CN109501322B - Fiber-reinforced synthetic sleeper and preparation method thereof - Google Patents

Fiber-reinforced synthetic sleeper and preparation method thereof Download PDF

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Publication number
CN109501322B
CN109501322B CN201811070914.XA CN201811070914A CN109501322B CN 109501322 B CN109501322 B CN 109501322B CN 201811070914 A CN201811070914 A CN 201811070914A CN 109501322 B CN109501322 B CN 109501322B
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glue injection
injection box
fiber
reinforced
resin matrix
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CN109501322A (en
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佘新光
魏凯耀
张兴刚
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Luoyang Sunrui Rubber and Plastic Technology Co Ltd
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Luoyang Sunrui Rubber and Plastic Technology Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/50Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B29C70/523Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement in the die
    • B29C70/524Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement in the die the transport direction being vertical
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/50Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B29C70/525Component parts, details or accessories; Auxiliary operations
    • B29C70/526Pultrusion dies, e.g. dies with moving or rotating parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/001Profiled members, e.g. beams, sections

Abstract

The invention relates to a fiber reinforced synthetic sleeper and a preparation method thereof, wherein the preparation method of the fiber reinforced synthetic sleeper comprises the following steps: s1, yarn guiding; s2, dipping; s3, post-processing; the impregnation is carried out by adopting an injection box, the injection box is provided with an injection hole, two ends of the injection box are respectively provided with an inlet and an outlet, the foaming resin matrix is injected into the injection box through the injection hole, the reinforced fiber material enters the injection box through the inlet and is impregnated in the foaming resin matrix, and the foaming resin matrix with the reinforced fiber material distributed inside and/or on the surface is sent out through the outlet. The invention solves the problem of insufficient impregnation of the fiber yarn bundle, and the resin liquid is directly immersed into the closed glue injection box from the glue injection machine and is not directly exposed to the air by arranging the sealed glue injection box, so that the production environment can be obviously improved.

Description

Fiber-reinforced synthetic sleeper and preparation method thereof
Technical Field
The invention relates to the field of polymer composite materials, in particular to a fiber reinforced synthetic sleeper and a preparation method thereof.
Background
The sleepers used in the railway lines at present are mainly prestressed reinforced concrete sleepers and wooden sleepers. The well-known prestressed reinforced concrete sleeper is widely used in railway tracks because of its abundant raw materials, easy to ensure the manufacture size, large quality, long service life and capable of improving the stability of the track. However, the prestressed reinforced concrete sleeper is difficult to install on site due to the heavy weight of a single member, and has the defects of poor elasticity, high rigidity and the like, so that the prestressed reinforced concrete sleeper is limited to be used in a specific area or position. The well-known wooden sleeper has the advantages of good elasticity, easy processing, convenient replacement and the like, and is widely used in special sections such as bridges, turnouts and the like. But the manufacturing of the wooden pillow needs high-quality hard wood, and the high-quality wood resource is limited, which is not beneficial to the sustainability of the ecological environment. Meanwhile, in order to prolong the service life of the wood pillow due to the corrosion resistance, a chemical preservative is used in the manufacturing process of the wood pillow, so that hidden dangers are brought to the environment and the health of workers.
Aiming at the defects of the prior common prestressed reinforced concrete sleeper and the wood sleeper and the continuous development of the composite material technology. The composite material of the long fiber reinforced foaming resin material is a good substitute material. The long glass fiber reinforced foamed resin has a structure similar to natural wood, and can be used as a rail transit facility and a building decoration material to replace wood.
The continuous fiber reinforced composite material pultrusion section with excellent performance replaces the traditional wood, steel, concrete and the like, and is widely applied to the field of bearing structures in the industries of buildings, bridges, electric power, energy and the like. Therefore, the demand for pultruded composites is rapidly increasing, with the ever-increasing performance requirements, the size of the structural members is increasing, and large-section large-thickness pultruded composites are produced at the same time.
At present, a dipping tank and a glue injection box device are mainly adopted in the process of dipping continuous fibers by resin liquid in continuous fiber reinforced composite material pultrusion profiles. Because the dipping tank device generally adopts an open type, the resin liquid is easy to volatilize, and potential safety hazards are caused to the production environment and the health of workers; and the open type gum dipping tank is suitable for single-component systems or systems which are cured slowly at normal temperature, such as phenolic resin, vinyl resin and the like. If the resin liquid can be directly immersed into the closed glue injection box from the glue injection machine without being directly exposed to the air in the use of the glue injection box device, the production environment can be obviously improved. In addition, the thickness of the section bar obtained by dipping the currently used glue injection box is relatively thin, and the thickness of the glue injection box does not exceed 5mm generally. Thus limiting the preparation of large cross-section, large-size pultruded composites.
Disclosure of Invention
To overcome the defects and shortcomings of the prior art, the invention discloses a fiber reinforced composite sleeper.
The invention is realized by the following technical scheme:
a method of making a fiber reinforced synthetic sleeper, comprising the steps of:
s1, yarn guiding, namely guiding a reinforced fiber material into a glue injection box;
s2, impregnating, namely injecting a foaming resin matrix into the glue injection box to impregnate the reinforced fiber material in the foaming resin matrix;
s3, post-processing, namely extruding, molding, cooling and cutting the foamed resin matrix with the reinforced fiber material distributed inside and/or on the surface to obtain the fiber reinforced composite sleeper;
the glue injection box is a sealed hollow box body, a glue injection hole is formed in the glue injection box, an inlet and an outlet are formed in each of two ends of the glue injection box, the foaming resin matrix is injected into the glue injection box through the glue injection hole, the reinforced fiber materials enter the glue injection box through the inlets and are impregnated in the foaming resin matrix, and the foaming resin matrix with the reinforced fiber materials distributed inside and/or on the surface is sent out through the outlets.
The glue injection box comprises an upper template and a lower template, the glue injection holes are formed in the upper template and/or the lower template, and the upper template and the lower template jointly surround to form a closed glue injection cavity; the inlet and the outlet are respectively communicated with the glue injection cavity.
Further, the upper template is provided with an upper template opening; the lower template is provided with a lower template opening; the positions of the upper template opening and the lower template opening correspond to each other to form the inlet together.
Furthermore, a plurality of fastening bolt holes and fastening bolts are arranged on the upper template and/or the lower template.
Furthermore, the glue injection box further comprises a plurality of middle templates, wherein the middle templates are arranged between the upper template and the lower template, and the glue injection cavity is divided into a plurality of glue injection cavities.
Furthermore, the upper end and the lower end of the middle template are respectively provided with an upper opening of the middle template and a lower opening of the middle template.
Further, the preparation method of the fiber reinforced synthetic sleeper also comprises the following steps:
s4, bonding more than two fiber reinforced composite sleepers obtained in the step S3 to each other.
Further, in step S4, two or more of the fiber-reinforced composite ties having different densities are bonded to each other.
Further, the reinforcing fiber material is at least one of continuous reinforcing fibers and/or fiber fabrics.
A fiber-reinforced synthetic sleeper obtained by the preparation method of the fiber-reinforced synthetic sleeper.
Compared with the prior art, the invention has the advantages that: the invention solves the problem of insufficient impregnation of a large number of fiber yarn bundles when the composite sleeper is manufactured by injecting glue, and the production environment can be obviously improved by arranging the sealed glue injection box to ensure that the resin liquid is directly immersed into the sealed glue injection box from the glue injection machine and is not directly exposed in the air. In addition, the fiber fabric is added in the synthetic sleeper to improve the shear strength, the bending elastic modulus and the spike pulling resistance strength of the synthetic sleeper along the long axis direction, so that the synthetic sleeper can be applied to a plurality of fields with high requirements on the sleeper strength, such as common railways, light rail railways, high-speed railways, heavy haul railways, landscape trestles, marine vessel platforms, municipal comprehensive pipe galleries and the like. In particular, the interior of a composite sleeper after a period of service, particularly around the threaded spikes, is susceptible to the formation of micro-cracks. The composite sleeper can effectively block cracks which are expanded along the long fiber direction and effectively avoid the further expansion of the cracks by arranging the reinforcing fibers, thereby improving the durability of the composite sleeper.
Drawings
In order to more clearly illustrate the technical solution of the present invention, the drawings of the present invention will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments of the present invention, and it is obvious to those skilled in the art that other drawings can be obtained based on the drawings without inventive labor.
FIG. 1: a schematic view of a device for producing a fiber-reinforced composite sleeper according to an embodiment of the present invention;
FIG. 2: an overall schematic of a fiber reinforced composite sleeper of an embodiment of the present invention;
FIG. 3: a schematic cross-sectional view of a fiber reinforced composite sleeper of an embodiment of the present invention;
FIG. 4: a first schematic diagram of a glue injection box of an embodiment of the invention;
FIG. 5: a second schematic diagram of the glue injection box of the embodiment of the invention;
FIG. 6: a third schematic diagram of the glue injection box of the embodiment of the invention;
FIG. 7: a schematic cross-sectional view of a synthetic sleeper obtained by the method for producing a fiber-reinforced synthetic sleeper according to example 1 of the present invention;
FIG. 8: a schematic cross-sectional view of a composite sleeper obtained by the method of making a fiber reinforced composite sleeper of example 2 of the present invention.
To further clarify the structure and connection between the various components of the present invention, the following reference numerals are given and described:
the device comprises a glue injection box-100, a yarn guide device-200, an extrusion device-300, a curing and forming device-400, an upper template-101, a lower template-102, glue injection holes-103, glue injection cavities-104', fastening bolt holes-105, fastening bolts-106, a middle template-107, an upper template opening-1013, a lower template opening-1023, a middle template upper opening-1071, a middle template lower opening-1072, a foamed resin matrix-1, continuous reinforcing fibers-2, a fiber fabric-3 and a bonding layer-4.
Detailed Description
In order to make the technical means, objectives and functions of the present invention easy to understand, embodiments of the present invention will be described in detail with reference to the specific drawings.
It should be noted that all terms used in the present invention for directional and positional indication, such as: the terms "upper", "lower", "left", "right", "front", "rear", "vertical", "horizontal", "inner", "outer", "top", "lower", "lateral", "longitudinal", "center", and the like are used only for explaining the relative positional relationship, the connection condition, and the like between the respective members in a certain state, and are only for convenience of describing the present invention, and do not require that the present invention must be constructed and operated in a certain orientation, and thus, should not be construed as limiting the present invention. In addition, the descriptions related to "first", "second", etc. in the present invention are for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an illustrative embodiment," "an example," "a specific example," or "some examples" or the like mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
As shown in fig. 1-3, embodiments of the present invention provide a method of making a fiber reinforced composite sleeper, comprising the steps of:
s1, yarn guiding, namely guiding a reinforced fiber material into a glue injection box 100;
s2, impregnating, namely injecting a foaming resin matrix 1 into the glue injection box 100 to impregnate the reinforced fiber material in the foaming resin matrix 1;
and S3, post-processing, namely extruding, molding, cooling and cutting the foamed resin matrix 1 with the reinforced fiber material distributed inside and/or on the surface to obtain the fiber reinforced composite sleeper.
The yarn guiding in step S1 is to guide at least one kind of the reinforcing fiber material into the injection box 100 through a yarn guiding device 200. The reinforced fiber material can be any one or more fiber roving from 1200tex to 9600tex, and can also be expanded into twisted yarns. The yarn guide device 200 effectively improves the distribution of the reinforcing fiber material in the composite sleeper and improves the uniformity of the performance of the composite sleeper. The impregnation in step S2 is to uniformly mix the foamed resin matrix and inject the mixture into the glue injection box 100, so that the reinforcing fiber material is impregnated in the foamed resin matrix. The foamed resin matrix may be a two-part foamed polyurethane including a mixture of isocyanate and polyol.
The post-processing of the step S3 is to send the foamed resin matrix with the reinforcing fiber material to the extrusion device 300 through the feeding device for extrusion, send the material output by the extrusion device 300 to the curing and molding device 400 for curing at a curing temperature ranging from 100 ℃ to 220 ℃, send the material to the outside of the molding die system through the traction device after the curing and molding process is completed, and cool and cut the material. Preferably, the curing and forming device 400 comprises an upper laminating machine, a lower laminating machine, a left side chain circulating device and a right side chain circulating device which roll circularly, the running speed is 0.1-3 m/min, and the brake temperature is controlled between 40-100 ℃. The synthetic sleeper completes the foaming, curing and forming processes in the curing channel formed by the synthetic sleeper. In some embodiments of the present invention, the method further comprises the following steps: and S4, bonding the more than two fiber reinforced composite sleepers obtained in the step S3 to each other through the bonding layer 4. In the prior art, the integrally formed composite sleeper is large in size and thickness, so that the problems of uneven impregnation and uneven heat dissipation are easily caused in the impregnation and curing forming process, and the performance of the composite sleeper is reduced. The density of the mutually bonded synthetic sleepers is in the range of 400kg/m3~1200 kg/m3. The density of the plurality of composite ties bonded to each other may be the same or may be different from each other. Preferably, in step S4, two or more of the fiber reinforced composite ties having different densities may be bonded to each other. It is further preferred that the density of the composite tie near the upper and lower ends is greater than the density of the composite tie in the middle. The structural design is favorable for reducing the dead weight of the fiber reinforced synthetic sleeper and reducing the construction difficulty on the basis of ensuring the strength of the fiber reinforced synthetic sleeper.
The reinforcing fiber material is at least one of continuous reinforcing fibers 2 and/or a fiber fabric 3. The material of the continuous reinforced fiber 2 and the material of the fiber fabric 3 are selected from any one or a combination of several of glass fiber, carbon fiber, aramid fiber and ultra-high molecular weight polyethylene fiber. The fiber fabric 3 is any one or combination of a plurality of woven cloth, non-woven fabric and three-dimensional fabric. The synthetic sleeper in the prior art is only provided with reinforcing fibers parallel to the long axis direction, so that the synthetic sleeper is easy to crack when in use and has the problem of low shear strength. Compared with the prior art, the fiber fabric 3 is arranged in the synthetic sleeper, and the shear strength of the synthetic sleeper is enhanced through the fiber fabric 3.
As shown in fig. 4 to 6, the glue injection box 100 is a sealed hollow box body, the glue injection box 100 is provided with glue injection holes 103, and the number of the glue injection holes 103 is adjusted according to the width of the template, and is generally 1 to 5. The thickness of the glue injection box 100 can be adjusted between 3mm and 30 mm. The two ends of the glue injection box 100 are respectively provided with an inlet and an outlet, the foaming resin matrix 1 is injected into the glue injection box 100 through the glue injection hole 103, the reinforced fiber material enters the glue injection box 100 through the inlet and is impregnated in the foaming resin matrix 1, and the foaming resin matrix 1 with the reinforced fiber material distributed inside and/or on the surface is sent out through the outlet. The number of the glue injection boxes 100 can be multiple, and the multiple glue injection boxes 100 are arranged in an up-and-down overlapping manner, so that the reinforced fiber materials can be conveniently gathered after being impregnated.
The glue injection box 100 comprises an upper template 101 and a lower template 102, the glue injection holes 103 are arranged on the upper template 101 and/or the lower template 102, and the upper template 101 and the lower template 102 jointly surround to form a closed glue injection cavity 104; the inlet and the outlet are respectively communicated with the glue injection cavity 104. The upper mold plate 101 and/or the lower mold plate 102 are provided with a plurality of fastening bolt holes 105 and fastening bolts 106. The upper die plate 101 and the lower die plate 102 are fixedly connected with each other through the fastening bolt holes 105 and the fastening bolts 106.
The upper template 101 comprises a rectangular upper template top wall and upper template side walls arranged around the edge of the upper template top wall, and the lower template 102 comprises a rectangular lower template top wall and lower template side walls arranged around the edge of the lower template top wall.
An upper template opening 1013 is provided on the upper template top wall; the top wall of the lower template is provided with a lower template opening 1023; the upper platen opening 1013 and the lower platen opening 1023 are positioned to correspond to each other to form the inlet.
In some embodiments of the present invention, the glue injection box 100 further includes a plurality of intermediate mold plates 107, and the intermediate mold plates 107 are disposed between the upper mold plate 101 and the lower mold plate 102 to divide the glue injection cavity 104 into a plurality of glue injection cavities 104'. The upper and lower ends of the middle template 107 are respectively provided with a middle template upper opening 1071 and a middle template lower opening 1072 for the reinforcing fiber material to pass through.
Example 1
In this embodiment, three glue injection boxes 100 are used to prepare the fiber reinforced composite sleeper, and each glue injection box 100 has the same size, and has a width of 235mm, a thickness of 14mm and a length of 1500 mm. The width is 235mm, and the surface density is 300g/m3The glass fiber grid cloth of (4) layers is respectively arranged at the upper and lower ends of the upper glue injection box 100 and the lower glue injection box 100, and enters the glue injection cavity 104 together with the glass fiber. The formula of the fiber reinforced synthetic sleeper comprises the following components in parts by mass: 100 parts of polyurethane isocyanate, 100 parts of polyol mixture, 30 parts of glass fiber checked cloth and 170 parts of continuous glass fiber. WhereinThe reinforcing fiber content amounted to 50%.
Through steps S1 to S3, a density of 740kg/m was produced3And (3) bonding the composite sleepers to one another to obtain an integral composite sleeper having a thickness of 75 mm. And then after two integral synthetic sleepers with the length of 2450mm are subjected to a grinding process, bonding the two integral synthetic sleepers under pressure by using a vinyl resin adhesive, and finally grinding, cutting, spraying paint and marking to prepare the synthetic sleeper product shown in the figure 7.
Example 2
In this embodiment, six glue injection boxes 100 are adopted, and each glue injection box 100 has the same size, and is 235mm wide, 14mm thick and 1500mm long. The width is 235mm, and the surface density is 300g/m3The glass fiber lattice cloth has 6 layers, and enters the glue injection cavity 104 together with the glass fiber. The formula of the fiber reinforced synthetic sleeper comprises the following components in parts by mass: 100 parts of polyurethane isocyanate, 100 parts of polyol mixture, 40 parts of glass fiber checked cloth and 200 parts of continuous glass fiber. Wherein the reinforcing fiber content is 55% in total.
Through steps S1 to S4, a density of 740kg/m was produced3And the thickness of the composite sleeper base material is 145 mm. The composite sleeper base material is manufactured into a composite sleeper product shown in figure 8 through the processes of grinding, cutting, painting and marking.
It is obvious that the above embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, those skilled in the art should also include various changes, modifications, substitutions and improvements without creative efforts to the embodiments.

Claims (6)

1. A method of making a fiber reinforced composite sleeper, comprising the steps of:
s1, yarn guiding, namely guiding a reinforced fiber material into a glue injection box (100);
s2, impregnating, namely injecting a foaming resin matrix (1) into the glue injection box (100) so that the reinforced fiber material is impregnated in the foaming resin matrix (1);
s3, post-processing, namely extruding, molding, cooling and cutting the foamed resin matrix (1) with the reinforced fiber material distributed inside and/or on the surface to obtain the fiber reinforced synthetic sleeper;
s4, bonding the fiber reinforced synthetic sleepers with different densities and more than two fiber reinforced synthetic sleepers obtained in the step S3;
the impregnation in the step S2 is to uniformly mix a foamed resin matrix and inject the mixture into the injection box 100, so that the reinforced fiber material is impregnated into the foamed resin matrix, the injection box (100) is a sealed hollow box body, an injection hole (103) is formed in the injection box (100), and an inlet and an outlet are respectively formed at two ends of the injection box (100);
the glue injection box (100) comprises an upper template (101) and a lower template (102), the glue injection holes (103) are formed in the upper template (101) and/or the lower template (102), and the upper template (101) and the lower template (102) jointly surround to form a closed glue injection cavity (104); the inlet and the outlet are respectively communicated with the glue injection cavity (104);
the glue injection box (100) further comprises a plurality of middle templates (107), wherein the middle templates (107) are arranged between the upper template (101) and the lower template (102) to divide the glue injection cavity (104) into a plurality of glue injection cavities (104');
the thickness of the glue injection box 100 can be adjusted between 3mm and 30 mm;
the foaming resin matrix (1) is injected into the glue injection box (100) through the glue injection hole (103), the reinforced fiber material enters the glue injection box (100) through the inlet and is impregnated in the foaming resin matrix (1), and the foaming resin matrix (1) with the reinforced fiber material distributed inside and/or on the surface is sent out through the outlet.
2. Method for producing a fibre-reinforced composite sleeper according to claim 1, characterized in that the upper mould plate (101) is provided with an upper mould plate opening (1013); the lower template (102) is provided with a lower template opening (1023); the upper template opening (1013) and the lower template opening (1023) correspond to each other in position and form the inlet together.
3. Method for producing a fibre-reinforced composite sleeper according to claim 1, characterized in that the upper mould plate (101) and/or the lower mould plate (102) is provided with a number of fastening bolt holes (105) and fastening bolts (106).
4. Method for producing a fibre-reinforced composite sleeper according to claim 1, characterized in that the upper and lower ends of the intermediate form (107) are provided with an intermediate form upper opening (1071) and an intermediate form lower opening (1072), respectively.
5. Method for producing a fibre-reinforced composite sleeper according to any one of claims 1 to 4, characterized in that: the reinforcing fiber material is at least one of continuous reinforcing fibers (2) and/or a fiber fabric (3).
6. A fiber reinforced composite sleeper characterized by: obtained with a method for the production of a fibre-reinforced synthetic sleeper according to any one of claims 1 to 5.
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