CN103866653A - Novel sandwich structure composite sleeper and continuous pultrusion molding process thereof - Google Patents
Novel sandwich structure composite sleeper and continuous pultrusion molding process thereof Download PDFInfo
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- CN103866653A CN103866653A CN201410070729.6A CN201410070729A CN103866653A CN 103866653 A CN103866653 A CN 103866653A CN 201410070729 A CN201410070729 A CN 201410070729A CN 103866653 A CN103866653 A CN 103866653A
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Abstract
A novel sandwich structure composite sleeper and a continuous pultrusion molding process thereof aim at the defects of larger density and smaller die cavity size of a composite sleeper. For solving the technical problems, the composite sleeper is realized by adopting the following technical scheme: the novel sandwich structure composite sleeper is characterized that the composite sleeper has a sandwich structure; the outer layer of the composite sleeper is of a continuous fiber-enhanced polyurethane foam layer with the thickness of 10-50mm; the interior of the composite sleeper is of a foam core material; the cross section of the foam core material is square or rectangle with round angels chamfered at four corners; the material of the foam core material is one from polyurethane foam, polyvinyl chloride foam and phenolic foam, and the density of the material is 100-500kg/m<3>. The continuous molding process for the composite sleeper comprises six procedures of yarn guiding, conveying of the foam core material, glue injecting of a foaming machine, uniform dipping, molding and cutting. The technology has the advantages of small density, large bearing strength, simple and convenient procedures, high cost performance and the like.
Description
Technical field
The present invention relates to technical field of composite materials, be specifically related to a kind of novel sandwich structure synthesis wooden sleeper structure and manufacture method thereof.
Background technology
Railway is one of China's main traffic transportation means, railroad sleeper adopts sleeper and reinforced concrete sleeper conventionally, as traditional sleeper, it has the processing of being easy to and transportation, insulating properties are high, damping property is excellent, but because its material is biomaterial, although through processing such as anticorrosion waterproof, its application life is still shorter, generally be no more than 15 years, its maintenance cost is also higher.Reinforced concrete sleeper, as the alternate material of sleeper, because weight is large, fragility is large, elasticity is low, easily occur the shortcomings such as crack, also is more and more difficult to meet the growth requirement of railway construction.For meeting the growth requirement of railway construction, developed country's development high molecular synthetic materials such as Japan, the U.S. replace original sleeper and reinforced concrete sleeper, wherein development is the most successfully the one-way glass fiber reinforcement polyurethane foam of Japanese ponding chemical industry Co., Ltd exploitation, i.e. synthesis wooden sleeper.This material has that good intensity is large, density is low, durability, flame retardancy, and higher mechanical property, lower density, corrosion-resistant and screw pull strength high.
Current domestic synthesis wooden sleeper patent is long fiber reinforcement homogeneous polyurethane foamed material, its manufacturing process generally include guide, foaming machine injecting glue, evenly soak pool, moulding, cutting, processing, bonding, process and the operation such as spray paint.The tall winter equality people of patent CN101314931A discloses a kind of long fiber reinforcement polyurethane foam homogeneous synthesis wooden sleeper formula and moulding process; Patent CN101328311A opens the people such as use military forces and discloses a kind of formula and continuous forming process of synthesis wooden sleeper, and this synthesis wooden sleeper is long fiber reinforcement homogeneous polyurethane foamed material; The people such as patent CN101550225A Sun Shou roc disclose the formula system of the self-skining flame retardation type polyurethane composite sleeper of a kind of available injection or pultrusion; CN101046077A stone island is bravely controlled and is disclosed one and have good durability, flame retardancy and shock resistance synthesis wooden sleeper and preparation method thereof.Above patent is long fiber reinforcement homogeneous polyurethane foamed material, partial monopoly is in synthesis wooden sleeper forming process, form flame-retardant layer at surface skining, its main moulding process has all adopted continuous pultrusion molding process, but above synthesis wooden sleeper has all adopted homogeneous material, extrudate density is larger, conventionally density is greater than 750kg/m3, arrange and infiltrate for ease of yarn bundle simultaneously, and prevent that inner thermal discharge from causing greatly burning core, the maximum cavity dimension of moulding is controlled conventionally as 210mm × 80mm, in the time making sleeper, need to carry out the bonding of piece and piece, virtually increase the cost of manufacture of synthesis wooden sleeper.
Summary of the invention
The present invention is directed to the large and less deficiency of cavity dimension of above-mentioned synthesis wooden sleeper density, proposed a kind of novel sandwich structure synthesis wooden sleeper and moulding process thereof.The object of the invention is to introduce a kind of novel sandwich structure synthesis wooden sleeper structure and continuous pultrusion molding process thereof.
For solving the problems of the technologies described above, the present invention is achieved by the following technical solutions.
A kind of novel sandwich structure synthesis wooden sleeper, it is characterized in that: this synthesis wooden sleeper is sandwich structure, synthesis wooden sleeper skin is continuous fibre enhancement polyurethane froth bed, its thickness is 10mm～50mm, synthesis wooden sleeper inside is foam core material, its shape of cross section is four jiaos of square or rectangulars that are rounded down, and the material of foam core material is the one in polyurethane foam, polyvinyl chloride foam, phenol formaldehyde foam, and density is 100 kg/ m3～500 kg/m3.
According to described novel sandwich structure synthesis wooden sleeper, it is characterized by: described synthesis wooden sleeper outer layer thickness is 20mm, described foam core material shape of cross section is rectangle, and foam core material material preferred density is the polyurethane foam of 250 kg/ m3.
According to described novel sandwich structure synthesis wooden sleeper, it is characterized in that: the skin of described synthesis wooden sleeper and foam core material increase have transition intermediate layer, its material is layer of polyurethane or phenolic resins layer.
According to described novel sandwich structure synthesis wooden sleeper, it is characterized in that: described transition intermediate layer preferred material is layer of polyurethane.
A continuous pultrusion molding process for novel sandwich structure synthesis wooden sleeper, is characterized in that: sandwich structure synthesis wooden sleeper continuous forming process comprises guide, foam core material conveying, foaming machine injecting glue, evenly soak pool, moulding, cutting amounts to six operations,
(1) guide, any one or several woven glass roving fabrics that are 1200Tex-19200Tex by specification guide to required cross section by yarn guide, collection yarn plate, and the speed of service is 0.1～1m/min, reduces as far as possible the wearing and tearing to yarn in guide process;
(2) foam core material is carried, and prefabricated polyurethane foam, polyvinyl chloride foam or phenol formaldehyde foam core are transported in synthesis wooden sleeper former by the identical speed of continuous rolling former, and speed is controlled at 0.1～1m/min;
(3) foaming machine injecting glue, PPG, catalyzer, blowing agent, foaming stabiliser, fire retardant, age resistor, isocyanates recipe ingredient are mixed in proportion in foaming machine, be evenly sprayed on the single layering of fiber or the upper surface of multiple layerings with the flow of 0.5-15kg/min;
(4) evenly soak pool, after the glue spraying of yarn bundle surface, enter rapidly and soak damp equipment and evenly soak pool, by the height control of stripper plate, and stripper plate moves back and forth and makes polyurethane evenly soak damp yarn bundle by certain frequency at vertical yarn bundle direct of travel;
(5) moulding, introduce in the die cavity of rolling former by the tractive force of continuous rolling former soaking fiber bundle and the foam core material of crossing resin in pool, the speed of service of fiber bundle and foam core material transporting velocity match, be controlled at 0.1～1m/min, can be temperature automatically controlled between 50～120 ℃, goods are transported to subsequent processing after completing foaming in rolling former die cavity, shape and solidifying;
(6) cutting, after goods are exported from rolling former, by chill station, adopts automatic cutting equipment length on request to cut, and completes the moulding of synthesis wooden sleeper.
According to the continuous pultrusion molding process of described novel sandwich structure synthesis wooden sleeper, it is characterized in that: the damp equipment that soaks of described operation (4) is made up of lower panel, top panel, lower panel is one flat plate, top panel is made up of one or more stripper plate, and stripper plate is flat board or structural type stripper plate.
According to the continuous pultrusion molding process of described novel sandwich structure synthesis wooden sleeper, it is characterized by: the rolling former of described operation (5) is by laminating machine and two of the left and right side chain circulating rolling installation composition of upper and lower two rollings capable of circulation, four sides synchronous circulating rotates, the height of die cavity and width can be according to need to the adjusting of goods within the scope of certain size, and die length is 15m～40m.
Described mould preferred length is 25m.
Owing to having adopted technique scheme, the present invention has following superiority:
1, this synthesis wooden sleeper has that production efficiency is high, cost is low, density is little, bearing strength is large, operation is easy, cost performance advantages of higher.This moulding process can meet the continuously shaped requirement of integral of all size sleeper, and this sandwich structure synthesis wooden sleeper has that density is little, bearing strength is large, operation is easy, cost performance advantages of higher simultaneously.
2, the present invention utilizes continuously shaped equipment to prepare light sandwich structure synthesis wooden sleeper, serialization and automated production are realized, greatly improve production efficiency, reduce following process link simultaneously, reduced cost of production, and the synthesis wooden sleeper excellent combination property of preparation, quality is light, stable performance, good mechanical performance, corrosion resistance is good, in certain field, can be used as sleeper and other bearing structure material.
Accompanying drawing explanation
Fig. 1 is sandwich structure synthesis wooden sleeper sectional drawing.
Fig. 2 is sandwich structure synthesis wooden sleeper schematic cross-section.
Fig. 3 is for being transition intermediate layer synthesis wooden sleeper schematic cross-section.
Fig. 4 is for soaking damp equipment schematic diagram.
Fig. 5 is continuous forming process schematic diagram.
In figure: 1, continuous fibre enhancement polyurethane froth bed; 2, foam core material; 3, transition intermediate layer;
4, roving; 5, foaming machine; 6, soak damp equipment lower panel; 7, soak the plate stripper plate of damp equipment; 8, soak damp device structure type stripper plate; 9, continuous rolling former.
The specific embodiment
Below in conjunction with accompanying drawing, the specific embodiment of the present invention is made a detailed explanation.
Embodiment
Sandwich structure synthesis wooden sleeper continuous forming process comprises guide, foam core material conveying, foaming machine injecting glue, evenly soaks pool, moulding, six operations of cutting, and each operation is described below:
(1) guide.
680 bundle 9600Tex woven glass roving fabrics 4 are guided to required cross section by yarn guide, 2 layers of collection yarn plate, and the speed of service is 0.4m/min.
(2) foam core material is carried.
The polyurethane foam of prefabricated density 250 kg/m3 is prefabricated into foam core material 2, the foam core material 2 that cross section is 150mm × 100mm to be transported in the continuously shaped equipment 9 of synthesis wooden sleeper with the speed of 0.4m/min equally.
(3) foaming machine injecting glue.
PPG, PPG, catalyzer, blowing agent, fire retardant, age resistor, isocyanates are mixed in foaming machine 5 in the ratio of 70:30:0.15:0.8:20:0.5:110, be evenly sprayed on the upper surface of fibrage 4 with the flow of 4.4kg/min.
(4) evenly soak pool.
As Fig. 4, after the glue spraying of yarn bundle surface, enter rapidly and soak damp equipment and evenly soak pool.By soaking the height control of the plate stripper plate 7 of damp equipment, and soak the plate stripper plate 7 of damp equipment and move back and forth and make polyurethane evenly soak damp yarn bundle by 40 beats/min of frequencies at vertical yarn bundle direct of travel.
(5) moulding.
The fiber bundle and the foam core material 2 that soak the roving 4 of crossing resin in pool are introduced in the die cavity of continuous rolling former 9 by the tractive force of continuous rolling former 9, rolling former four sides synchronous circulating rotates, die cavity overall length is 25m, die cavity is of a size of 210mm × 140mm, die cavity temperature control is 85 ℃, and gait of march is 0.4m/min.
(6) cutting.
After goods are exported from continuous rolling former 9, by the chill station of certain length 15m, adopt automatic cutting equipment to cut by the siding-to-siding block length of 3m～2.7m, complete the moulding of synthesis wooden sleeper.
The present invention relates to a kind of novel sandwich structure synthesis wooden sleeper and continuous pultrusion molding process thereof.In document and patent, have no this respect report at home at present.This patented technology is mainly used in the continuously shaped of sandwich structure synthesis wooden sleeper, has that density is little, bearing strength is large, operation is easy, cost performance advantages of higher, and this sandwich structure synthesis wooden sleeper can be used for sleeper and other bearing structure material.Be with a wide range of applications and significant economic benefit.
Claims (8)
1. a novel sandwich structure synthesis wooden sleeper, it is characterized in that: this synthesis wooden sleeper is sandwich structure, synthesis wooden sleeper skin is continuous fibre enhancement polyurethane froth bed (1), its thickness is 10mm～50mm, synthesis wooden sleeper inside is foam core material (2), its shape of cross section is four jiaos of square or rectangulars that are rounded down, and the material of foam core material (2) is the one in polyurethane foam, polyvinyl chloride foam, phenol formaldehyde foam, and density is 100 kg/ m3～500 kg/m3.
2. novel sandwich structure synthesis wooden sleeper according to claim 1, it is characterized in that: described synthesis wooden sleeper outer layer thickness is 20mm, described foam core material (2) shape of cross section is rectangle, and foam core material (2) material preferred density is the polyurethane foam of 250 kg/ m3.
3. novel sandwich structure synthesis wooden sleeper according to claim 1, is characterized in that: it is layer of polyurethane or phenolic resins layer that the skin of described synthesis wooden sleeper and foam core material (2) increase has transition intermediate layer (3), its material.
4. novel sandwich structure synthesis wooden sleeper according to claim 3, is characterized in that: described transition intermediate layer (3) preferred material is layer of polyurethane.
5. a continuous pultrusion molding process for novel sandwich structure synthesis wooden sleeper, is characterized in that: sandwich structure synthesis wooden sleeper continuous forming process comprises guide, foam core material conveying, foaming machine injecting glue, evenly soak pool, moulding, cutting amounts to six operations,
(1) guide, any one or several woven glass roving fabrics that are 1200Tex-19200Tex by specification guide to required cross section by yarn guide, collection yarn plate, and the speed of service is 0.1～1m/min, reduces as far as possible the wearing and tearing to yarn in guide process;
(2) foam core material is carried, and prefabricated polyurethane foam, polyvinyl chloride foam or phenol formaldehyde foam core are transported in synthesis wooden sleeper former by the identical speed of continuous rolling former, and speed is controlled at 0.1～1m/min;
(3) foaming machine injecting glue, PPG, catalyzer, blowing agent, foaming stabiliser, fire retardant, age resistor, isocyanates recipe ingredient are mixed in proportion in foaming machine, be evenly sprayed on the single layering of fiber or the upper surface of multiple layerings with the flow of 0.5-15kg/min;
(4) evenly soak pool, after the glue spraying of yarn bundle surface, enter rapidly and soak damp equipment and evenly soak pool, by the height control of stripper plate, and stripper plate moves back and forth and makes polyurethane evenly soak damp yarn bundle by certain frequency at vertical yarn bundle direct of travel;
(5) moulding, introduce in the die cavity of rolling former by the tractive force of continuous rolling former soaking fiber bundle and the foam core material of crossing resin in pool, the speed of service of fiber bundle and foam core material transporting velocity match, be controlled at 0.1～1m/min, can be temperature automatically controlled between 50～120 ℃, goods are transported to subsequent processing after completing foaming in rolling former die cavity, shape and solidifying;
(6) cutting, after goods are exported from rolling former, by chill station, adopts automatic cutting equipment length on request to cut, and completes the moulding of synthesis wooden sleeper.
6. the continuous pultrusion molding process of novel sandwich structure synthesis wooden sleeper according to claim 5, it is characterized in that: the damp equipment that soaks of described operation (4) is made up of lower panel, top panel, lower panel is one flat plate, top panel is made up of one or more stripper plate, and stripper plate is flat board or structural type stripper plate.
7. the continuous pultrusion molding process of novel sandwich structure synthesis wooden sleeper according to claim 5, it is characterized in that: the rolling former of described operation (5) is by laminating machine and two of the left and right side chain circulating rolling installation composition of upper and lower two rollings capable of circulation, four sides synchronous circulating rotates, the height of die cavity and width can be according to need to the adjusting of goods within the scope of certain size, and die length is 15m～40m.
8. the continuous pultrusion molding process of novel sandwich structure synthesis wooden sleeper according to claim 6, is characterized in that: described mould preferred length is 25m.
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| CN104452485A (en) * | 2014-12-19 | 2015-03-25 | 中格复合材料（南通）有限公司 | Railway sleeper made of composite materials and manufacturing method thereof |
| CN104652182A (en) * | 2015-03-11 | 2015-05-27 | 中格复合材料（南通）有限公司 | Rail sleeper and method for mounting nut sleeve |
| CN105332324A (en) * | 2015-11-25 | 2016-02-17 | 中格复合材料（南通）有限公司 | Composite sleeper |
| CN106013602A (en) * | 2016-06-17 | 2016-10-12 | 南京工业大学 | Pultrusion wooden core material composite profile |
| CN109228410A (en) * | 2018-10-19 | 2019-01-18 | 洛阳科博思新材料科技有限公司 | Fibre reinforced composites dipping systems and its resin fibre hybrid mold and application |
| CN109311241A (en) * | 2016-06-17 | 2019-02-05 | 三菱重工业株式会社 | The manufacturing device and manufacturing method of drawing molded product |
| CN110939470A (en) * | 2019-12-05 | 2020-03-31 | 青岛海力威新材料科技股份有限公司 | Sealing water stop for tunnel |
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| CN110939470A (en) * | 2019-12-05 | 2020-03-31 | 青岛海力威新材料科技股份有限公司 | Sealing water stop for tunnel |
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