), more preferably is to replace whole polystyrene.In one embodiment, this matrix material comprises poly-(methyl methacrylate) component of about 20 to about 65 weight %, this poly-(methyl methacrylate) component contains poly-(methyl methacrylate) at least about 90 weight %, this matrix material also comprises the about 40 high density polyolefins components to about 80 weight percents, and this polyolefin component contains at least about the high density polyethylene(HDPE) of 75 weight % (HDPE).

Preferred plane molded plastic structure matrix material has at least one pair of parallel relative groove face and ligulate face, has defined the width or the length of matrix material between groove face and ligulate face.Preferred matrix material also has tabular size, and wherein length is the problem of design alternative, and width is extremely about ten times of about twices of height or thickness.

The purposes of molded plastic structure matrix material comprises builds load-bearing equipment, for example bridge.Therefore, according to a further aspect in the invention, one bridge block is provided, build with I type beam of the present invention, have at least two row parallel big I type girder and a plurality of less I type secondary beam by the bridge pier support, secondary beam is parallel to each other, and be vertically fixed between the big I type girder of two row, wherein the size of the upper surface of I type time flange of beam and lower surface is wanted can embed among the opening that is defined by the I type girder upper surface and the lower surface edge of a wing.

Distance between the I type girder of embarking on journey and the I type secondary beam of embarking on journey depends on various factors, for example edge of a wing size and wing plate size, the plastic components of this matrix material, and the bridge load that will bear.In addition, whether the horizontal axle of I type girder or I type secondary beam stretches along direction of travel is a selection problem in the design, may depend on above-mentioned factor whole or in part.

Because secondary beam is to embed among the opening that is defined by the I type girder upper surface and the lower surface edge of a wing, the upper surface of I type secondary beam I type girder upper surface below recessed, recessed distance is at least the thickness of I type girder top flange.Therefore the bridge of building in this respect according to the present invention will further comprise the platform surface that is fixed on I type girder or the I type secondary beam.Distance between the top flange of the parallel I type girder that the size of preferred platform surface will be fit to embark on journey.The better selected thickness of platform surface size will provide a upper surface for platform surface, and the upper surface of the parallel I type girder that this upper surface is embarked on journey together is substantially on same plane.Other preferred platform surfaces constitute with flat substantially molded plastic structure matrix material of the present invention, and it has interlocking groove face and ligulate face.

Molded assembly of the present invention allows to build load type assembling external member with less firmware, has reduced initial bridge construction cost, and the expense of secular maintenance cost and the perishable assembly of replacing.This plastics composite also will be used for a long time than the timber of handling, and wants much less in the needed maintenance of usage period internal ratio timber, helps saving cost more.

The present invention provides a kind of composite architectural materials equally, and this material is to mix with high density polyolefins and poly-(methyl methacrylate).This material can be used to construct various object, for example railroad tie and structural slab.

In addition, although the unpredictability of mixed polymer, people also find, use the PMMA replace polystyrene, and polyolefine and poly-(methyl methacrylate) can constitute immiscible polymeric blends.This observations is astonishing, is because the predict what plastics of having no idea can constitute acceptable not mixed polymer mixture mutually with polystyrene.For example, polyvinyl chloride just can not constitute this mixture with polyolefine.

Polyolefine of the present invention/PMMA mixture has beyond thought characteristic.For example, it is harder than polyolefine/polystyrene blends, though polystyrene is the same substantially with the hardness separately that PMMA measures with tensile modulus.Equally surprisingly, almost the PMMA with independent is the same strong for the mixture of polyolefine/PMMA.

The above-mentioned target of the present invention, other targets, feature and advantage will be more apparent according to the detailed embodiment and the description of drawings of following preferred embodiment.

Description of drawings

Figure 1 shows that sectional view according to I type beam of the present invention;

Fig. 2 is the side-view of I type beam among Fig. 1, and is vertical with sectional view;

Figure 3 shows that sectional view according to C type beam of the present invention;

Fig. 4 is the side-view of C type beam among Fig. 3, and is vertical with sectional view;

Figure 5 shows that sectional view according to T type beam of the present invention;

Fig. 6 is the fish-eye view of T type beam among Fig. 5;

Figure 7 shows that sectional view according to ligulate panel of the present invention and flute profile panel;

Figure 8 shows that side-view according to bridge of the present invention with I type beam assembling of the present invention;

Fig. 9 is the top view sectional view of bridge among Fig. 8;

Figure 10 shows that small-sized I type beam according to the present invention is vertically fixed to according to the top view sectional view on the large-scale I type beam of the present invention;

Figure 11 is the diagram of viscosity logarithmic value and shearing rate logarithmic value, and this figure has compared the extruding composite material with different PMMA per-cents;

Figure 12 is the viscosity logarithmic value of extruding composite material and the diagram of PMMA per-cent;

Figure 13 a is the hot-fluid analysis of measuring the fusing point of the first heating of extruding composite material;

Figure 13 b is the hot-fluid analysis of measuring the fusing point of extruding composite material after the first heating shown in Figure 13 a;

Figure 13 c is the diagram of the compound matrix material fusing point of extruding as PMMA per-cent function;

Figure 13 d is the diagram of the Heat of fusion of extruding composite material as PMMA per-cent function;

Figure 14 is the stress and the tensile diagram of extruding composite material;

Figure 15 is the diagram of modulus as the function of the PMMA per-cent of extruding composite material;

Figure 16 is a logarithmic diagram of the time of modulus logarithm and extruding composite material;

Figure 17 is a series of SEM images of extruding composite material surface tissue;

Figure 18 is a series of SEM images of surface tissue of the PMMA/HDPE extruding composite material of 60/40 ratio;

Figure 19 is that peak stress by the matrix material of jet moulding structure is as the diagram of the function of PMMA per-cent;

Figure 20 be matrix material by jet moulding structure when fracture tension force as the diagram of the function of PMMA per-cent;

Figure 21 is by the stress of the matrix material of jet moulding structure and tensile diagram;

Figure 22 is that modulus by the matrix material of jet moulding structure is as the diagram of the function of PMMA per-cent;

Figure 23 is that HDPE phase place fusing point by the matrix material of jet moulding structure is as the diagram of the function of PMMA per-cent.

Embodiment

Molded plastic structure matrix material of the present invention is to use common continuous polymer mixture technology preparation, this technology is by United States Patent (USP) case the 5th, 298,214 and 6, mixing high density polyolefins and polystyrene are disclosed in 191, No. 228, by United States Patent (USP) case the 5th, mixing high density polyolefins and thermoplastic coated fibres material are disclosed for 916, No. 932.The disclosure of these three patent cases mode by reference is incorporated herein.

According to United States Patent (USP) case the 6th, 191, No. 228 disclosed, matrix material can adopt and contain 20 polystyrene component to about 50 weight % of having an appointment, this component contains the polystyrene at least about 90 weight %, and containing 50 the high density polyolefins components of having an appointment to about 80 weight %, this component contains at least about the high-density polystyrene of 75 weight % (HDPE).The matrix material that contains 25 to about 40 weight % the polystyrene component of having an appointment is preferred, and the matrix material that contains 30 to about 40 weight % the polystyrene component of having an appointment is more preferably to select.The polyolefin component that contains at least about the HDPE of 80 weight % is preferred, and is more preferably to select at least about the HDPE content of 90 weight %.

United States Patent (USP) case the 6th, 191, No. 228 disclosed hybrid technology also can be used for the present invention, comprises the matrix material that poly-(methyl methacrylate) component adds polystyrene component with preparation, perhaps replaces polystyrene component with poly-(methyl methacrylate) component.Can adopt and contain poly-(methyl methacrylate) (PMMA) matrix material of component, this component contains the PMMA of at least 90 weight %,, the remaining component of matrix material is the high density polyolefins component, it contains the high-density polystyrene (HDPE) of at least 75 weight %.The polyolefin component that contains at least about the HDPE of 80 weight % is preferred, and HDPE content is more preferably selected at least about 90 weight %.The minimum of PMMA component is wanted to make melt viscosity produce perceptible increase effectively in the mixture.It is preferred containing 0.1 to about 65 weight % poly-(methyl methacrylate) matrix material (PMMA) of having an appointment.The matrix material that contains 10 to about 40 weight % the PMMA of having an appointment is more preferably to select, and the matrix material that contains 20 to about 35 weight % the PMMA of having an appointment is optimal selection.

Polyolefine of the present invention/PMMA mixture has beyond thought characteristic.For example, it is harder than polyolefine/polystyrene blends, though polystyrene is the same substantially with the hardness separately that PMMA measures with tensile modulus.It is also than polyolefine/polystyrene blends flexible more.The ability that absorbs energy when " toughness " definition (Toughness) is deformation and do not rupture.For example, the bridge made from polyolefine/PMMA mixture.Equally surprisingly, almost the PMMA with independent is the same strong for the mixture of polyolefine/PMMA.

According to United States Patent (USP) case the 5th, 916, No. 932 disclosed methods, this matrix material can further be coated with the blending in of fibers of (thermoplastic-coated) with thermoplastic, the thermoplastic coated fibres has 0.1 millimeter of minimum length, so the product of finishing contain the 10 thermoplastic coated fibres to about 80 weight % of having an appointment.The United States Patent (USP) case discloses the matrix material that contains 20 to about 90 weight % the polymeric constituent of having an appointment for the 5th, 916, No. 932, and this polymeric constituent is HDPE and the about 10 thermoplastic coated fibers to about 80 weight % of at least 80 weight %.

Be applicable to that polyolefine-poly styrene composite material of the present invention demonstrates the compression modulus of 170000psi at least and the ultimate compression strength of 2500psi at least.Preferred polyolefine-poly styrene composite material demonstrates the compression modulus of 185000psi at least and the ultimate compression strength of 3000psi at least.More excellent polyolefine-poly styrene composite material demonstrates the compression modulus of 200000psi at least and the ultimate compression strength of 3500psi at least.

Be applicable to that preferably polyolefine of the present invention-PMMA matrix material demonstrates the compression modulus of 227000psi at least and the ultimate compression strength of 3900psi at least.Optimum polyolefine-PMMA matrix material demonstrates the compression modulus of 249000psi at least and the ultimate compression strength of 4300psi at least.

The matrix material that contains the thermoplastic coated fiber according to the present invention demonstrates the compression modulus of 350000psi at least.The compression modulus of preferred fibre is 400000psi at least.

The matrix material that contains the thermoplastic coated fiber demonstrates the ultimate compression strength of 4000psi at least.The ultimate compression strength of preferred fibre is 5000psi at least.

Polyolefine of the present invention/PMMA mixture is applicable to composite architectural materials, for example three-dimensional timber.Timber with these mixture manufacturings can be used for such as joist, pillar and crossbeam.Polyolefine/PMMA wood toughness provides further security, and material can sink earlier before fracture, will give the alarm for the fault that might take place like this.Contain the polyolefine/thermoplastic fibres of PMMA mixture and also be applicable to the making of railroad tie.

For some purposes, railroad tie for example, it is very important that composite architectural materials demonstrates very special attribute.For example, this material must be non-water or fuel absorbent, anti-degraded and resistance to wearing has tolerance to the temperature in the common scope that rail exposed to the open air, and is nonconducting.In addition, railroad tie must meet certain machinery standard.For example, the railroad tie of plastics composite will possess along the axial compression modulus at least about 170000psi of sleeper.The meaning of term " sleeper is axial " is the longest axle of railroad tie.More preferably select and be, the composite architectural materials that can be used as railroad tie possess along sleeper axial at least about 200000psi and the compression modulus of 225000psi more preferably.Optimal selection is that when as railroad tie, this plastics composite will have the compression modulus at least about 250000psi.

The present invention is specially adapted to railroad tie because composite architectural materials along disalignment to having demonstrated different qualities.Because the fibre content of (major axis of railroad tie) high orientation on the direction on ground, sleeper is along axially demonstrating incredible intensity and hardness.Simultaneously, on the Z-axis of the direction of passing fibre content, this sleeper more soft relatively pliable and tough (flexible).Therefore, can not make railway bending or the pressurized that vertically is laid on the sleeper according to the present invention with the railroad tie of composite architectural materials manufacturing, because on this direction, there is certain elasticity.But because the intensity on the major axis of sleeper, the railway that is laid on will can laterally not move or separate.Because this factor, railroad tie of the present invention is just superior a lot of compared with the wooden crossties of present usefulness or concrete system sleeper.

In addition, about railroad tie, importantly when placing lateral load minimum about 24000 pounds of following times, the rail that is laid on above the sleeper can not be separately above about 0.3175 centimetre.Lateral load is meant the outside pressure that Train wheel applies to rail.This composite architectural materials also should be able to bear the vertical static load at least about 39000 pounds.This index is to weigh that sleeper is stopped train thereon and the tolerance that do not cause permanent deformation, or to the stressed tolerance that enters sleeper of railway.In addition, the toughness of polyolefine/PMMA material improved material can the disruptive ability by ailing the time.The ability that also needs at least 140000 pounds of vertical dynamic loads.This index is to weigh sleeper to stand the ability that train passes through.

Polyolefine/polystyrene and polyolefine/PMMA mixture can both be used for constituting the construction package that the edge of a wing is housed of the present invention.According to the sectional view of I type beam 10 of the present invention as shown in Figure 1, the test pattern of identical I type beam as shown in Figure 2.I type beam has traditional structure, and this structure is to be made of intermediary wing plate or main element 20, top flange 30 and lower flange 40.Edge of a wing parts comprise projecting part 50, and it has exceeded the width of wing plate 20.As described below, the surface of wing plate 60 constitutes a structure, this structure can with other structural engagement (as with less beam).Obviously will the fly wing to wing width B of plate member of the width A of edge of a wing parts is big.Will the fly wing to wing height of plate member of the height C of edge of a wing parts is little.Although the height of edge of a wing parts is low and the width wing plate parts are narrow, I type beam can support heavy type structure, and can be used for the structure of bearing load, for example the bridge class.

According to the sectional view of C type beam 12 of the present invention as shown in Figure 3, the side-view of identical C type beam as shown in Figure 4.C type beam also has middle wing plate parts 20, top flange 30 and lower flange 40.Edge of a wing parts also comprise projecting part 50, and it has exceeded the width of wing plate 20.As described below, the surface of wing plate 60 also constitutes a structure, this structure can with other structural engagement (as with less beam).

According to the sectional view of T type beam 15 of the present invention as shown in Figure 5, the fish-eye view of identical T type beam as shown in Figure 6.T type beam has a structure, and this structure is to be made of intermediary wing plate 20 and top flange 30, does not possess the lower flange.Edge of a wing parts also comprise projecting part 50, and it has exceeded the width of wing plate 20.As described below, the surface of wing plate 60 constitutes a structure, this structure can combine with other structures (as with less beam).

Fig. 7 has shown the ligulate-

flute profile panel

100 and 150 of assembling.Panel 100 comprises the end 110 with ligulate assembly 120 and the opposite end 130 of defining slot 140.Panel 150 comprises the end 160 with ligulate assembly 170 and the opposite end 180 of defining slot 190.Engage with the groove 190 of panel 150 with the ligulate assembly 120 interlockings ground that illustrates panel 100.The groove 140 of panel 100 also can engage with the ligulate assembly of another panel to interlocking.Similarly, the ligulate assembly 170 of panel 150 can engage with the groove of another panel.The flat-top 125 of panel 100 and the flat-top 175 of panel 150 can be used as load carrying face or barrier when panel is assembled into a structure.

Fig. 8 and Fig. 9 have showed respectively with the side-view of the vehicle bridge 200 of above-mentioned building configuration assembling and the sectional view at a part of top.In bridge structure, bigger I

type beam railway

213 and 214

end

211 and 212 has separately been pinned by

stake

216 and 217 usefulness firmware (not shown)s respectively.The other end 220 of I type beam and 221 is locked on

corresponding post

223 and 224 similarly.Less I type joist 228,229 and 230 end 225,226 and 227 are fixed on the face 260 of I type beam 213, and the corresponding the other end 231,232 and 233 of three less I type beams is fixed on respectively on the face 261 of I type beam 214.Similarly, less I type joist 237,238 and 239 end 234,235 and 236 are fixed on the face 262 of I type beam 214.

Figure 10 is the top view sectional view, expression with

L type bail

243 and 244 and firmware 245,246,247 and 248 ends 225 with less I type joist 228 be fixed on the face 260 of I type beam 213 greatly.Be fixed to bail 243 and

firmware

245 and 246 ends 225 also in Fig. 8, to have on the face 260 of I type beam 213 and show I type beam 228.Fig. 8 has also shown with bail 247 and

firmware

248 and 249 ends 231 with I type beam 228 and has been fixed on the face 261 of I type beam 214.

Fig. 8 and Fig. 9 have also shown with interlocking

panel

271 and 272 bridge piers 270 that constitute, have wherein engaged with the groove 275 of panel 272 to tongue 274 interlockings of panel 271.The tongue 276 interlockings ground of panel 272 engages with groove 277, or the

like.Panel

271 and 272

corresponding end face

279 and 280 comprise the surface 290 of bridge pier 270.

Suitable firmware is with commonly used basically, includes but not limited to nail, screw, spike, bolt etc.

United States Patent (USP) case the 5th, 298,214,5,916,932 and 6,191, No. 228 disclosed molding methods can be used for constructing molded plastic structure matrix material shape of the present invention.But, because compared with the crossbeam of the square-section of previous casting, the object of formation has irregular cross section, this matrix material mixture is preferably under the pressure and is squeezed into the mould from forcing machine, for example be pressed into the mould massively from about 900 to about 1200psi, and prevented to form the space.Similarly, may be necessary along the horizontal axis application of force of crossbeam, for example the hydro-cylinder that prolongs with horizontal shaft length takes out the refrigerative model from mould.

According to the matrix material I type beam of polyolefine of the present invention and polystyrene, have 61 square feet sectional area, it demonstrates 900in ⁴Rotational inertia.According to polyolefine of the present invention-poly styrene composite material I type beam, have 119 square inches sectional area, demonstrate 4628in ⁴Rotational inertia.This has represented the rotational inertia of the maximum that any thermoplastic materials produced of any structure, and has compared square-section wooden frame with 63 square inches of sectional areas 257 and 425in ⁴Between the rotational inertia measured and square-section wooden frame with 48 square inches of sectional areas 144 and 256in ⁴Between the rotational inertia measured.Final result is, if with the Composite Preparation of square-section, polyolefine-poly styrene composite material bridge rated load rate is attached most importance to 120000 pounds, if make with I type beam of the present invention, only weighs 30000 pounds.

Polyolefine/polystyrene and polyolefine/PMMA mixture also can be used for constituting and possesses preferable about 1/8 inch structural slab to about 1 inch thickness.The length of structural slab and the scope of width preferably are about 8 inches to about 20 feet independently of one another.Structural slab also has the compression modulus of 200000psi at least and the intensity of 3000psi at least.The definition of " intensity " is that a kind of material stands stress and can not fragment into many sections top.

Therefore molded plastic structure matrix material of the present invention is representing the most effective non-degrading texture material of preparation up to now, and it has the favorable mechanical performance.The substructure that the invention enables preparation to possess the rated load rate becomes possibility, and this substructure is from former lost a large amount of shoddies.

The intention of above preferred embodiment should be regarded as for example, rather than limit its scope by the present invention that claims defined.It is evident that, only otherwise, also can adopt the many variations and the array configuration of above-mentioned feature departing from the present invention in claims.These variations can not be regarded and violate spirit of the present invention and category as all these variations all will be included in the scope of following claim.

Example

Following example provides the representative preparation method according to polyolefine/PMMA of the present invention.

Example 1-extruding

With Lan Kasier (Randcastle) Special Mixed squeezer under 180RPM and 200-210 ℃, with HDPE (CPChem Marlex HHM-5502BN) and PMMA (the resin glass V045100 of Atofina) mechanical stirring and melting mixing.The component ratio of HDPE/PMMA is: 100/0,90/10,80/20,70/30,65/35,60/40,50/50,40/60,30/70,20/80,10/90 and 0/100.

Carry out the rheology test, the viscosity of the granular matrix material that research was pushed.The PMMA content of the matrix material that pushed increases towards the direction of pure PMMA, and the viscosity of the matrix material that pushed is also along with increasing (Figure 11).No matter be high shear rate or low shear rate, all observe the non-linear dependency (Figure 12) of stickiness to PMMA concentration.

The matrix material that pushed is carried out thermomechanical analysis, check fusing point and melting heat (Figure 13 a-d).Fusible polyolefine per-cent is relevant approx in the melting heat of mixture and the mixture.

Carry out crooked experiment, the mechanical characteristics of the matrix material that research was pushed.The sample diameter range is between the 1.18-1.95 millimeter.In order to keep 16: 1 L: the D ratio, supporting span is 20 millimeters or 28 millimeters.Figure 14 is the stress and the tensile diagram of every kind of matrix material that pushed.Table I has been illustrated the modulus (stress and tensile ratio in the crooked deformation) of the matrix material of the extruding that constitutes according to component:

Table I

％PMMA	％HDPE	Modulus (MPa)	Standard deviation (MPa)	Modulus (ksi)
％PMMA	％HDPE	Modulus (MPa)	Standard deviation (MPa)	Modulus (ksi)	0	100	1154	36	167
10	90	1508	94	219	0	100	1154	36	167
10	90	1508	94	219	20	80	1916	87	278
30	70	2017	104	292	20	80	1916	87	278
30	70	2017	104	292	35	65	1689	85	245
40	60	1805	113	262	35	65	1689	85	245
40	60	1805	113	262	50	50	2053	269	298
60	40	2495	250	362	50	50	2053	269	298
60	40	2495	250	362	70	30	2667	155	387
80	20	2761	147	400	70	30	2667	155	387
80	20	2761	147	400	100	0	3437	104	498

The modulus of the matrix material that pushed increases (Figure 15) with PMMA content.Figure 16 is the diagram of modulus logarithm as logarithmic function of time, and this figure shows the modulus of mixture and the resistibility of the deformation that causes is in time increased with PMMA content.

Obtain the SEM image, check the surface tissue (Figure 17) of the matrix material that pushed.60/40 PMMA/HDPE matrix material demonstrates common successive form (Figure 18).Known common successive form demonstrates in the different stages and has very high stress transfer.

Example 2-jet molding

Win V55-200 jet molding machine with treasured, HDPE (CP Chem Marlex HHM-5502BN) and PMMA (the resin glass V045100 of Atofina) are carried out mechanically mixing and jet molding.The temperature that matrix material carries out molding is at 392 °F.The component ratio of HDPE/PMMA is: 100/0,90/10,80/20,70/30,65/35,60/40,50/50 and 40/60.

In all mixtures, the tensile strength of mixture all keeps sizable homoeostasis, rises to common continuum (containing) from pure polyolefine.(Figure 19).If sneak into the PMMA of high per-cent in polyolefine, tensile straining descends with nonlinear way, but still more much higher than pure PMMA.(Figure 20).

The modulus of mixture increases with PMMA, but reduces the tension force failure and produced toughness.(Figure 21).Multiple mixture all has higher toughness than simple PMMA or polyolefine.Table II has been concluded the result of Figure 21:

Table II

％PMMA	Width (inch)	Thickness (inch)	Modulus (ksi)	Peak stress (ksi)	Tension force during the % fracture
％PMMA	Width (inch)	Thickness (inch)	Modulus (ksi)	Peak stress (ksi)	Tension force during the % fracture	0	0.494	0.138	180.682	3.7	73.447
10	0.495	0.138	227.439	3.9	50.713	0	0.494	0.138	180.682	3.7	73.447
10	0.495	0.138	227.439	3.9	50.713	20	0.495	0.137	248.911	4.3	19.046
30	0.496	0.138	267.694	4.5	6.716	20	0.495	0.137	248.911	4.3	19.046
30	0.496	0.138	267.694	4.5	6.716	35	0.496	0.137	284.208	4.5	5.326
40	0.496	0.137	294.963	4.4	3.639	35	0.496	0.137	284.208	4.5	5.326
40	0.496	0.137	294.963	4.4	3.639	50	0.497	0.132	328.982	4.6	2.873
60	0.496	0.135	346.735	4.3	2.013	50	0.497	0.132	328.982	4.6	2.873

These mixtures are substantially all observed the mixing rule of modulus, and this shows reached remarkable good stress transfer between the different steps in this mixing system.(Figure 22).Figure 23 provides DSC reheat result.

The description of above-mentioned example and preferred embodiment should be regarded as for example, rather than limit its scope by the present invention that claims defined.It is evident that, only otherwise, also can adopt the many variations and the array configuration of above-mentioned feature departing from the present invention in claims.These variations can not be regarded and violate spirit of the present invention and category as all these variations all will be included in the scope of following claim.

Claims

1. molded plastic structure matrix material, it comprises the wing plate parts of arranging along a transverse axis, and it is at least one along transverse axis arrangement and the edge of a wing parts parallel with these wing plate parts, these edge of a wing parts by monoblock casting become upper surface or lower surface engages with these wing plate parts, wherein said matrix material be by (A) high density polyolefins and (B) thermoplastic coated fibres material or (C) mixture of a certain in polystyrene, poly-(methyl methacrylate) or two kinds or its combination constitute.

2. according to the molded plastic structure matrix material of claim 1, wherein said high density polyolefins is high density polyethylene(HDPE) (HDPE).

3. according to the molded plastics matrix material of claim 1, wherein said thermoplastic coated fibres material is the carbon fibre or the glass fibre of thermoplastic coating.

4. according to the molded plastics matrix material of claim 1, wherein the vertical range of these edge of a wing parts (thickness) is about 1/10th to about 1/2nd of these wing plate parts vertical range of not containing any edge of a wing parts.

5. according to the molded plastics matrix material of claim 1, wherein the whole width of these edge of a wing parts is that about twice of width of these wing plate parts is to about ten times, the former is perpendicular to the transverse axis of these edge of a wing parts and measures, and the latter is perpendicular to the transverse axis of these wing plate parts and measures.

6. according to the molded plastics matrix material of claim 1, it is characterized by matrix material is I type beam.

7. according to the molded plastics matrix material of claim 1, it is characterized by matrix material is C type beam.

8. according to the molded plastics matrix material of claim 1, it is characterized by matrix material is T type beam.

9. flat substantially molded plastic structure matrix material, it comprises groove face and cast-in-block ligulate face, each face is all perpendicular with the face of this matrix material, wherein this matrix material be by (A) high density polyolefins and (B) thermoplastic coated fibres material or (C) mixture of one or both in polystyrene or poly-(methyl methacrylate) constitute, wherein this groove face defines a groove, and the size of this ligulate face will make it engage with a groove interlocking, the size of this groove is defined by this groove face, and the size of this groove face and ligulate face will allow a plurality of flat substantially molded plastic structure matrix materials interlocking assemble, to disperse the some loads that is born in all component.

10. according to the flat molded plastics matrix material of claim 9, it comprises at least one pair of parallel relative groove face and ligulate face, has defined the width or the length of this matrix material between the two.

11. according to the flat plastics composite of claim 10, wherein said width is that the big or small about twice of the height (thickness) of this matrix material is to about ten times.

12. bridge of building with the I type beam in the claim 6, it comprises a plurality of parallel big I type girders by the bridge pier support of embarking on journey, with a plurality of less I type secondary beams, secondary beam is parallel to each other, and be vertically fixed between the adjacent lines of these big I type girders, wherein the size of the upper surface of these I types time flange of beam and lower surface is wanted can embed among the opening that is defined by the upper surface and the lower surface edge of a wing of these I type girders.

13. the bridge according to claim 12, it comprises that also one is fixed on the platform surface on this I type girder or the secondary beam.

14. the bridge according to claim 13, the size of wherein said platform surface will be mated between the top flange of these parallel I type girders of embarking on journey.

15. the bridge according to claim 14, wherein said platform surface has a thickness, and selecting this thickness is will be for this platform surface provides a upper surface, this upper surface with the upper surface of these parallel I type girders of embarking on journey substantially on same plane.

16. bridge according to claim 13, wherein said platform surface is to constitute with a plurality of flat substantially molded plastic structure composite material faces, these panels comprise groove face and cast-in-block ligulate face, this ligulate face is parallel with this groove face, all perpendicular to the plane and the direction of travel of this composite material face, wherein each composite material face is to be made of the mixture of (A) high density polyolefins with (B) a thermoplastic coated fibres material, poly-(methyl methacrylate) or its combination to each face; Panel for each matrix material, this groove face defines a groove, and the size of this ligulate face is wanted and can be engaged with a groove interlocking, this groove has the size of the groove that is defined by this groove face, to such an extent as to described a plurality of composite material face constitutes interlocking assembly, wherein adjacent panels combines by the mode of glossal canal; And the size of the groove face of each panel and ligulate face wants to allow the flat substantially molded plastic structure matrix material interlocking of described majority assemble, to disperse the some loads that is born in all component.

17. molded plastics matrix material according to claim 1 or 9, wherein said matrix material comprises poly-(methyl methacrylate) component of about 20 to about 65 weight %, this component contains poly-(methyl methacrylate) at least about 90 weight %, and comprising about 40 high density polyolefins components to about 80 weight %, this component contains at least about the high density polyethylene(HDPE) of 75 weight % (HDPE).

18. molded plastics matrix material according to claim 1 or 9, wherein said matrix material comprises about 20 polymeric constituents to about 90 weight %, and about 10 thermoplastic coated fibers to about 80 weight %, wherein said polymeric constituent comprises poly-(methyl methacrylate) component of about 20 to about 65 weight %, this component contains poly-(methyl methacrylate) at least about 90 weight %, and comprises about 40 high density polyolefins to about 80 weight %.

19. according to the molded plastics matrix material of claim 1 or 9, wherein said matrix material comprises about 20 polymeric constituents to about 90 weight %, this component is the HDPE of at least 80 weight %, and comprises the about 10 thermoplastic coated fibers to about 80 weight %.

20., it is characterized by the compression modulus that demonstrates 170000psi at least and the ultimate compression strength of 2500psi at least according to the molded plastics matrix material of claim 17.

21. a composite architectural materials, it comprises the mixture of high density polyolefins and poly-(methyl methacrylate).

22. according to the composite architectural materials of claim 21, it also comprises in thermoplastic coated fibres material and the polystyrene one or both.

23. according to the composite architectural materials of claim 21, wherein said high density polyolefins is high density polyethylene(HDPE) (HDPE).

24. according to the composite architectural materials of claim 22, wherein said thermoplastic coated fibres material is the carbon fibre or the glass fibre of thermoplastic coating.

25. composite architectural materials according to claim 21, wherein said matrix material comprises poly-(methyl methacrylate) component of about 20 to about 65 weight %, this component contains poly-(methyl methacrylate) at least about 90 weight %, and comprising about 40 high density polyolefins components to about 80 weight %, this component contains at least about the high density polyethylene(HDPE) of 75 weight % (HDPE).

26. according to the composite architectural materials of claim 22, wherein said matrix material comprises about 20 polymeric constituents to about 90 weight %, this component is the HDPE of at least 80 weight %, and comprises the about 10 thermoplastic coated fibers to about 80 weight %.

27. a railroad tie, it comprises the molded plastics matrix material according to claim 2.

28. a railroad tie, it comprises the composite architectural materials according to claim 21.

29. according to the railroad tie of claim 28, it has compression modulus at least about 250000psi along this railroad tie.

30. according to the railroad tie of claim 29, the railway that wherein links to each other is under at least 24000 pounds the lateral load, under at least 39000 pounds the vertical static load, or at least 140000 pounds dynamic vertical load down, can be separately above 0.3175 centimetre.

31. a structural slab, it comprises the composite architectural materials according to claim 21.