CN209775594U - Integrated composite material sleeper - Google Patents
Integrated composite material sleeper Download PDFInfo
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- CN209775594U CN209775594U CN201920364175.9U CN201920364175U CN209775594U CN 209775594 U CN209775594 U CN 209775594U CN 201920364175 U CN201920364175 U CN 201920364175U CN 209775594 U CN209775594 U CN 209775594U
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Abstract
an integrated composite sleeper. The composite sleeper contains fibers therein, the density of the composite sleeper increases from the inside to the outside in the radial direction of the composite sleeper, and the increase in the density of the composite sleeper is achieved by increasing the fiber content of the fibers in the composite sleeper from the inside to the outside in the radial direction of the composite sleeper. The utility model provides an integral type combined material sleeper's top layer intensity is high, and the concentrated load on sleeper surface can obtain effective dispersion moreover to avoid the problem of the intact, inside damage in top layer, prolong the life of sleeper.
Description
Technical Field
The application relates to but is not limited to rail transit equipment technical field, especially relates to but is not limited to an integral type combined material sleeper.
Background
In railway systems, ties are one of the important components for transferring loads and stabilizing the track. The technical level and quality of the sleeper directly affect the design and operation safety of the railway track.
Currently, the sleepers commonly used in railway design are wooden sleepers and concrete sleepers. The two types of sleepers have many defects, such as easy corrosion of wooden sleepers, short service life, shortage of raw material resources and the like; the concrete sleeper has the advantages of heavy weight, easy fragmentation, poor damping effect and the like. In the face of the problems of the traditional materials, a novel composite material composite sleeper is developed and applied, wherein the outstanding application is a fiber reinforced polymer foam composite material composite sleeper. The composite sleeper made of the composite material has the advantages of low density, high strength, no water absorption, aging corrosion resistance and the like, and importantly, has the processing performance equal to that of wood, and is convenient for engineering design, field construction, application and maintenance.
Chinese patent application No. CN200810140888.3 discloses a formula and continuous forming process for synthesizing a sleeper. In the application of the composite sleeper, the upper surface is often crushed by the fastener, and the lower surface is often extruded and damaged by ballast or other hard objects, so that the service life of the sleeper is shortened. Such problems arise because the sleeper is of lower density, retains the advantage of being lightweight, but is susceptible to damage when subjected to evenly distributed concentrated loads. If the density of the sleeper is increased, the weight of the sleeper is increased, and the sleeper is not favorable for product application. It has been reported that a protective layer can be added to the surface of a composite sleeper, but such a protective layer is often disposed on the surface of a sleeper by means of secondary adhesion, which has a problem of stress concentration and a risk of falling off. In addition, the density difference between the added protective layer and the sleeper body is obvious, when concentrated load is transmitted to the sleeper body, the phenomenon of stress concentration still exists, the problems of intact surface layer and internal damage are caused, and the long-term use of the sleeper cannot be completely guaranteed. As a result, synthetic sleepers having a protective layer have not found practical use.
SUMMERY OF THE UTILITY MODEL
The application provides an integral type combined material sleeper, has solved the problem that synthetic sleeper top layer intensity is poor, easy damage.
In particular, the present application provides an integrated composite tie containing fibers therein, the density of the composite tie increasing from the inside to the outside in a radial direction of the composite tie, and the increase in the density of the composite tie is achieved by increasing the fiber content of the fibers in the composite tie from the inside to the outside in the radial direction of the composite tie.
In embodiments of the present application, the composite tie may include a transition layer, and the fibers in the transition layer may be distributed from inside to outside in a radial direction of the composite tie from a first fiber content to a second fiber content.
In an embodiment of the present application, the fibers in the transition layer may be distributed from inside to outside in a radial direction of the composite sleeper in a linear increasing fashion from a first fiber content to a second fiber content.
in an embodiment of the present application, the first fiber content may be linearly increased to the second fiber content according to formula I:
y1＝k1x+b1
In the formula, y1The fiber content of the point to be measured is expressed in units of percent;
x is the distance between the point to be measured and the inner edge of the transition layer, and the unit is m;
k1The fiber content growth rate is a nonnegative number and the unit is 1/m;
b1In the range of 2% -25%.
in the embodiment of the present application, the density of the transition layer may increase linearly according to formula II, where formula II is:
y2＝k2x+b2
In the formula, y2Is the density of the point to be measured in kg/m3；
x is the distance between the point to be measured and the inner edge of the transition layer, and the unit is m;
k2Is the density growth rate of the transition layer, which is a non-negative number and has a unit of kg/m4；
b2In the range of 100-1200, the unit is kg/m3。
in an embodiment of the present application, the composite tie may further include a first density layer disposed on a side of the transition layer closer to the center of the composite tie and/or a second density layer disposed on a side of the transition layer farther from the center of the composite tie, and the fibers in the first density layer are uniformly distributed with a first fiber content and the fibers in the second density layer are uniformly distributed with a second fiber content.
in an embodiment of the present application, the composite sleeper may include the first density layer and the transition layer in this order from inside to outside in a radial direction. The thickness of the first density layer can be 1/10-9/10 of the height of the composite sleeper, and the transition layer is the rest.
in an embodiment of the present application, the composite sleeper may include the transition layer and the second density layer in this order from inside to outside in a radial direction. The thickness of the transition layer can be 6/50-49/50 of the height of the composite tie, with the remainder being the second density layer.
In an embodiment of the present application, the composite sleeper may include the first density layer, the transition layer, and the second density layer in this order from inside to outside in a radial direction. The thickness of the first density layer may be 1/10-9/10 of the height of the composite tie, the thickness of the transition layer may be 1/100-22/50 of the height of the composite tie, and the remainder is the second density layer.
In the embodiment of the application, the composite sleeper can sequentially comprise a first density layer, a transition layer and a second density layer from inside to outside in the radial direction, fibers in the first density layer are uniformly distributed according to a first fiber content, fibers in the second density layer are uniformly distributed according to a second fiber content, fibers in the transition layer are uniformly distributed according to a third fiber content, and the first fiber content is less than the third fiber content is less than the second fiber content.
In embodiments of the present application, the first fiber content may be 2% to 25% and the second fiber content may be 17% to 60%.
In the embodiment of the present application, the density of the first density layer may be 100kg/m3-1200kg/m3the density of the second density layer may be 500kg/m3-1900kg/m3。
the present application further provides a method of manufacturing a one-piece composite tie as described above, the method comprising:
Calculating the fiber content of the fibers in the composite material sleeper according to the expected density of the composite material sleeper, and converting to obtain the fiber content of the fibers on a fiber arrangement frame;
according to the fiber content of the fibers on the fiber arrangement frame, the fibers are arranged on the fiber arrangement frame, so that the fibers pass through a yarn arranging plate to carry out pre-arrangement yarn arrangement;
Drawing the fibers passing through the creel plate to an impregnation device to impregnate the fibers with a resin matrix material; and
And molding the fibers impregnated with the resin matrix material to obtain the integrated composite material sleeper.
In an embodiment of the present application, the arranging the fibers on the fiber arranging frame may include:
optionally, uniformly arranging the fibers forming the first density layer on the fiber arranging stand;
arranging fibers forming a transition layer on the fiber arrangement frame at the periphery of the fibers forming the first density layer;
Optionally, the fibers forming the second density layer are uniformly arranged on the fiber arranging frame at the periphery of the fibers forming the transition layer.
The composite material sleeper of this application adopts specific fibre mode of arranging-makes fibrous fibre content is in the composite material sleeper increases from inside to outside on the radial direction of composite material sleeper, makes the density of composite material sleeper increases gradually to the high density on top layer by inside low density, has not only strengthened the intensity on top layer, still makes the concentrated load on surface obtain the active dispersion to avoid the problem of the intact, internal damage on top layer, prolonged the life of sleeper.
The composite material sleeper of this application adopts integrated into one piece's mode to make and obtains, belongs to the sleeper of integral type, has avoided the risk that drops that the sleeper secondary bonds the existence.
additional features and advantages of the application will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the application. The objectives and other advantages of the present application may be realized and attained by the structure particularly pointed out in the written description.
Drawings
The accompanying drawings are included to provide a further understanding of the claimed subject matter and are incorporated in and constitute a part of this specification, illustrate embodiments of the subject matter and together with the description serve to explain the principles of the subject matter and not to limit the subject matter.
Fig. 1 is a schematic cross-sectional view of a composite tie according to an embodiment of the present application.
Fig. 2 is a schematic illustration of a manufacturing process for a composite tie according to an embodiment of the present application.
FIG. 3 is a schematic structural diagram of a primary fiber yarn arranging plate according to an embodiment of the present application.
fig. 4 is a schematic structural diagram of a secondary fiber yarn arranging plate of an application example.
The reference numbers in the figures are:
10-composite material sleeper 11-first density layer
12-transition layer 13-second Density layer
14-fiber 15-resin
21-fiber arranging frame 22-fiber fabric frame
23-fibre creel 231-primary fibre creel
2311-one-time yarn arranging plate yarn arranging hole 2312-one-time yarn arranging plate bracket
232-secondary fiber yarn arranging plate 2321-secondary yarn arranging plate yarn arranging hole
2322-Secondary creeper bracket 24-impregnation equipment
25-Forming device 26-sawing device
Detailed Description
to make the objects, technical solutions and advantages of the present application more apparent, embodiments of the present application will be described in detail below with reference to the accompanying drawings. It should be noted that the embodiments and features of the embodiments in the present application may be arbitrarily combined with each other without conflict.
The present application provides an integral composite tie containing fibers therein, the density of the composite tie increasing from the inside to the outside in the radial direction of the composite tie, and the increase in the density of the composite tie is achieved by increasing the fiber content of the fibers in the composite tie from the inside to the outside in the radial direction of the composite tie.
In this application, the term "composite tie" is defined as a composite tie formed of fibers and a resin matrix material.
in the present application, the term "radial direction of the sleeper" is defined as the direction on a cross-section perpendicular to the length direction of the sleeper, starting from the center of the cross-section (i.e. the intersection of the diagonals of a square cross-section) and pointing towards the edges of the cross-section.
It should be understood that in the present application, "density of ties" refers to the density of the local ties, which can be calculated from the mass of the local ties/volume of the local ties, and thus the "density of ties" can increase from the inside to the outside in the radial direction of the composite tie.
In this application, the term "fiber content" is defined as the volume of fiber in a unit volume of a tie as a percentage of the unit volume of the tie.
In the present application, the density and fiber content of the sleeper with variations are based on 1mm3-1cm3per unit volume of (c).
In embodiments of the present application, the composite tie may include a transition layer, and the fibers in the transition layer may be distributed from inside to outside in a radial direction of the composite tie from a first fiber content to a second fiber content.
In an embodiment of the present application, the fibers in the transition layer may be distributed from inside to outside in a radial direction of the composite sleeper in a linear increasing fashion from a first fiber content to a second fiber content.
It will be appreciated that in addition to a linear increase, other means of increasing from the first fiber content to the second fiber content may be employed, such as an exponential increase, a logarithmic increase, an increase in increasing portions in a parabola or increasing portions in a hyperbola, and the like.
In an embodiment of the present application, the first fiber content may be linearly increased to the second fiber content according to formula I:
y1＝k1x+b1
In the formula, y1The fiber content of the point to be measured is expressed in units of percent;
x is the distance between the point to be measured and the inner edge of the transition layer, and the unit is m;
k1the fiber content growth rate is a nonnegative number and the unit is 1/m;
b1In the range of 2% -25%.
When the composite tie includes a first density layer, the inner edge of the transition layer is located at the interface of the transition layer and the first density layer; when the composite tie does not include a first density layer, the inner edge of the transition layer is the center of the composite tie.
In the embodiment of the present application, the density of the transition layer may increase linearly according to formula II, where formula II is:
y2＝k2x+b2
In the formula, y2Is the density of the point to be measured in kg/m3；
x is the distance between the point to be measured and the inner edge of the transition layer, and the unit is m;
k2Is the density growth rate of the transition layer, which is a non-negative number and has a unit of kg/m4；
b2in the range of 100-1200, the unit is kg/m3。
In an embodiment of the present application, the composite tie may further include a first density layer disposed on a side of the transition layer closer to the center of the composite tie and/or a second density layer disposed on a side of the transition layer farther from the center of the composite tie, and the fibers in the first density layer are uniformly distributed with a first fiber content and the fibers in the second density layer are uniformly distributed with a second fiber content.
In an embodiment of the present application, the composite sleeper may include the first density layer and the transition layer in this order from inside to outside in a radial direction. The thickness of the first density layer can be 1/10-9/10 of the height of the composite sleeper, and the transition layer is the rest.
In an embodiment of the present application, the composite sleeper may include the transition layer and the second density layer in this order from inside to outside in a radial direction. The thickness of the transition layer can be 6/50-49/50 of the height of the composite tie, with the remainder being the second density layer.
In the embodiment of the present application, as shown in fig. 1, the composite sleeper 10 may include the first density layer 11, the transition layer 12, and the second density layer 13 in this order from inside to outside in the radial direction. The thickness of first density layer 11 may be 1/10-9/10 of the height of composite tie 10, the thickness of transition layer 12 may be 1/100-22/50 of the height of composite tie 10, and the remainder is second density layer 13. In this embodiment, the transition layer 12 and the second density layer 13 sequentially surround the first density layer 11, at this time, the cross sections of the transition layer 12 and the second density layer 13 are annular, and the thickness of the transition layer 12 refers to the thickness of the transition layer 12 surrounding one side of the first density layer 11. In other embodiments, the thickness of the transition layer and the second density layer having an annular cross-section are as defined herein.
In the embodiment of the application, the composite sleeper can sequentially comprise a first density layer, a transition layer and a second density layer from inside to outside in the radial direction, fibers in the first density layer are uniformly distributed according to a first fiber content, fibers in the second density layer are uniformly distributed according to a second fiber content, fibers in the transition layer are uniformly distributed according to a third fiber content, and the first fiber content is less than the third fiber content is less than the second fiber content. The thickness of the first density layer can be 1/10-9/10 of the height of the composite sleeper, the thickness of the transition layer can be 1/50-44/50 of the height of the composite sleeper, and the thickness of the second density layer can be 1/50-40/50 of the height of the composite sleeper.
in the embodiment of the present application, the density of the first density layer may be 100kg/m3-1200kg/m3(which may be calculated as the mass of the first density layer/volume of the first density layer), the density of the second density layer may be 500kg/m3-1900kg/m3(this can be calculated from the mass of the second density layer/volume of the second density layer).
embodiments of the present application further provide a method for manufacturing a composite sleeper as described above, where the method includes:
Calculating the fiber content of the fibers in the composite material sleeper according to the expected density of the composite material sleeper, and converting to obtain the fiber content of the fibers on a fiber arrangement frame;
According to the fiber content of the fibers on the fiber arrangement frame, the fibers are arranged on the fiber arrangement frame, so that the fibers pass through a yarn arranging plate to carry out pre-arrangement yarn arrangement;
Drawing the fibers passing through the creel plate to an impregnation device to impregnate the fibers with a resin matrix material; and
And molding the fibers impregnated with the resin matrix material to obtain the composite material sleeper.
the manufacturing method of the composite material sleeper disclosed by the embodiment of the application adopts an integrated forming mode, and the falling risk of secondary bonding of the sleeper is avoided.
In an embodiment of the present application, as shown in fig. 2, the method may include:
Calculating the fiber content of the fibers 14 in the composite material sleeper according to the expected density of the composite material sleeper, and converting to obtain the fiber content of the fibers on a fiber arrangement frame;
The fibers 14 forming the transition layer are distributed on a fiber distribution frame 21, so that the fibers 14 pass through a yarn arrangement plate 23 to carry out pre-distribution yarn arrangement;
Drawing the fibers 14 through the creel plate 23 to an impregnation device 24 to impregnate the fibers 14 with a resin matrix material 15; and
Feeding the fibers 14 impregnated with the resin matrix material 15 into a molding device 25 for foaming and curing to complete molding;
The formed sleeper semi-finished product is cut to the desired dimensions using a sawing device 26, resulting in the composite sleeper 10.
In an embodiment of the present application, the method may further include: the fibers 14 forming the transition layer are uniformly arranged on the fiber arranging frame 21 before the fibers 14 forming the transition layer are arranged on the fiber arranging frame 21, and then the fibers 14 forming the transition layer are arranged on the fiber arranging frame 21 at the outer periphery of the fibers 14 forming the first density layer.
In an embodiment of the present application, the method may further include: after the fibers 14 forming the transition layer are arranged on the fiber arranging shelf 21, the fibers 14 forming the second density layer are uniformly arranged on the fiber arranging shelf 21 at the periphery of the fibers 14 of the transition layer before the fibers 14 are pre-arranged and arranged through the yarn arranging plate 23.
On the yarn arranging plate 23, the fiber bundles are pre-arranged and arranged according to the density distribution of the sleepers. The yarn guide 23 corresponds to an enlarged cross-section of the sleeper, the hole distribution of the yarn guide 23 being the same as the distribution of the fibres in the sleeper. In contrast, to facilitate the fiber bundle routing during the manufacturing process, the distance between the fiber holes in the routing plate 23 is greater than the actual distance of the fiber bundles in the tie. Depending on the production line, the distance between the fibre holes in the yarn creeling plate 23 is typically about 5-20 times the actual distance of the fibre bundles in the sleeper. If the distance between two adjacent fiber bundles in the sleeper is 3mm, the distance between the corresponding fiber holes on the yarn arranging plate is 15mm-60mm (obtained by 3mm x (5-20 times)). In production, after the first fiber content and the second fiber content (and the third fiber content) are determined, the fiber content of the fibers on the creel plate 23 and the fiber arranging frame 21 can be calculated according to the multiple of the distance between the fiber holes on the creel plate 23 and the actual distance of the fiber bundles in the sleeper, and then the fibers are arranged on the fiber arranging frame 21 according to the calculation result.
as shown in fig. 3 and 4, the yarn arranging plate 23 includes a primary fiber yarn arranging plate 231 (including a primary yarn arranging plate yarn arranging hole 2311 and a primary yarn arranging plate support 2312) and a secondary fiber yarn arranging plate 232 (including a secondary yarn arranging plate yarn arranging hole 2321 and a secondary yarn arranging plate support 2322). The size of the secondary fiber yarn creel plate 232 and the distance between the fiber holes in it are smaller than the primary fiber yarn creel plate 231, for example, the distance between the fiber holes in the secondary fiber yarn creel plate 232 may be 2-10 times the actual distance of the fiber bundles in the sleeper. However, the multiple of the distance between the fiber holes on the secondary fiber yarn arranging plate 232 and the actual distance of the fiber bundles in the sleeper is constant, and the multiple of the distance between the fiber holes on the primary fiber yarn arranging plate 231 and the actual distance of the fiber bundles in the sleeper is also constant, so that the designed sleeper density can be obtained.
In other embodiments, the yarn creel 23 may not include the secondary fiber yarn creel 232, or include the secondary fiber yarn creel 232 and a tertiary fiber yarn creel, a quaternary fiber yarn creel, or the like. A secondary fiber yarn arranging plate 232, a tertiary fiber yarn arranging plate, a quaternary fiber yarn arranging plate, and the like may be disposed between the primary fiber yarn arranging plate 231 and the impregnation device 24.
In the embodiment of the present application, the resin matrix material may include polyether polyol a, polyether polyol B, polyether polyol C, a coupling agent, a catalyst, a foam stabilizer, a foaming agent, a flame retardant, an antioxidant, a light stabilizer, and an isocyanate, and the weight ratio of each component of the resin matrix material and the fiber may be:
In the examples herein, the polyether polyol a may have a functionality of 4 to 6 and a hydroxyl number of 200 to 800;
The polyether polyol B may have a functionality of 2 to 4 and a hydroxyl number of 50 to 800;
The polyether polyol C may have a functionality of 2 to 3 and a hydroxyl number of 50 to 500.
In the examples herein, the functionality of the coupling agent may be 1 to 4.
In the embodiment of the present application, the polyether polyol a, the polyether polyol B and the polyether polyol C may be obtained by polymerizing propylene oxide or copolymerizing propylene oxide and ethylene oxide (where the content of propylene oxide is greater than the content of ethylene oxide) with a combination of one or more of sorbitol, sucrose, xylitol, 1, 2-propanediol, ethylene glycol, diethylene glycol, 1, 4-butanediol, neopentyl glycol, glycerol, trimethylolpropane, ethanolamine, diethanolamine, triethanolamine, ethylenediamine, toluenediamine, methylenedianiline and pentaerythritol as a starter.
in the embodiment of the present application, the coupling agent may be one or more of an amino group-containing silane coupling agent, an epoxy group-containing silane coupling agent, a mercapto group-containing silane coupling agent, and an isocyanate group-containing silane coupling agent; the amino-containing silane coupling agent can be gamma-aminopropyltriethoxysilane (KH-550), gamma-aminopropyltrioxymethylsilane (KH-540), N- (beta-aminoethyl) -gamma-aminopropyltrimethoxysilane (KH-792), N- (beta-aminoethyl) -gamma-aminopropyltriethoxysilane (KH-552), or the like; the epoxy-containing silane coupling agent can be gamma-glycidoxypropyltrimethoxysilane (KH560), beta- (3, 4-epoxycyclohexyl) ethyltrimethoxysilane (KH-566), gamma-glycidoxypropyltriethoxysilane (KH-561), or the like; the silane coupling agent containing the mercapto can be gamma-mercapto propyl trimethoxy silane (KH-590), gamma-mercapto propyl triethoxy silane (KH-580) and the like; the isocyanate group-containing silane coupling agent may be gamma-isocyanatopropyltrimethoxysilane (Siquest A-Link 35), gamma-isocyanatopropyltriethoxysilane (Siquest A-Link 25), or the like.
in the embodiment of the present application, the catalyst may be one or more of a tertiary amine catalyst, an organometallic catalyst, and the like; the tertiary amine catalyst may be triethylenediamine, acid blocked triethylenediamine, trimethyl-N-2-hydroxypropylhexanoic acid (TMR), acid blocked TMR (e.g., TMR-2, TMR-3, TMR-4, etc.), N-dimethylcyclohexylamine, or N-methyldicyclohexylamine, etc.; the organometallic catalyst may be dibutyltin dilaurate, potassium isooctanoate, or the like.
in embodiments herein, the foam stabilizer may be an organosilicon compound, which may be one or more of B8404, B8407, B8409, B8423, and B8433.
In the examples herein, the blowing agent may be a physical blowing agent, which may be 141b, cyclopentane, pentane, pentafluoropropane (245fa), or 1,1,1,3, 3-pentafluorobutane (365mfc), or the like; the chemical foaming agent is water as a foaming agent.
In the present embodiment, the flame retardant may be one or more of a halogenated phosphate ester addition type flame retardant, a phosphate ester addition type flame retardant, and a halogenated hydrocarbon and other halogen-containing addition type flame retardants; the halogenated phosphate ester additive flame retardant can be tris (2-chloroethyl) phosphate (TCEP), tris (2-chloropropyl) phosphate TCPP, tris (dichloropropyl) phosphate TDCP and the like; the phosphate ester additive flame retardant can be dimethyl methylphosphonate (DMMP), diethyl ethylphosphonate (DEEP), dimethylpropyl phosphonate (DMPP) and the like; the halogenated hydrocarbon and other additive halogen-containing flame retardant may be decabromodiphenyl ether (DE-83R), decabromodiphenyl ethane, etc.
In the embodiment, the antioxidant can be one or more of hindered phenol antioxidant, aromatic secondary amine antioxidant, phosphite antioxidant and the like; the hindered phenol antioxidant may be triethylene glycol bis- [3-3 (t-butyl-4-hydroxy-5-methylphenyl) propionate ] (245), tetrakis [ beta- (3, 5-di-t-butyl-4-hydroxyphenyl) propionate ] (1010), thiodiethylene bis [3- (3, 5-di-t-butyl-4-hydroxyphenyl) propionate ] (1035), isooctyl 3, 5-di-t-butyl-4-hydroxyphenyl propionate (1135), or butyloctylated diphenylamine (5057).
In the embodiment, the light stabilizer may be one or more of an ultraviolet absorber, a hindered amine light stabilizer and a spandex anti-yellowing agent; the ultraviolet absorbent may be N- (ethoxycarbonylphenyl) -N ' -methyl-N ' -phenylformamidine (UV-1), 2- (2' -hydroxy-3 ' -dodecyl-5 ' -methylphenyl) benzotriazole (UV-571), or hydroxyphenol benzotriazole ultraviolet absorbent (UV-1130); the hindered amine light stabilizer may be 292, etc.; the spandex yellow inhibitor can be bis (N, N-dimethyl hydrazide amino 4-phenyl) methane (HN-150), 4' -hexamethylene bis (1, 1-dimethyl semicarbazide) (HN-130) and the like.
In the present embodiment, the isocyanate may be a PAPI (polyarylpolymethylene isocyanate) or modified PAPI, and may be selected from one or more of PM-200, PM-100, and the like.
In the present embodiment, the fibers may be selected from any one or more of glass fibers, aramid fibers, basalt fibers, and carbon fibers. The fibers may be continuous fibers, and may be reinforced with long fibers, short fibers, fiber powder, or the like. The fibers may be randomly oriented within the sleeper along the length of the sleeper, perpendicular to the length of the sleeper, or in multiple orientations.
In the present embodiment, the molding apparatus 25 may be a continuous molding apparatus.
The density and the fibre content of the sleepers with variations, referred to in the following examples, are based on 1mm3Per unit volume of (c).
Example 1
The composite sleeper of this embodiment comprises, in order from the inside to the outside in the radial direction (i.e. in the direction from the centre of the sleeper to the surface layer), a first density layer 11, a transition layer 12 and a second density layer 13. The fibers 14 in the first density layer 11 are distributed uniformly with a first fiber content, the fibers 14 in the second density layer 13 are distributed uniformly with a second fiber content, the fibers 14 in the transition layer 12 are distributed from the inside to the outside in the radial direction of the composite sleeper 10 in the form of a linear increase from the first fiber content to the second fiber content, and the first fiber content is increased linearly to the second fiber content according to the formula y 0.02x +0.1, so that the density of the transition layer 12 is increased linearly from the density of the first density layer to the density of the second density layer from the inside to the outside in the radial direction of the composite sleeper according to the formula y 100x + 500.
The composite material sleeper of the embodiment has the length of 4.5m, the width of 230mm and the height of 140mm, wherein the width of the first density layer 11 is 100mm, and the thickness of the first density layer is 60 mm; the thickness of the second density layer 13 is 20mm, and the transition layer 12 is arranged between the first density layer 11 and the second density layer 13.
The first fiber content is 10% and the second fiber content is 22%. The density of the first density layer is 500kg/m3The density of the second density layer is 1100kg/m3。
The raw materials for making the composite sleeper of this example are shown in the following table:
The temperature during molding was 40 ℃.
Example 2
the composite sleeper of this embodiment comprises, in order from the inside to the outside in the radial direction (i.e. in the direction from the centre of the sleeper to the surface layer), a first density layer 11, a transition layer 12 and a second density layer 13. The fibers 14 in the first density layer 11 are distributed uniformly with a first fiber content, the fibers 14 in the second density layer 13 are distributed uniformly with a second fiber content, the fibers 14 in the transition layer 12 are distributed from the inside to the outside in the radial direction of the composite sleeper 10 in the form of a linear increase from the first fiber content to the second fiber content, and the first fiber content increases linearly to the second fiber content according to the formula y 0.017x +0.12, so that the density in the transition layer 12 increases linearly from the density of the first density layer to the density of the second density layer from the inside to the outside in the radial direction of the composite sleeper according to the formula y 75x + 600.
The length of the composite material sleeper is 3m, the width is 260mm, and the height is 260mm, wherein the width of the first density layer 11 is 150mm, and the thickness is 150 mm; the thickness of the second density layer 13 is 30mm, and the transition layer 12 is arranged between the first density layer 11 and the second density layer 13.
The first fiber content is 12% and the second fiber content is 25%. The density of the first density layer is 600kg/m3The density of the second density layer is 1200kg/m3。
The raw materials for making the composite sleeper of this example are shown in the following table:
The temperature during molding was 40 ℃.
Example 3
the composite sleeper of this embodiment includes, in order from the inside to the outside in the radial direction (i.e., in the direction from the center of the sleeper to the surface layer), a transition layer 12 and a second density layer 13. The fibers 14 in the second density layer 13 are distributed uniformly with a second fiber content, the fibers 14 in the transition layer 12 are distributed in the radial direction of the composite sleeper 10 from the inside to the outside in a linear increasing manner from a first fiber content to a second fiber content, and the first fiber content is increased linearly to the second fiber content according to the formula y of 0.043x +0.1, so that the density of the transition layer 12 is increased linearly from the minimum density of the transition layer to the density of the second density layer in the radial direction of the composite sleeper from the inside to the outside according to the formula y of 140x + 500.
The composite sleeper of the embodiment has a length of 3m, a width of 240mm and a height of 240mm, wherein the thickness of the transition layer 12 is 200mm, and the thickness of the second density layer 13 is 20 mm.
The first fiber content is 10% and the second fiber content is 53%. The transition layer has a minimum density of 500kg/m3The density of the second density layer is 1900kg/m3。
The raw materials for manufacturing the composite sleeper of this example were the same as those of example 1.
The temperature during molding was 45 ℃.
Example 4
The composite sleeper of the present embodiment includes, in order from the center to the surface layer, a first density layer 11, a transition layer 12, and a second density layer 13. The fibers 14 in the first density layer 11 are uniformly distributed with a first fiber content, the fibers 14 in the second density layer 13 are uniformly distributed with a second fiber content, and the fibers 14 in the transition layer 12 are uniformly distributed with a third fiber content.
The composite material sleeper of the embodiment has the length of 6m, the width of 230mm and the height of 160mm, wherein the width of the first density layer 11 is 130mm, and the thickness of the first density layer is 60 mm; the thickness of the second density layer 13 is 10mm, and the transition layer 12 is arranged between the first density layer 11 and the second density layer 13.
the first fiber content is 12%, the second fiber contentThe secondary fiber content is 25% and the tertiary fiber content is 18%. The density of the first density layer is 600kg/m3the density of the second density layer is 1200kg/m3The density of the transition layer is 800kg/m3。
the raw materials for manufacturing the composite sleeper of this example were the same as those of example 1.
The temperature during molding was 50 ℃.
performance testing
The performance of the ties made from the above examples was tested according to CJ/T399-2012 (polyurethane foam composite ties). The results are reported in the following table.
The fatigue resistance of the composite sleeper in the embodiment of the application is obviously superior to that of the existing composite sleeper, which shows that the surface strength of the composite sleeper in the embodiment of the application is obviously higher, and the concentrated load on the surface of the sleeper is effectively dispersed; in addition, the composite sleeper of the embodiment of the application also has spike pulling resistance which is obviously superior to that of the existing composite sleeper.
Although the embodiments disclosed in the present application are described above, the descriptions are only for the convenience of understanding the present application, and are not intended to limit the present application. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the disclosure as defined by the appended claims.
Claims (10)
1. An integral composite tie comprising fibres, wherein the density of the composite tie increases from the inside to the outside in the radial direction of the composite tie and wherein the increase in the density of the composite tie is achieved by increasing the fibre content of the fibres in the composite tie from the inside to the outside in the radial direction of the composite tie.
2. The one-piece composite tie of claim 1 wherein the composite tie includes a transition layer, the fibers in the transition layer being distributed from the first fiber content to the second fiber content from the inside out in a radial direction of the composite tie.
3. The one-piece composite tie of claim 2 wherein the fibers in the transition layer are distributed from the inside to the outside in a radial direction of the composite tie in a linear increase from the first fiber content to the second fiber content.
4. The one-piece composite tie of claim 3 wherein said first fiber content increases linearly to said second fiber content according to formula I:
y1＝k1x+b1
In the formula, y1The fiber content of the point to be measured is expressed in units of percent;
x is the distance between the point to be measured and the inner edge of the transition layer, and the unit is m;
k1The fiber content growth rate is a nonnegative number and the unit is 1/m;
b1In the range of 2% -25%.
5. The integrated composite tie of claim 4 wherein the density of said transition layer increases linearly according to formula II:
y2＝k2x+b2
In the formula, y2Is the density of the point to be measured in kg/m3；
x is the distance between the point to be measured and the inner edge of the transition layer, and the unit is m;
k2is the density growth rate of the transition layer, which is a non-negative number and has a unit of kg/m4；
b2In the range of 100-1200, the unit is kg/m3。
6. The one-piece composite tie of claim 2 further comprising a first density layer disposed on a side of the transition layer proximate the center of the composite tie and a second density layer disposed on a side of the transition layer distal from the center of the composite tie, and wherein the fibers in the first density layer are uniformly distributed with a first fiber content and the fibers in the second density layer are uniformly distributed with a second fiber content.
7. The one-piece composite tie of claim 6,
the composite material sleeper sequentially comprises the first density layer and the transition layer from inside to outside in the radial direction, and the thickness of the first density layer is 1/10-9/10 of the height of the composite material sleeper; or
The composite material sleeper sequentially comprises the transition layer and the second density layer from inside to outside in the radial direction, and the thickness of the transition layer is 6/50-49/50 of the height of the composite material sleeper; alternatively, the first and second electrodes may be,
The composite material sleeper sequentially comprises the first density layer, the transition layer and the second density layer from inside to outside in the radial direction, the thickness of the first density layer is 1/10-9/10 of the height of the composite material sleeper, and the thickness of the transition layer is 1/100-22/50 of the height of the composite material sleeper.
8. The one-piece composite tie of claim 1 comprising, in order from inside to outside in the radial direction, a first density layer, a transition layer, and a second density layer, the fibers in the first density layer being uniformly distributed with a first fiber content, the fibers in the second density layer being uniformly distributed with a second fiber content, the fibers in the transition layer being uniformly distributed with a third fiber content, the first fiber content < the third fiber content < the second fiber content.
9. the one-piece composite tie as claimed in any one of claims 2 to 8 wherein said first fiber content is between 2% and 25% and said second fiber content is between 17% and 60%.
10. The one-piece composite tie as claimed in any one of claims 6 to 8 wherein said first density layer has a density of 100kg/m3-1200kg/m3the density of the second density layer is 500kg/m3-1900kg/m3。
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