EP1144759B1 - Mat consisting of tubes and method of fabrication - Google Patents

Abstract

The invention relates to a tube mat (1) made of elastomer material in the form of an extruded product, comprising at least a first face side and a second face side, which are arranged perpendicular or at an angle in relation to the direction of extrusion; as well as a plurality of tubes (2) extending between the two face sides parallel with the direction of extrusion. The tube mat (1) as defined by the invention is characterized in that at least a part of the tube are closed at adjustable intervals, specifically with formation of an enclosed air column in each case, whereby the tube closure forms a one-piece elastomer composite with the tube mat. Furthermore, introduced is a method for producing the tube mat (1) as defined by the invention. According to the method, following extrusion, the tubes are pressed shut in points with the help of a pressure applicator roller that is provided with pins distributed over the circumference of the roller, specifically with formation of beads (5) and closing bridges (6). The vulcanization is carried out subsequently.

Description

• eine erste und zweite Stirnseite, die senkrecht oder gewinkelt zur Extrusionsrichtung angeordnet sind; sowie
• mehrere Röhren, die zwischen den beiden Stirnseiten parallel in Extrusionsrichtung verlaufen.

The invention relates to a tubular mat made of elastomeric material in the form of an extrudate, comprising at least

• a first and second end face, which are arranged perpendicular or angled to the direction of extrusion; such as
• several tubes that run parallel between the two end faces in the direction of extrusion.

A generic tube mat is described, for example, in the publications DE-C-33 45 388, DE-C-34 03 234, DE-C-35 24 719 and EP-B-0 569 867 in detail described.

With the previously known tubular mats, dirt and water could be found on the front occur, which then often led to the tube mat no longer being full Function with regard to their elasticity.

The object of the invention is to provide a tube mat in which the ingress of dirt and water is largely excluded, combined with an improvement in the elastic properties of the article simultaneous increase in service life, and this with dynamic Duration stresses.

This problem is solved in that at least some of the tubes in adjustable intervals are closed, each with training enclosed air column, the tube closure one piece Forms an elastomer bond with the tube mat.

The tube closure can be vertical in a line or at an angle not equal to 90 °, preferably at an angle of 45 ° to 80 °. to the direction of extrusion run.

• Die erste und zweite Stirnseite der Röhrenmatte sind geschlossen, und zwar unter Ausbildung eines vollständig geschlossenen Röhrensystems.
• Die erste und/oder zweite Stirnseite der Röhrenmatte ist/sind teilweise oder vollständig offen, und zwar unter Ausbildung eines entsprechenden offenen Stirnbereiches. Im Mittenbereich der Röhrenmatte liegt jedoch ein geschlossenes Röhrensystem vor.

With regard to the tube closure, the following two variants are used in particular:

• The first and second end faces of the tube mat are closed, with the formation of a completely closed tube system.
• The first and / or second end face of the tube mat is / are partially or completely open, specifically with the formation of a corresponding open end area. However, there is a closed tube system in the center area of the tube mat.

• Die Röhrenmatte besteht aus einer vulkanisierten Kautschukmischung auf der Basis von Ethylen-Propylen-Dien-Mischpolymerisat (EPDM), wobei die Härte in Shore A 30° bis 50° beträgt.
• Der alternative Werkstoff ist eine vulkanisierte Kautschukmischung auf der Basis von Naturkautschuk (NR), wobei hier die Härte in Shore A 30° bis 60° beträgt.

The following materials are expediently used for the tube mat:

• The tube mat consists of a vulcanized rubber mixture based on ethylene-propylene-diene copolymer (EPDM), the hardness in Shore A being 30 ° to 50 °.
• The alternative material is a vulcanized rubber mixture based on natural rubber (NR), whereby the hardness in Shore A is 30 ° to 60 °.

Further usual mixture ingredients of the respective rubber mixture are for example sulfur or sulfur donor, accelerator, zinc oxide, filler and Anti-aging agents.

• Sie dient als elastische Matte im Gleisbett oder Schotterbett. Unter diesem Gesichtspunkt wird die Röhrenmatte auch als Gleisbettmatte bzw. Unterschottermatte bezeichnet. Die Matte kann dabei gegebenenfalls mit einer Vliesschutzschicht oder dergleichen abgedeckt sein.
• Die Röhrenmatte hat die Funktion einer elastischen Einlage in Schwellenschuhsystemen.
• Sie dient ferner als elastische Unterlage in Schienenstützpunkten, insbesondere wiederum in Form einer Schienenunterlage, die unterhalb des Schienenfußes angeordnet ist.

The tube mat according to the invention is used in particular in rail traffic technology, specifically in the context of vibration damping and sound insulation for the following areas of application:

• It serves as an elastic mat in the track bed or ballast bed. From this point of view, the tube mat is also referred to as a track bed mat or sub-ballast mat. The mat can optionally be covered with a fleece protective layer or the like.
• The tube mat has the function of an elastic insert in sleeper shoe systems.
• It also serves as an elastic base in rail support points, in particular again in the form of a rail base, which is arranged below the rail base.

In addition, the object of the invention is for the tube mat of the above described type to provide a method that a secure tube closure guaranteed and economical.

• nach der Extrusion werden mit Hilfe einer Andrückrolle, die über den Umfang der Rolle verteilt mit Stiften versehen ist, die Röhren zugedrückt, und zwar unter Ausbildung von Sicken und Verschlußstegen;
• anschließend wird vulkanisiert.

A particularly advantageous process for producing the tube mat according to the invention is characterized by the following process steps:

• after the extrusion, the tubes are pressed in with the aid of a pressure roller, which is provided with pins distributed over the circumference of the roller, with the formation of beads and sealing webs;
• then vulcanization.

Fig. 1

eine Röhrenmatte mit Verschluß der Röhren unter Linienführung im Winkel ungleich 90° zur Extrusionsrichtung;

Fig. 2

Details des Röhrenverschlusses gemäß Schnittlinie A-A (Fig. 1);

Fig. 3

eine Röhrenmatte mit Verschluß der Röhren unter einer Linienführung senkrecht zur Extrusionsrichtung;

Fig. 4

eine Röhrenmatte gemäß Schnittlinie A-A (Fig. 3);

Fig. 5

eine Röhrenmatte gemäß Schnittlinie B-B (Fig. 3);

Fig. 6

einen Verfahrensablauf der Herstellung einer Röhrenmatte gemäß Fig. 1.

Further advantageous process parameters are presented in the context of the description of the figures. Show it:

Fig. 1

a tube mat with closure of the tubes with lines at an angle not equal to 90 ° to the direction of extrusion;

Fig. 2

Details of the tube closure according to section line AA (Fig. 1);

Fig. 3

a tube mat with closure of the tubes under a line perpendicular to the direction of extrusion;

Fig. 4

a tube mat according to section line AA (Fig. 3);

Fig. 5

a tube mat according to section line BB (Fig. 3);

Fig. 6

a process flow of the production of a tube mat according to FIG. 1.

1

Röhrenmatte

2

Röhren

3

Röhrenverschluß

4

Oberseite der Röhrenmatte

5

Sicke

6

Verschlußsteg

7

Röhrenmatte

8

Röhren

9

Röhrenverschluß

10

Röhrenverschluß

11

erste Stirnseite der Röhrenmatte

12

zweite Stirnseite der Röhrenmatte

13

Extruder mit Austrittsöffnung

14

Tragrollen

15

Andrückrolle

16

Stifte

17

Vulkanisationskanal

In connection with these figures, the following list of reference numbers applies:

1

mat made of tubes

2

roar

3

tubular lock

4

Top of the tube mat

5

Beading

6

closure web

7

mat made of tubes

8th

roar

9

tubular lock

10

tubular lock

11

first face of the tube mat

12

second face of the tube mat

13

Extruder with exit opening

14

idlers

15

capstan

16

pencils

17

vulcanization tunnel

Fig. 1 shows a tube mat 1 made of elastomeric material, ie rubber or rubber-like plastic. This tube mat is an extrudate with the extrusion direction Y. A length L of up to 100 m can be achieved.

The tube mat 1 has a plurality of tubes 2 , which run parallel in the extrusion direction Y. The tubes are closed at adjustable intervals a , with the formation of an enclosed air column. The tube closure 3 runs here in a line X at an angle α of approximately 55 ° to the extrusion direction Y. This creates several closed tube segments I, II, III and IV.

• Der Schnitt erfolgt entlang der Linie X mittig durch den Röhrenverschluß 3. Dadurch entsteht eine Stirnseite der Röhrenmatte, die vollständig geschlossen ist.
• Der Schnitt erfolgt entlang der Linie Z senkrecht zur Extrusionsrichtung Y. Dadurch entsteht ein Röhrensegment III, das innerhalb der Stirnseite der Röhrenmatte offen ist. Dies kann jedoch in Kauf genommen werden, wenn die Röhrenmatte wenigstens ein geschlossenes Röhrensegment, insbesondere mehrere geschlossene Röhrensegmente in Reihenschaltung besitzt. Dies ist bei der Verwendung der Röhrenmatte 1 als Gleisbettmatte bzw. Unterschottermatte auch der Fall.

Depending on the requirements, there are now two options for an article cut:

• The cut is made along the line X in the middle through the tube closure 3 . This creates an end face of the tube mat that is completely closed.
• The cut is made along the line Z perpendicular to the extrusion direction Y. This creates a tube segment III, which is open within the face of the tube mat. However, this can be accepted if the tube mat has at least one closed tube segment, in particular a plurality of closed tube segments connected in series. This is also the case when using the tube mat 1 as a track bed mat or sub-ballast mat.

Fig. 2 shows the tube closure 3 , wherein a bead 5 is formed on the top 4 of the tube mat 1 within the closure area. The tube closure itself is caused by the closure web 6 .

If the article is now cut along the line X centrally through the closure web 6 , a closed end face of the tube mat 1 is created .

3 shows a tube mat 7 with tubes 8 . In the manufacture of this tube mat as an initially web-like structure, a plurality of tube closures 9, 10 are formed, which, in contrast to the exemplary embodiment according to FIG. 1, run in a line X perpendicular to the extrusion direction Y. The tubes 8 are closed at an adjustable distance b , specifically to form a closed tube segment V.

Within the scope of this exemplary embodiment, the article is cut along the line X , a first end face 11 and a second end face 12 being formed, each of which is completely closed. There is only a single closed tube segment V here .

Such a tube mat is used, for example, as an elastic insert in the Sleeper shoe systems used.

FIG. 4 shows the cross-section (AA) of the tube mat 7 according to FIG. 3, the tubes 8 , viewed in cross-section, being essentially semicircular in shape, in an alternative structural arrangement. However, tubes with a different cross-sectional shape (for example circular) are also possible.

FIG. 5 now shows a longitudinal section (BB) of the tube mat 7 according to FIG. 3, specifically with the formation of a closed tube 8 . With regard to the tube closure 9 , 10 , the same applies as for the tube closure 3 according to FIG. 2.

FIG. 6 now describes the procedural sequence of a tube mat 1 according to FIG. 1.

The web-shaped tube mat 1 emerges from the extruder 13 in the extrusion direction Y. The tube mat is now guided on a load-bearing sliding system, in particular in the form of support rollers 14 . A pressure roller 15 , which is provided with pins 16 distributed over the circumference of the roller, now presses the tubes selectively (ie exclusively within the closure area), with the formation of beads 5 and closure webs 6 (FIG. 2). The tube closure 3 (Fig. 1, 2) runs in a line X at an angle not equal to 90 °.

Now the tube mat 1 enters a vulcanization channel 17 . The vulcanization takes place without pressure in the UHF channel, in a salt bath system or hot air system.

The pins 17 are advantageously interchangeable. Pins with a diameter of about 20 mm, for example, have proven their worth in track bed mats or sub-ballast mats.

In another arrangement principle of the pressure roller 15 and the pins 16 , a tube closure 3 can also be realized, which runs in a line X perpendicular to the direction of extrusion Y.

Claims (16)

1. Mat made of tubes (1, 7) of elastomer material in the form of an extrusion, comprising at least

   a first and a second end side (11,12) which are arranged perpendicular or at an angle to the extrusion direction (Y); and

   a plurality of tubes (2, 8) which run parallel in the extrusion direction (Y) between the two end sides (11, 12);

   characterised in that

   at least some of the tubes (2, 8) are closed at adjustable intervals (a, b) forming in each case an enclosed column of air, the tube closure (3, 9, 10) forming a one-piece elastomer composite with the mat made of tubes (1, 7).
2. Mat made of tubes according to claim 1, characterised in that the tube closure (9, 10) runs in a line (X) perpendicular to the extrusion direction (Y).
3. Mat made of tubes according to claim 1, characterised in that the tube closure (3) runs in a line (X) at an angle α other than 90°, preferably at an angle of 45° to 80°, to the extrusion direction (Y).
4. Mat made of tubes according to one of claims 1 to 3, characterised in that the first and second end sides (11, 12) are closed, forming a completely closed tube system.
5. Mat made of tubes according to one of claims 1 to 3, characterised in that the first and/or second end sides (11, 12) are partly or completely open, forming a corresponding open end area but a closed tube system in the middle area of the mat made of tubes.
6. Mat made of tubes according to one of claims 1 to 5, characterised in that this is made of a vulcanised rubber mixture on the basis of ethylene-propylene-diene mixed polymer (EPDM) .
7. Mat made of tubes according to claim 6, characterised in that the hardness in Shore A is 30° to 50°.
8. Mat made of tubes according to one of claims 1 to 5, characterised in that this is made of a vulcanised rubber mixture on the basis of natural rubber (NR).
9. Mat made of tubes according to claim 8, characterised in that the hardness in Shore A is 30° to 60°.
10. Mat made of tubes according to one of claims 1 to 9, in particular in conjunction with claims 3 and 5, for use as an elastic mat in the track bed or ballast bed, wherein the mat is covered if necessary with a protective layer of fleece or the like.
11. Mat made of tubes according to one of claims 1 to 9, in particular in conjunction with claims 2 and 4, for use as an elastic inlay in sleeper shoe systems.
12. Mat made of tubes according to one of claims 1 to 9, in particular in conjunction with claims 2 and 4, for use as an elastic underlay in rail supporting points, in particular in the form of a rail underlay which is arranged underneath the rail foot.
13. Method for production of a mat made of tubes according to one of claims 1 to 12, wherein

    after extrusion, the tubes are pressed together within the closure area with the aid of a pressure roller (15) which is provided with pins (16) distributed over the circumference of the roller, forming indentations (5) and closing walls(6),

    and then vulcanisation is carried out.
14. Method according to claim 13, characterised in that changeable pins (16) are used.
15. Method according to claim 13 or 14, characterised in that the vulcanisation is carried out without pressure in the UHF channel, in a salt bath installation or hot air installation.
16. Method according to one of claims 13 to 15, characterised in that the mat made of tubes (1, 7) is produced in a great length, forming closed tube segments (I, II, III, IV, V), and then cut into articles depending on the application.

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