JP2018193848A - Railroad tie and manufacturing method thereof - Google Patents

Abstract

To provide a railroad tie and a manufacturing method thereof capable of effectively suppressing a positional deviation (jacking) in the approximately vertical direction due to vibration and the like even if the weight of the railroad tie is reduced.SOLUTION: A railroad tie 10 is provided with a main body part 11 having a longitudinal direction and width direction and made of resin, and projections 12a, 12b which project from both the side surfaces 10c, 10c in the width direction of the main body part 11 toward the width direction of the main body part 11.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a sleeper tree embedded in, for example, gravel or the like and a method for manufacturing the same.

  In recent years, urethane resin foam molded products containing reinforcing fibers have been used as resin sleepers laid under rails for railroad tracks. Examples of the reinforcing fibers include glass fibers having light weight performance and excellent performance such as mechanical strength and weather resistance.

  For example, Patent Document 1 discloses an I-shaped extrusion molded sleeper in which an aluminum alloy is molded in order to meet demands for weight reduction and high durability.

  Moreover, in patent document 2, in order to oppose the shift | offset | difference force which acts on a rail at the time of driving | running | working of a train, on the surface of the sleeper in which the synthetic resin material containing glass fiber was shape | molded in the direction substantially perpendicular | vertical to a longitudinal direction The structure which has arrange | positioned the recessed part or the convex part is disclosed.

  Further, Patent Document 3 discloses a sleeper made of synthetic wood, which is a long glass fiber reinforced rigid urethane resin foam, in order to prevent the sleeper from being displaced in the long axis direction by filling the convex portion with ballast. ing.

JP 2013-112352 A Japanese Utility Model Publication No. 7-25001 JP-A-7-42101

  The conventional sleeper described above has the following problems.

  In the pillows disclosed in Patent Documents 2 and 3, a lightweight pillow made of synthetic resin containing glass fibers floats in or on gravel or the like (ballast) by vibration or the like. There is a risk that.

  Further, for example, in the sleeper disclosed in Patent Document 1, a metal such as an aluminum alloy is formed, and the weight of the metal is larger than that of a synthetic resin, so that there is no problem of floating in the first place. On the other hand, with the sleeper disclosed in Patent Document 1, it is difficult to reduce the weight.

  Further, the sleepers disclosed in Patent Documents 2 and 3 are considered to have an effect on lateral displacement in a direction substantially parallel to the rail. However, since the structures disclosed in Patent Documents 2 and 3 are not structures that are bitten into the ballast, they are resistant to misalignment (lateral misalignment) in a direction substantially parallel to the rail, but are perpendicular to the rail. It is difficult to suppress the deviation (floating resistance) in

  An object of the present invention is to provide a sleeper that can effectively suppress the occurrence of misalignment (floating) in a substantially vertical direction due to vibration or the like even if the sleeper is lightened, and a method for manufacturing the sleeper. There is.

  A sleeper according to the present invention includes a main body portion having a longitudinal direction and a width direction and made of resin, and projecting portions projecting in the width direction of the main body portion from side surfaces on both sides in the width direction of the main body portion. ing.

  According to the sleeper according to the present invention, even if the sleeper is lightened, it is possible to effectively suppress the occurrence of displacement (floating) in the substantially vertical direction due to vibration or the like.

The perspective view which shows the whole pillow structure which concerns on one Embodiment of this invention. Sectional drawing which shows the state by which the sleeper tree of FIG. 1 was embed | buried in gravel. Sectional drawing which shows the dimension of the upper surface of a sleeper of FIG. 1, a bottom face, the maximum width, and the minimum width. Schematic which shows the structure of the manufacturing apparatus used when manufacturing the sleeper of FIG. Sectional drawing which shows the internal structure of the extrusion apparatus contained in the manufacturing apparatus of FIG. The flowchart which shows the flow of the manufacturing method of the sleeper of FIG. Sectional drawing which shows the structure of the sleeper tree which concerns on other embodiment of this invention.

  Hereinafter, the present invention will be described in detail.

  A sleeper according to the present invention (first invention) has a longitudinal direction and a width direction and is made of a resin, and a protrusion protruding in the width direction of the main body portion from both side surfaces in the width direction of the main body portion. Department.

  The sleeper is a resin sleeper because it has a resin body. The sleeper tree is preferably used by being embedded in gravel or the like. In the sleeper, the sleeper is configured to include protrusions that protrude in the width direction from the side surfaces on both sides of the main body when viewed in a cross section perpendicular to the longitudinal direction.

  As said resin, a polyurethane resin, a phenol resin, a polyester resin etc. can be used, for example.

  The longitudinal direction and the width direction of the main body are, for example, a direction orthogonal to the vertical direction in the installed state of the sleeper trees, and are a surface direction and a horizontal direction of the upper surface to be installed. The longitudinal direction and the width direction of the sleeper correspond to the longitudinal direction and the width direction of the main body, respectively. When the cross section perpendicular to the longitudinal direction of the main body is viewed, the protruding portions protrude in the width direction of the main body from the side surfaces on both sides in the width direction of the main body. For example, two protruding portions protruding from the side surfaces on both sides of the main body portion may be provided on each of the side surfaces on both sides, or may be provided one by one. It is preferable that two protrusions are provided on each side surface of the main body.

  The main body has a bottom surface and a top surface. When installing the sleeper, the sleeper is installed such that the bottom surface of the main body is positioned below and the top surface of the main body is positioned above. In the sleeper installation state, the bottom surface of the main body is positioned below, and the top surface of the main body is positioned above. The bottom and top surfaces of the sleeper correspond to the bottom and top surfaces of the main body, respectively. The two side surfaces of the main body portion where the protruding portion is located connect the bottom surface and the upper surface of the main body portion. The protruding portion preferably protrudes along the bottom surface of the main body portion. In this case, gravel is arranged on the projecting portion in a state where the sleeper tree is embedded in gravel or the like, and movement of the sleeper tree is suppressed. It is preferable that the protruding portion protrudes along the upper surface of the main body portion.

  Since the sleeper has the above-mentioned shape and cross-sectional shape, the projecting part is caught in a state where it is embedded in gravel or the like (ballast), so that the sleeper is moved in a direction substantially perpendicular to the projecting direction of the projecting part ( (Floating) is suppressed. Therefore, the resin sleeper which is lightweight and easily moved due to the influence of vibration or the like is less likely to move in the substantially vertical direction by the protruding portion, thereby suppressing the sleeper sleeper.

  As a result, even the lighter sleeper made of resin can effectively suppress the occurrence of displacement (floating) in the substantially vertical direction due to vibration or the like.

  The protrusion is preferably made of resin, and is preferably resin. The resin of the main body part and the resin of the protruding part may be the same or different. From the viewpoint of preventing breakage of the protrusion, the resin of the main body and the resin of the protrusion are preferably the same.

  The sleeper tree according to the second invention is the sleeper tree according to the first invention, wherein the ratio of the smallest width of the sleeper tree to the largest width of the sleeper tree in the direction parallel to the bottom surface of the main body is 0.60-0. 95.

  Here, the range of the ratio between the maximum width and the minimum width of the sleeper (minimum width of the sleeper / maximum width of the sleeper) is defined. The maximum width and the minimum width can also be measured by a cross-sectional view of the sleeper tree.

  When the ratio of the maximum width of the sleeper tree to the minimum width (minimum width of the sleeper tree / maximum width of the sleeper tree) is 0.95, it means that the protrusion amount of the protrusion (the size of the step) is relatively small. doing. On the other hand, when the ratio between the maximum width and the minimum width of the tree (minimum width of the sleeper tree / maximum width of the sleeper) is 0.60, the protrusion amount of the protrusion (the size of the step) is relatively large. Means.

  By setting the degree of protrusion of the protrusion so as to be within the above range, as described above, it is possible to effectively suppress the occurrence of displacement in a substantially vertical direction within gravel or the like (ballast).

  In addition, if the ratio of the minimum width to the maximum width of the sleeper (minimum width of the sleeper / maximum width of the sleeper) is 0.95 or less, it is effective to generate a displacement (floating) in a substantially vertical direction due to vibration or the like. If it is 0.60 or more, it is possible to secure a nail driving place for fastening the rail in a large area. Therefore, in the present invention, the ratio between the maximum width and the minimum width of the sleeper (minimum width of the sleeper / maximum width of the sleeper) is preferably set to be equal to or higher than the lower limit, and set to be equal to or lower than the upper limit. preferable.

  The sleeper according to the third invention is a sleeper according to the first or second invention, wherein the ratio of the width of the upper surface of the sleeper to the width of the lower surface of the sleeper (the width of the upper surface of the sleeper / the width of the lower surface of the sleeper) 0.6 to 1.0.

  Here, the ratio between the width of the bottom surface of the sleeper tree and the width of the top surface (the width of the top surface of the sleeper / the width of the bottom surface of the sleeper) is set to be within the above range.

  Here, when the ratio of the width of the upper surface to the width of the bottom surface of the sleeper (the width of the upper surface of the sleeper / the width of the bottom surface of the sleeper) is 1.0, it means that the upper surface and the bottom surface have the same width. Yes. In this case, for example, a configuration in which protrusions having the same width are provided on the upper surface side and the bottom surface side is assumed.

  When configured so that the width of the bottom surface of the sleeper is approximately equal to or less than the width of the top surface and the width of the top surface of the sleeper is about 60% or more of the width of the bottom surface, the vertical direction in gravel or the like (ballast) The occurrence of misalignment can be effectively suppressed.

  A sleeper according to a fourth aspect of the present invention is a sleeper according to any one of the first to third aspects, wherein the main body includes reinforcing fibers arranged along the longitudinal direction of the main body.

  Here, the reinforcing fibers arranged along the longitudinal direction of the main body are mixed in the resin. A sleeper formed by reinforcing fibers impregnated with a resin is a synthetic sleeper.

  Thereby, the synthetic sleeper which improved the intensity | strength in a specific direction can be obtained.

  From the viewpoint of further improving the strength in a specific direction, it is preferable that not only the main body portion but also the projecting portion includes the reinforcing fiber, and it is preferable that the reinforcing fiber disposed along the longitudinal direction of the main body portion is included.

  The sleeper tree according to the fifth invention is the sleeper tree according to the fourth invention, wherein the reinforcing fiber includes any one of glass fiber, carbon fiber, and wood fiber.

  Here, any one of glass fiber, carbon fiber, and wood fiber is used as the reinforcing fiber included in the main body.

  Thereby, the sleeper tree excellent in the rigidity in a specific direction can be obtained by arrange | positioning these reinforcement fibers along the longitudinal direction of a main-body part and a sleeper tree.

  From the viewpoint of further improving the rigidity in a specific direction, when the protrusion includes a reinforcing fiber, the reinforcing fiber preferably includes any one of glass fiber, carbon fiber, and wood fiber.

  A sleeper according to a sixth invention is the sleeper according to any one of the first to fifth inventions, wherein the resin of the main body is a polyurethane resin.

  Here, a polyurethane resin is used as the resin contained in the main body.

  As a result, as described above, it is possible to obtain an inexpensive and lightweight resin sleeper that is more unlikely to be displaced in the substantially vertical direction within the gravel.

  From the viewpoint of making the sleeper much lighter, it is preferable that the protruding portion contains a resin, and the resin contains a polyurethane resin.

  A sleeper according to a seventh aspect of the present invention is the sleeper according to any one of the first to sixth aspects, wherein the main body portion includes powder particles as a filler.

  Here, a sleeper is formed using a resin containing powdery particles. Powdery particles are included as a filler.

  Thereby, since the bending bending strength of the main part of a sleeper tree increases, it becomes possible to make the size of a sleeper tree smaller than the size of an existing sleeper tree.

  From the viewpoint of increasing the bending deflection strength of the main body portion, the protruding portion preferably includes powder particles.

  The sleeper tree according to the eighth invention is the sleeper tree according to the seventh invention, wherein the powder particles are at least one selected from inorganic powders and organic powders.

  Here, at least one of inorganic powder and organic powder is used as the powdery particles.

  Thereby, since the bending bending strength of the main part of a sleeper tree increases, it becomes possible to make the size of a sleeper tree smaller than the size of an existing sleeper tree.

  The sleeper tree according to the ninth invention is the sleeper tree according to the eighth invention, wherein the inorganic powder is a metal carbonate, mineral, sulfate, potassium salt, ash, clay, metal nitride, titanium compound, And at least one selected from sulfides.

  Here, at least one selected from metal carbonates, minerals, sulfates, potassium salts, ash, clays, metal nitrides, titanium compounds, and sulfides is used as the inorganic powder.

  Thereby, since the bending bending strength of the main part of a sleeper tree increases, it becomes possible to make the size of a sleeper tree smaller than the size of an existing sleeper tree.

  A sleeper manufacturing method according to a tenth invention is a sleeper manufacturing method according to any one of the first to ninth inventions, wherein a plurality of reinforcing fibers are aligned in the first direction and aligned. A step of feeding the reinforcing fibers along the first direction (first step), a first raw material containing the compound (A), and a second raw material containing the compound (B) that reacts with the compound (A). A step (second step) of impregnating the expanded curable resin composition obtained into the aligned reinforcing fibers (second step), and allowing the reinforcing fibers impregnated with the foam curable resin composition to pass through the molding passage. The foam curable resin composition is foam-cured and molded to obtain a foamed molded product (third process).

  Here, the foam curable resin obtained by mixing the first raw material containing the compound (A) and the second raw material containing the compound (B) that reacts with the compound (A) while feeding the aligned reinforcing fibers The composition is impregnated into the reinforced reinforcing fibers, and the foam curable resin composition is foam-cured and molded while feeding the reinforcing fibers into a molding passage formed by a mold or the like.

  Thereby, the reinforcement fiber is arrange | positioned along the longitudinal direction of a main-body part, and the sleeper which has said main-body part and protrusion part can be manufactured easily.

  The aligned reinforcing fibers are reinforcing fiber bundles. The first raw material is preferably a liquid raw material. The second raw material is preferably a liquid raw material. The foam curable resin composition is preferably a foam curable resin liquid. It is preferable that the foam curable resin composition is foam-cured and formed into an irregular cross-sectional shape.

  A sleeper manufacturing method according to an eleventh aspect of the invention is a sleeper manufacturing method according to the tenth aspect of the invention, and obtains the foam molded body itself as a sleeper.

  Here, a sleeper tree is obtained by the third step. A sleeper having the above-described shape can be obtained by foam-curing the foam-curable resin composition and molding the foam-cured resin composition into an irregular cross-sectional shape. When the foam curable resin composition is foam-cured and molded, the projecting portions may have a shape projecting in the width direction of the main body portion from the side surfaces on both sides in the width direction of the main body portion.

  A sleeper manufacturing method according to a twelfth aspect of the present invention is a sleeper manufacturing method according to the tenth aspect of the present invention, further comprising a step of bonding a plurality of foamed molded bodies to obtain a sleeper (fourth step). Yes.

  Here, a sleeper tree is obtained by the fourth step. A plurality of foamed moldings are prepared in advance. And a plurality of foaming moldings are pasted up and the sleeper tree of the shape mentioned above is obtained.

  A sleeper manufacturing method according to a thirteenth invention is a sleeper manufacturing method according to any one of the tenth to twelfth inventions, wherein a plurality of sleepers are continuously manufactured.

  Here, the sleeper tree mentioned above is manufactured continuously.

  A batch-type manufacturing method by continuously forming a foam curable resin composition into a desired cross-sectional shape by foaming a foam curable resin composition while feeding reinforcing fibers into a molding passage formed by a mold or the like. In comparison, it is possible to suppress the manufacturing cost of the sleeper and easily manufacture the sleeper having various dimensions in the extrusion direction.

  When the foam curable resin composition is foam-cured and molded, it may be continuously molded. In order to obtain a plurality of sleepers, the step of bonding a plurality of foamed molded bodies may be performed continuously. The first step and the second step are preferably performed online. The second step and the third step are preferably performed online. The third step and the fourth step are preferably performed online. The first step, the second step, the third step, and the fourth step are preferably performed online.

  The sleeper tree according to an embodiment of the present invention will be described below with reference to FIGS.

  As shown in FIG. 1, the sleeper 10 of the present embodiment includes a main body 11 and protrusions 12 a and 12 b. The main body portion 11 is obtained from a resin containing reinforcing fibers arranged along the longitudinal direction of the main body portion 11. The sleeper 10 is a synthetic sleeper including reinforcing fibers. The projecting portions 12 a and 12 b project in the width direction from the side surfaces 10 c and 10 c on both sides of the main body portion 11 in the width direction. The protrusions 12 a and 12 b protrude in the width direction from the side surfaces 10 c and 10 c on both sides in the width direction of the main body 11 in the installed state in a cross-sectional view perpendicular to the longitudinal direction of the main body 11.

  Further, as shown in FIG. 1, the sleeper 10 has a bottom surface 10a, an upper surface 10b, and side surfaces 10c and 10c on both sides in the width direction. The outer peripheral surface of the sleeper 10 is formed by the bottom surface 10a, the upper surface 10b, and the side surfaces 10c and 10c on both sides. The sleeper 10 has side surfaces on both sides in the length direction (the left front side and the right back side in FIG. 1).

  As shown in FIG. 2, the bottom surface 10 a is a surface on the side where the sleeper tree 10 is most deeply embedded when the pillow 10 is embedded in the gravel 20. In the embedded state shown in FIG. Preferably they are arranged. The bottom surface 10a is preferably a flat surface.

  As shown in FIG. 2, the upper surface 10 b is a surface on the opposite side of the bottom surface 10 a in the sleeper tree 10 and is disposed along a direction substantially parallel to the bottom surface 10 a (substantially horizontal direction). As shown in FIG. 2, the upper surface 10 b is a surface on the side that does not have to be buried in the gravel 20 when the sleeper tree 10 is buried in the gravel 20. The upper surface 10b is preferably a flat surface.

  The side surfaces 10c and 10c on both sides connect the bottom surface 10a and the top surface 10b, as shown in FIG. The side surfaces 10c, 10c on both sides have surfaces that are substantially perpendicular to the bottom surface 10a and the top surface 10b. Protruding portions 12a and 12b are provided on the side surfaces 10c and 10c on both sides, respectively.

  As shown in FIG. 1, the main body 11 is a rectangular parallelepiped portion that forms the center of the sleeper 10. As described above, the main body 11 is preferably obtained from a resin containing reinforcing fibers arranged along the longitudinal direction.

  As shown in FIGS. 1 and 2, the protruding portions 12 a and 12 b are portions protruding in the width direction from the side surfaces (side surfaces 10 c and 10 c) on both sides in the width direction of the main body portion 11. Two are provided in 10c.

  As shown in FIGS. 1 and 2, the protruding portion 12a is provided to protrude in the width direction on the upper surface 10b side of the side surfaces 10c, 10c on both sides.

  As shown in FIGS. 1 and 2, the protruding portion 12b is provided to protrude in the width direction on the bottom surface 10a side of the side surfaces 10c, 10c on both sides.

  Thereby, a concave portion is formed between the protruding portion 12a and the protruding portion 12b on the side surfaces 10c, 10c on both sides in the width direction of the sleeper 10. The shape of the recess may be a polygonal shape or a shape having a curved surface. When the concave portion has a curved surface, the side surface may be a curved surface, and the boundary portion between the side surface and the protruding portion may be a curved surface.

  Moreover, the sleeper 10 of this embodiment has a size of height (h) × width (w) × length (l) = 100 mm × 260 mm × 2600 mm. The height, width, and length refer to the maximum height, maximum width, and maximum length, respectively.

  Regarding the size of the sleeper 10, the height (h) is preferably in the range of 60 to 180 mm, more preferably in the range of 70 to 140 mm, and still more preferably in the range of 80 to 120 mm.

  The width (w) is preferably in the range of 100 to 300 mm, more preferably in the range of 120 to 280 mm, and still more preferably in the range of 160 to 260 mm.

  Further, the length (l) is preferably in the range of 500 to 5000 mm, more preferably in the range of 1800 to 3800 mm, and still more preferably in the range of 2000 to 3500 mm.

  As described above, the sleeper 10 according to the present embodiment includes the main body 11 and the protrusions 12a and 12b. The main body portion 11 is preferably obtained from a resin containing reinforcing fibers arranged along the longitudinal direction. The projecting portions 12 a and 12 b project in the width direction from the side surfaces 10 c and 10 c on both sides of the main body portion 11 in the width direction.

  The sleeper 10 of this embodiment has a cross-sectional shape in which the protruding portions 12a and 12b that protrude in the width direction from the side surfaces 10c and 10c on both sides are formed as described above. In the sleeper tree 10 of the present embodiment, since the above-described configuration is provided, the gravel 20 or the like enters the concave portion between the projecting portion 12a and the projecting portion 12b in the state embedded in the gravel 20 or the like, and the projecting portion 12a, 12b is caught and the movement (floating) of the sleeper 10 in a direction substantially perpendicular to the protruding direction of the protruding portions 12a and 12b can be suppressed.

  Therefore, the resin sleeper 10 that is lightweight and easily moved under the influence of vibration or the like is less likely to move in the substantially vertical direction by the protrusions 12a and 12b, so that the weight of the resin sleeper 10 is reduced. Even in this case, it is possible to effectively suppress the occurrence of displacement (floating) in the substantially vertical direction due to vibration or the like.

  Further, as shown in FIG. 3, the sleeper 10 of the present embodiment has a width of the upper surface 10b (maximum width: the sum of the width of the main body portion 11 and the width of the projecting portion 12a) d1, and the width of the main body portion (minimum width). When d2 is the width of the bottom surface 10a (maximum width: the sum of the width of the main body 11 and the width of the protruding portion 12b) d3, it is molded so as to satisfy the following relational expressions (1A), (1B), (2). ing. The width can also be evaluated by a cross-sectional view.

  In the sleeper 10 of the present embodiment, as shown in FIG. 3, the sleeper 10 is molded so that the ratio of the minimum width d2 to the maximum widths d1 and d3 is 0.60 to 0.95.

  d2 / d1 = 0.60-0.95 (1A)

  d2 / d3 = 0.60-0.95 (1B)

  The relational expressions (1A) and (1B) indicate the degree of protrusion of the protruding portions 12a and 12b protruding in the width direction from the side surfaces 10c and 10c.

  In the sleeper according to the present invention, the ratio (the smallest width of the sleeper / the largest width of the sleeper) is preferably 0.60 or more, more preferably 0.65 or more, preferably 0.95 or less, more preferably 0. .90 or less, more preferably 0.85 or less. When the ratio (the smallest width of the sleeper / the largest width of the sleeper) is not less than the above lower limit and not more than the above upper limit, when the sleeper is embedded in gravel or the like, it is positioned in a substantially vertical direction due to vibration or the like. It is possible to effectively suppress the occurrence of deviation (floating).

  Moreover, in the sleeper 10 of this embodiment, as shown in FIG. 3, it shape | molds so that ratio of the width | variety d1 of the upper surface 10b with respect to the width | variety d3 of the bottom face 10a may be set to 0.6-1.0.

  d1 / d3 = 0.6 to 1.0 (2)

  This relational expression (2) shows a comparison between the upper surface 10b side and the bottom surface 10a side of the protruding portions 12a and 12b protruding from the left and right side surfaces 10c and 10c.

  Here, d1 / d3 = 1.0 means that the width of the upper surface 10b is the same as the width of the bottom surface 10a.

  Then, d1 / d3 = 0.6 means that no protrusion is provided on the upper surface side and the width of the upper surface is shorter than the width of the bottom surface, as shown in FIG. I mean. Alternatively, d1 / d3 = 0.6 means that the protruding amount of the protruding portion on the upper surface side is small and the width of the upper surface is shorter than the width of the bottom surface.

  In the sleeper according to the present invention, the ratio (width of the upper surface of the sleeper / width of the bottom of the sleeper) is preferably 0.6 or more, more preferably 0.65 or more, preferably 1.0 or less, more preferably 0. .95 or less. When the ratio (the width of the top surface of the sleeper / the width of the bottom surface of the sleeper) is not less than the above lower limit and not more than the above upper limit, when the sleeper is embedded in gravel, etc., it is positioned in a substantially vertical direction due to vibration or the like. It is possible to effectively suppress the occurrence of deviation (floating).

  The width d1 is preferably in the range of 60 to 300 mm, more preferably in the range of 72 to 280 mm, and still more preferably in the range of 96 to 260 mm.

  The width d2 is preferably in the range of 60 to 285 mm, more preferably in the range of 72 to 266 mm, and still more preferably in the range of 160 to 247 mm.

  Furthermore, the width d3 is preferably in the range of 100 to 300 mm, more preferably in the range of 120 to 280 mm, and still more preferably in the range of 160 to 260 mm.

  The thickness of the protrusion is preferably 5 mm or more, more preferably 10 mm or more, preferably 40 mm or less, more preferably 35 mm or less. When the protrusion is thick, damage to the protrusion is suppressed. When the thickness of the protrusion is thin, it is possible to effectively suppress the occurrence of displacement (floating) in the substantially vertical direction due to vibration or the like. When the thickness of the protruding portion is not less than the above lower limit and not more than the above upper limit, breakage of the protruding portion can be satisfactorily suppressed, and occurrence of misalignment (floating) in a substantially vertical direction due to vibration or the like is effectively caused. Can be suppressed. The thickness of the protrusion is the thickness per protrusion. The thickness of the protrusion is measured in the direction connecting the upper surface and the bottom surface of the sleeper.

  Hereinafter, details of ingredients contained in the sleeper according to the present invention will be described.

(Components of foam curable resin composition)
The foam curable resin composition that is a molding material of the sleeper 10 of the present embodiment is preferably a resin composition that foams and cures in a relatively short time. For example, a polyurethane resin composition is suitably used. The foam curable resin composition is preferably liquid. The foam curable resin composition includes a compound (A) and a compound (B) that reacts with the compound (A). The foam curable resin composition can be foamed with a foaming agent. In the present specification, the polyurethane resin composition includes a resin composition that becomes a polyurethane resin after the reaction.

  When a polyurethane resin is used as the foam curable resin, the foam curable resin composition includes a polyol compound as the compound (A) and an isocyanate compound as the compound (B) that reacts with the polyol compound. Yes. The filler is preferably dispersed and mixed in the raw material containing the polyol compound, and is preferably dispersed and mixed only in the raw material containing the polyol compound.

(Compound (A))
Examples of the polyol compound that is a raw material of the urethane resin include polylactone polyol, polycarbonate polyol, aromatic polyol, alicyclic polyol, aliphatic polyol, polyester polyol, polymer polyol, and polyether polyol.

  Examples of the polylactone polyol include polypropiolactone glycol, polycaprolactone glycol, and polyvalerolactone glycol.

  Polycarbonate polyol is obtained by, for example, a dealcoholization reaction between a hydroxyl group-containing compound such as ethylene glycol, propylene glycol, butanediol, pentanediol, hexanediol, octanediol, and nonanediol, and diethylene carbonate and dipropylene carbonate. Polyol and the like.

  Examples of the aromatic polyol include bisphenol A, bisphenol F, phenol novolak, and cresol novolak.

  Examples of the alicyclic polyol include cyclohexanediol, methylcyclohexanediol, isophoronediol, dicyclohexylmethanediol, and dimethyldicyclohexylmethanediol.

  Examples of the aliphatic polyol include ethylene glycol, propylene glycol, butanediol, pentanediol, and hexanediol.

  Examples of the polyester polyol include a polymer obtained by dehydration condensation of a polybasic acid and a polyhydric alcohol, a polymer obtained by ring-opening polymerization of a lactone such as ε-caprolactone and α-methyl-ε-caprolactone, And a condensate of hydroxycarboxylic acid and the above polyhydric alcohol.

  Specific examples of the polybasic acid include adipic acid, azelaic acid, sebacic acid, terephthalic acid, isophthalic acid, and succinic acid. Specific examples of the polyhydric alcohol include bisphenol A, ethylene glycol, 1,2-propylene glycol, 1,4-butanediol, diethylene glycol, 1,6-hexane glycol, and neopentyl glycol. It is done.

  Specific examples of the hydroxycarboxylic acid include castor oil and a reaction product of castor oil and ethylene glycol.

  Examples of the polymer polyol include a polymer obtained by graft polymerization of an ethylenically unsaturated compound such as acrylonitrile, styrene, methyl acrylate, and methacrylate on an aromatic polyol, alicyclic polyol, aliphatic polyol, polyester polyol, or the like, polybutadiene Examples thereof include polyols, modified polyols of polyhydric alcohols, and hydrogenated products thereof.

  Examples of the modified polyol of the polyhydric alcohol include compounds modified by reacting the raw material polyhydric alcohol with an alkylene oxide.

  Examples of the polyhydric alcohol include trihydric alcohols such as glycerin and trimethylolpropane; pentaerythritol, sorbitol, mannitol, sorbitan, diglycerin, dipentaerythritol, etc., sucrose, glucose, mannose, fructose, methylglucoside and Tetravalent to octavalent alcohols such as derivatives thereof; phenol, phloroglucin, cresol, pyrogallol, catechol, hydroquinone, bisphenol A, bisphenol F, bisphenol S, 1-hydroxynaphthalene, 1,3,6,8-tetrahydroxynaphthalene , Antolol, 1,4,5,8-tetrahydroxyanthracene, 1-hydroxypyrene, etc., phenol polybutadiene polyol; castor oil polyol; hydroxyalkyl (meth) Polyfunctional (e.g. functionality 2 to 100) polyol such as (co) polymers and polyvinyl alcohol acrylate include condensates of phenol and formaldehyde (novolac) it is.

  The method for modifying the polyhydric alcohol is not particularly limited, but a method of adding alkylene oxide (hereinafter abbreviated as AO) is preferably used.

  As AO, C2-C6 AO, for example, ethylene oxide (hereinafter abbreviated as EO), 1,2-propylene oxide (hereinafter abbreviated as PO), 1,3-propyloxide, 1,2- Examples include butylene oxide and 1,4-butylene oxide. Among these, from the viewpoint of excellent properties and reactivity, PO, EO, and 1,2-butylene oxide are preferable, and PO and EO are more preferable. When two or more kinds of AO are used (for example, PO and EO), the addition method may be block addition or random addition, or a combination thereof.

  Examples of polyether polyols include ring-opening polymerization of at least one alkylene oxide such as ethylene oxide, propylene oxide, and tetrahydrofuran in the presence of at least one low molecular weight active hydrogen compound having two or more active hydrogens. And the resulting polymer. Examples of the low molecular weight active hydrogen compound having two or more active hydrogens include diols such as bisphenol A, ethylene glycol, propylene glycol, butylene glycol, and 1,6-hexanediol, and triols such as glycerol and trimethylolpropane. And amines such as ethylenediamine and butylenediamine.

  A polyol compound can use 1 type, or 2 or more types. It is preferable to use polyester polyol or polyether polyol because the effect of reducing the total calorific value upon burning is great.

(Compound (B))
Examples of the polyisocyanate compound that is a raw material of the urethane resin include aromatic polyisocyanates, alicyclic polyisocyanates, and aliphatic polyisocyanates.

  Examples of the aromatic polyisocyanate include phenylene diisocyanate, tolylene diisocyanate, xylylene diisocyanate, diphenylmethane diisocyanate, dimethyldiphenylmethane diisocyanate, triphenylmethane triisocyanate, naphthalene diisocyanate, and polymethylene polyphenyl polyisocyanate.

  Examples of the alicyclic polyisocyanate include cyclohexylene diisocyanate, methylcyclohexylene diisocyanate, isophorone diisocyanate, dicyclohexylmethane diisocyanate, and dimethyldicyclohexylmethane diisocyanate.

  Examples of the aliphatic polyisocyanate include methylene diisocyanate, ethylene diisocyanate, propylene diisocyanate, tetramethylene diisocyanate, and hexamethylene diisocyanate.

  One or more polyisocyanate compounds can be used. The main component of the urethane resin is preferably diphenylmethane diisocyanate for reasons such as ease of use and availability.

  When the resin is a phenol resin, the compound (A) is preferably phenol, cresol, xylenol, paraalkylphenol, paraphenylphenol, resorcinol, and modified products thereof, and the compound (B) is formaldehyde, paraformaldehyde. , Furfural, acetaldehyde and the like are preferable.

  When the resin is a polyester resin, the compound (A) is preferably a dicarboxylic acid such as terephthalic acid or 2,6-naphthalenedicarboxylic acid, and the compound (B) is ethylene glycol, 1,3-propanediol, Polyhydric alcohols such as 1,4-butanediol and 1,4-cyclohexanedimethanol are preferred.

(Reinforcing fiber)
Examples of the reinforcing fiber include inorganic carbon fiber and organic short fiber. One type or two or more types of reinforcing fibers can be used. Reinforcing fibers can be impregnated with the foam curable resin composition.

  More specifically, examples of the reinforcing fibers include inorganic fibers such as glass fibers, asbestos fibers, mineral fibers, stainless fibers, slag fibers, silica alumina fibers, alumina fibers, silica fibers, zirconia fibers, and carbon fibers. Is mentioned. Examples of reinforcing fibers include natural fibers (wood fibers) such as cotton and linen, recycled fibers such as rayon, and organic short fibers such as synthetic fibers such as polyamide, polyester, and polyolefin.

  The content of the reinforcing fiber is preferably 30 parts by weight or more, more preferably 40 parts by weight or more, and 240 parts by weight or less with respect to 100 parts by weight of the foam curable resin composition. Preferably, it is 200 parts by weight or less. The content of the reinforcing fiber is preferably 15 parts by weight or more, more preferably 30 parts by weight or more, and 190 parts by weight or less with respect to 100 parts by weight of the constituent components excluding the reinforcing fibers in the sleeper tree. It is preferable that it is 150 parts by weight or less. When the content of the reinforcing fiber is not less than the above lower limit and not more than the above upper limit, it is possible to obtain a sleeper that has good strength and is lightweight.

(Filler)
The foam curable resin composition preferably contains a filler. The filler is preferably powdery fine particles. Examples of the powdery fine particles include inorganic powders and organic powders. As for the said filler, only 1 type may be used and 2 or more types may be used.

  Examples of inorganic powders include metal carbonates, minerals, sulfates, potassium salts, ash, clays, metal nitrides, titanium compounds, and sulfides.

  More specifically, examples of the powder filler include carbonates of metals such as calcium carbonate, magnesium carbonate, zinc carbonate, barium carbonate; dosonite, hydrotalcite, talc, mica, montmorillonite, bentonite, sepiolite, imogolite. Minerals such as sericite, gypsum fiber and magnesium sulfate; sulfates such as calcium sulfate and barium sulfate; potassium salts such as calcium silicate; ash such as fly ash and shirasu balloon, clay, activated clay, cinnabar, pumice, etc. Clays; metal nitrides such as aluminum nitride, boron nitride and silicon nitride; carbides such as carbon black, graphite, charcoal powder and silicon carbide; titanium compounds such as potassium titanate and lead zirconate titanate; molybdenum sulfide and the like Examples thereof include sulfides.

  Examples of the powder filler include organic powders such as wood powder, bamboo powder, starch, and rice bran.

  By using these fillers, the bending deflection strength of the main part of the sleeper tree is increased, so that the size of the sleeper tree can be made smaller than that of the existing sleeper tree.

  The content of the filler is preferably 5 parts by weight or more, more preferably 10 parts by weight or more with respect to a total of 100 parts by weight of the compound (A) and the compound (B). The amount is preferably 500 parts by weight or less, more preferably 320 parts by weight or less, and further preferably 240 parts by weight or less. The content of the filler is preferably 1 part by weight or more, more preferably 5 parts by weight or more, and preferably 50 parts by weight or less, based on 100 parts by weight of the sleeper, 45 parts by weight. The following is more preferable. When the content of the filler is not less than the above lower limit and not more than the above upper limit, the bending deflection strength of the main body can be further increased, and the size of the sleeper can be further reduced.

(Foaming agent)
A foaming agent is a substance that generates a gas upon decomposition or a substance that itself becomes a gas.

  The foam curable resin composition preferably contains a foaming agent. In the foam curable resin composition, the foaming agent can be added at an appropriate time.

  Examples of the foaming agent include water and organic halogen compounds. The foaming agent is preferably water because it is easily available and excellent in convenience. As for the said foaming agent, only 1 type may be used and 2 or more types may be used together.

  Examples of the organic halogen compounds include organic chlorine compounds, organic fluorine compounds, organic bromine compounds, and organic iodine compounds. The organic halogen compound may be an organic halogen compound in which all of the hydrogen atoms are substituted with halogen atoms, or may be an organic halogen compound in which some of the hydrogen atoms are substituted with halogen atoms. From the viewpoint of improving the foamability at the time of forming the molded body and maintaining the thermal conductivity of the molded body low for a longer period of time, the organic halogen compound is preferably an organic chlorine compound or an organic fluorine compound.

  Examples of the organic chlorine compound include saturated organic chlorine compounds and unsaturated organic chlorine compounds. Examples of the saturated organic chlorine compound include dichloroethane, propyl chloride, isopropyl chloride, butyl chloride, isobutyl chloride, pentyl chloride, and isopentyl chloride. From the viewpoint of improving foamability at the time of forming the molded body and maintaining the thermal conductivity of the molded body low for a long period of time, the organochlorine compound is preferably a saturated organochlorine compound and has 2 carbon atoms. More preferably, it is a saturated organochlorine compound of ˜5.

  Examples of the organic fluorine compound include saturated organic fluorine compounds and unsaturated organic fluorine compounds.

  Examples of the saturated organic fluorine compound include hydrofluorocarbon. Examples of the hydrofluorocarbon include difluoromethane (HFC32), 1,1,1,2,2-pentafluoroethane (HFC125), 1,1,1-trifluoroethane (HFC143a), 1,1,2,2- Tetrafluoroethane (HFC134), 1,1,1,2-tetrafluoroethane (HFC134a), 1,1-difluoroethane (HFC152a), 1,1,1,2,3,3,3-heptafluoropropane (HFC227ea) ), 1,1,1,3,3-pentafluoropropane (HFC245fa), 1,1,1,3,3-pentafluofane (HFC365mfc) and 1,1,1,2,2,3,4 , 5,5,5-decafluoropentane (HFC4310mee) and the like.

  Examples of the unsaturated organic fluorine compound include hydrofluoroolefin. Examples of the hydrofluoroolefin include 2,3,3,3-tetrafluoropropene (HFO-1234yf), 1,3,3,3-tetrafluoropropene (HFO-1234ze) (E and Z isomers), and 1 1,1,4,4,4-hexafluoro-2-butene (HFO1336mzz) (E and Z isomers) and the like.

  Furthermore, examples of the organic fluorine compound include compounds having a chlorine atom, a fluorine atom, and a double bond. Examples of the compound having a chlorine atom, a fluorine atom and a double bond include 1,2-dichloro-1,2-difluoroethene (E and Z isomers), hydrochlorofluoroolefin and the like. Examples of the hydrochlorofluoroolefin include 1-chloro-3,3,3-trifluoropropene (HCFO-1233zd) (E and Z isomers), 1-chloro-2,3,3-trifluoropropene (HCFO-). 1233yd) (E and Z isomers), 1- (4) chloro-1,3,3-trifluoropropene (HCFO-1233zb) (E and Z isomers), 2-chloro-1,3,3-tri Fluoropropene (HCFO-1233xe) (E and Z isomers), 2-chloro-2,2,3-trifluoropropene (HCFO-1233xc), 2-chloro-3,3,3-trifluoropropene (HCFO- 1233xf), 3-chloro-1,2,3-trifluoropropene (HCFO-1233ye) (E and Z isomers), 3-chloro-1,1,2 Trifluoropropene (HCFO-1233yc), 3,3-dichloro-3-fluoropropene, 1,2-dichloro-3,3,3-trifluoropropene (HCFO-1223xd) (E and Z isomers), 2- Chloro-1,1,1,4,4,4-hexafluoro-2-butene (E and Z isomers), and 2-chloro-1,1,1,3,4,4,4-heptafluoro- 2-butene (E and Z isomers) and the like.

  The content of the foaming agent (the total content when a plurality of foaming agents are used) is preferably 0.01 weight with respect to a total of 100 parts by weight of the compound (A) and the compound (B). Part or more, more preferably 0.05 part by weight or more, preferably 5 parts by weight or less, more preferably 2 parts by weight or less. When the content of the foaming agent is not less than the above lower limit and not more than the above upper limit, foaming is promoted and a lightweight foamed molded product (sleeper) is favorably formed. A light sleeper can be suitably used, for example, for a bridge that is required to be light.

(Other optional ingredients)
For example, additives such as a catalyst, a colorant, a foam stabilizer, and an ultraviolet absorber may be added and mixed in advance with each raw material as necessary. Alternatively, these additives may be added to the raw material containing the compound (A) or may be added to the raw material containing the compound (B), and at the same time when the compound (A) and the compound (B) are mixed. It may be added.

<Manufacturing apparatus 30 for sleeper 10>
As shown in FIG. 4, the manufacturing apparatus 30 for manufacturing the sleeper 10 according to the present embodiment includes a hopper 31, a belt feeder 32, a mixing extruder 35, pumps 34, 36, and 38, tanks 33 and 37, a spraying apparatus 39, The kneading plates 41 and 41, the impregnation plate 42, and the molding passage 43 are provided.

  As shown in FIG. 5, the mixing extruder 35 includes biaxial screws 35b and 35b in a cylinder 35a.

  Then, a filler (inorganic filler (a filler that is an inorganic powder)) 31 a in the hopper 31 is supplied into the cylinder 35 a of the mixing extruder 35 by the belt feeder 32. Further, the first raw material 33 a in the tank 33 is supplied into the cylinder 35 a of the mixing extruder 35 by the pump 34.

  The filler 31a and the first raw material 33a supplied into the cylinder 35a are uniformly mixed by the rotation of the screws 35b and 35b, discharged from the discharge port, and quantitatively supplied to the spraying device 39 via the pump 36. . Here, the first raw material 33a is liquid.

  At the same time, the second raw material 37 a in the tank 37 is supplied in a fixed amount to the spraying device 39 via the pump 38. Here, the second raw material 37a is liquid.

  In the spraying device 39, the first raw material 33a and the second raw material 37a are uniformly mixed to obtain a foam curable resin composition 39a, which is sprayed from the discharge port of the spraying device 39 onto the reinforcing fibers 40b.

  The reinforcing fibers 40b on which the foam curable resin composition 39a is dispersed are crushed between the squeezing plates 41 and 41 and the impregnating plate. The foam curable resin composition 39a is uniformly impregnated between the fibers of the reinforcing fibers 40b.

  Moreover, the filler 31a dispersed in the foam curable resin composition 39a is also uniformly impregnated between the fibers of the reinforcing fiber 40b.

  Then, the reinforcing fiber 40 a impregnated with the foam curable resin composition 39 a is further fed into the molding passage 43. At this time, the foam curable resin composition 39 a is foam-cured in the molding passage 43 and formed into a cross-sectional shape along the inner wall surface of the molding passage 43. In this way, a rod-like long fiber reinforced foam molded body in which the reinforcing fibers 40b and the filler 31a are uniformly dispersed is continuously formed.

  In the molding passage 43, a mold or the like corresponding to the desired shape can be arranged so as to obtain a long fiber reinforced foam molded body having a desired shape. In this case, a sleeper having an irregular cross-sectional shape can be easily manufactured.

  A rectangular parallelepiped mold may be disposed in the molding passage 43. In this case, a rectangular parallelepiped foamed molded product can be obtained. By changing the size of the rectangular parallelepiped mold, rectangular parallelepiped foamed molded products having different sizes can be obtained. By adhering a rectangular parallelepiped foamed molded product and a rectangular parallelepiped foamed molded product having a different size from the foamed molded product, it protrudes outward from the side surfaces on both sides in the width direction of the main body and the main body. A sleeper tree with a protruding portion can be obtained. In addition, the magnitude | size and number of each foaming molding to adhere | attach can be suitably changed according to the shape of the sleeper. The second foam molded body (main body part) may be bonded to the first foam molded body (main body part), and the second foam molded body and the third foam molded body are bonded to the first foam molded body (main body part). And the second foam molded body, the third foam molded body, and the fourth foam molded body may be bonded to the first foam molded body (main body portion). In this method, a sleeper tree is manufactured by combining a plurality of foamed molded products, and therefore, the shape and size of the sleeper tree can be easily designed.

  The above-mentioned metal mold disposed in the molding passage 43 can be changed as appropriate according to the size of the desired shape and changes in the shape.

<Method for producing pillow 10>
The sleeper 10 of this embodiment can be manufactured according to the flowchart shown in FIG.

  That is, in step S11, the reinforcing fiber (glass fiber) 40b is fed in a predetermined direction.

  Next, in step S12, the reinforcing fiber 40b is impregnated with the foam curable resin composition 39a in which the first raw material 33a, the second raw material 37a, and the filler 31a are uniformly mixed.

  At this time, the reinforcing fiber 40b is squeezed between the squeezing plate 41 and the impregnating plate 42 before the molding passage 43 in the transport direction. Thereby, the foaming curable resin composition 39a can be uniformly impregnated between the fibers of the reinforcing fiber 40b.

  Next, in step S13, the reinforcing fiber 40a impregnated with the foam curable resin composition 39a is conveyed so as to pass through the molding passage 43.

  Next, in step S <b> 14, the foam curable resin composition 39 a is foamed in the molding passage 43.

  Next, in step S15, the foam curable resin composition 39a is cooled and cured in the molding passage 43 in a foamed state.

  As a result, when transported downstream of the molding passage 43, the sleeper 10 molded into a desired cross-sectional shape by the molding passage 43 can be obtained.

[Other Embodiments]
As mentioned above, although one Embodiment of this invention was described, this invention is not limited to the said embodiment, A various change is possible in the range which does not deviate from the summary of invention.

(A)
In the said embodiment, as shown in FIG. 1 and FIG. 2, the sleeper provided so that protrusion part 12a, 12b may protrude in the width direction from the upper end part and lower end part in the side surfaces 10c, 10c of both sides in sectional view, respectively. 10 has been described as an example. However, the present invention is not limited to this.

  For example, as shown in FIG. 7A, the sleeper 110 may be provided so that the protruding portion 112b protrudes in the width direction from the lower end portions of the side surfaces 110c and 110c on both sides.

  The sleeper 110 may have the same shape as the sleeper 110 shown in FIG. 7A, and the upper surface of the sleeper 110 corresponds to the bottom surface, and the lower surface of the sleeper 110 corresponds to the upper surface.

(B)
In the said embodiment, as shown in FIG.1 and FIG.2, protrusion part 12a, 12b protrudes in the width direction so that it may become left-right symmetrical from the upper end part and lower end part in the side surfaces 10c, 10c of both sides in sectional view, respectively. The sleeper tree 10 provided as described above has been described as an example. However, the present invention is not limited to this.

  For example, as shown in FIG. 7B, the protruding portion 212a protrudes in the width direction from the upper end portion of one side surface 210c, and the protruding portion 212b protrudes in the width direction from the lower end portions of both side surfaces 210c. Alternatively, the sleeper 210 may be asymmetrical.

  Further, as shown in FIG. 7C, as a left-right asymmetric configuration, the protruding portion 312c protrudes in the width direction from the center portion on one side surface 310c, and protrudes from the upper end portion and the lower end portion on the other side surface 310c, respectively. The sleeper 310 may be provided so that the portions 312a and 312b protrude in the width direction.

  Furthermore, for example, as shown in FIG. 7 (d), a sleeper 410 is provided so that projecting portions 412a, 412b, and 412c project in the width direction from the upper end portion, the central portion, and the lower end portion of the side surfaces 410c on both sides. There may be.

(C)
In the said embodiment, the pillow 10 shape | molded with the synthetic resin containing glass fiber was mentioned as an example, and was demonstrated. However, the present invention is not limited to this.

  For example, instead of glass fibers, other reinforcing fibers such as carbon fibers and wood fibers may be used.

(D)
In the said embodiment, the example which manufactures the sleeper whose resin is urethane resin was given and demonstrated. However, the present invention is not limited to this.

  For example, the resin may be another synthetic resin such as a phenol resin and a polyester resin.

  Hereinafter, the present invention will be described more specifically by giving examples and comparative examples. The present invention is not limited to the following examples.

  The following materials were prepared.

(Compound (A): Polyol compound)
Polyether polyol (manufactured by Sumika Covestro Urethane “МULTRANOL 9158”)

(Compound (B): Isocyanate compound)
Diphenylmethane diisocyanate (“Millionate MR-200” manufactured by Tosoh Corporation)

(Reinforcing fiber)
Glass fiber with a fiber diameter of 12 μm (manufactured by UG substrate)

(Filler)
Fly ash ("Finash" manufactured by Yoden Business)

(Foaming agent)
water

(Foam stabilizer)
Silicone foam stabilizer (“SZ-1729” manufactured by Toray Dow Corning)

(catalyst)
Dioctyltin (“SCAT31A” manufactured by Nitto Kasei Co., Ltd.)

Example 1
The reinforcing fibers were aligned in the first direction. Separately, the compound (A), the foaming agent, the filler, and the foam stabilizer were kneaded with an extruder to obtain a first liquid raw material. The obtained 1st liquid raw material and the 2nd liquid raw material containing a compound (B) were mixed, and the foaming curable resin composition was obtained. In addition, the blending ratio of each component in the foam curable composition is 140 parts by weight of the isocyanate compound with respect to 100 parts by weight of the polyol compound, and the foaming agent with respect to 100 parts by weight of the total of the polyol compound and the isocyanate compound. They were 0.72 parts by weight, 386.4 parts by weight of filler, 1.44 parts by weight of foam stabilizer, and 0.24 parts by weight of catalyst. While feeding the aligned reinforcing fibers, the obtained foam curable resin composition is sprayed on the reinforcing fibers and crushed between the kneading plate and the impregnating plate to reinforce the foam curable resin composition. The fiber was impregnated. In addition, the usage-amount of the reinforcement fiber was 160 weight part with respect to 100 weight part of foaming curable resin compositions. Next, a mold provided with cores on both side surfaces of the rectangular parallelepiped mold was disposed in the molding passage. The foam curable resin composition impregnated in the obtained reinforcing fiber is conveyed to a molding passage, and the foam curable resin composition is foam-cured in the molding passage to have a cross-sectional shape shown in Table 1, and is reinforced. A sleeper was obtained in which the fibers were arranged along the longitudinal direction of the sleeper.

(Examples 2 and 3)
A sleeper having a cross-sectional shape shown in Table 1 was obtained in the same manner as in Example 1 except that the size of the core provided on both side surfaces of the rectangular parallelepiped mold was changed.

(Example 4)
In the same manner as in Example 1, a foam curable resin composition was obtained, and the reinforcing fiber was impregnated with the foam curable resin composition. Next, a rectangular parallelepiped mold having a size different from that of the mold used in Example 1 was disposed in the molding passage. The foam curable resin composition impregnated in the obtained reinforcing fiber is conveyed to a molding passage, and the foam curable resin composition is foam-cured in the molding passage to obtain a first rectangular foam-shaped foam molding. Obtained. Next, a rectangular parallelepiped mold having a size different from that of the above mold was placed in the molding passage. The foam curable resin composition impregnated in the obtained reinforcing fiber is conveyed to a molding passage, and the foam curable resin composition is foam-cured in the molding passage to obtain a second rectangular foam-shaped foam molded product. Two were obtained. The second foamed molded product is bonded to the top and bottom surfaces of the obtained first first foamed molded product using an epoxy adhesive, and has the cross-sectional shape shown in Table 1, and the reinforcing fiber is a sleeper tree. A sleeper arranged along the longitudinal direction was obtained.

(Comparative Example 1)
A sleeper having a cross-sectional shape shown in Table 1 was obtained in the same manner as in Example 1 except that a rectangular parallelepiped mold was used without providing a core. In addition, the sleeper obtained in this comparative example 1 is a rectangular parallelepiped foaming molded object, and does not have a protrusion part.

(Comparative Example 2)
A sleeper having the cross-sectional shape shown in Table 1 was obtained in the same manner as in Comparative Example 1 except that the size of the mold was changed. In addition, the sleeper obtained in this comparative example 2 is a rectangular parallelepiped foaming molding, and does not have a protrusion part.

<Measurement method>
Floating resistance: The obtained sleeper (test specimen length: 200 mm) was filled up with gravel (Camel sand No. 5), and the load required to take out the entire sleeper was measured.

  Bending and bending: The amount of bending when the obtained sleeper (test body length: 200 mm) was applied with a force of 8 kN to the center between the supporting points at a distance between supporting points of 115 mm was measured.

  Here, as shown in Table 1, the sleeper of Example 1 has the same shape as the sleeper 10 of the above-described embodiment.

  As shown in Table 1, the sleeper of Example 1 has a shape including protrusions protruding in the width direction from the side surfaces on both sides of the main body in the width direction. Two protrusions are provided in total on the upper surface side and the bottom surface side of the main body. In the sleeper of Example 1, the ratio (d2 / d3) of the minimum width d2 to the maximum width d3 is 0.73, and the ratio (d1 / d3) of the top surface width d1 to the bottom surface width d3 is 1.0, The floating resistance was 3.9 N, and the bending deflection was 1.39 mm.

  Next, as shown in Table 1, the sleeper of Example 2 has a shape including protrusions protruding in the width direction from the side surfaces on both sides in the width direction of the main body. A total of two protrusions are provided on the bottom surface side of the main body. In the sleeper of Example 2, the ratio (d2 / d3) of the minimum width d2 to the maximum width d3 is 0.73, and the ratio (d1 / d3) of the top surface width d1 to the bottom surface width d3 is 0.73, The floating resistance was 3.7 N, and the bending deflection was 1.49 mm.

  Next, as shown in Table 1, the sleeper of Example 3 has a shape including protrusions that protrude in the width direction from the side surfaces on both sides of the main body in the width direction. A total of two protrusions are provided on the bottom surface side of the main body. In the sleeper of Example 3, the ratio (d2 / d3) of the minimum width d2 to the maximum width d3 is 0.95, and the ratio (d1 / d3) of the top surface width d1 to the bottom surface width d3 is 0.95, The floating resistance was 2.7 N and the bending deflection was 1.3 mm.

  Next, as shown in Table 1, the sleeper of Example 4 has a shape including protruding portions that protrude in the width direction from the side surfaces on both sides in the width direction of the main body portion. In the sleeper of Example 4, the ratio (d2 / d3) of the minimum width d2 to the maximum width d3 is 0.73, and the ratio (d1 / d3) of the top surface width d1 to the bottom surface width d3 is 1.0, The floating resistance was 3.9 N, and the bending deflection was 1.39 mm.

  On the other hand, as shown in Table 1, the sleeper of Comparative Example 1 has a rectangular parallelepiped shape. In the sleeper of Comparative Example 1, the ratio (d2 / d3) of the minimum width d2 to the maximum width d3 is 1.0, and the ratio (d1 / d3) of the top surface width d1 to the bottom surface width d3 in cross-sectional view is 1.0. The floating resistance was 2.4 N, and the bending deflection was 1.26 mm.

  In addition, the sleeper of Comparative Example 1 has the same circumscribed rectangle as the sleeper of Examples 1 to 4 in a cross-sectional view.

  As shown in Table 1, the sleeper of Comparative Example 2 has a rectangular parallelepiped shape. In the sleeper of Comparative Example 2, the ratio (d2 / d3) of the minimum width d2 to the maximum width d3 is 1.0, and the ratio (d1 / d3) of the top surface width d1 to the bottom surface width d3 in a cross-sectional view is 1.0. The floating resistance was 2.2 N, and the bending deflection was 2.46 mm.

  In addition, the sleeper of the comparative example 2 has the same area as the sleeper of Examples 1-4 in sectional view.

  As a result of the above, even when a sleeper that can be reduced in weight is obtained, by providing a protruding portion that protrudes from the side surface, compared to the sleeper according to Comparative Examples 1 and 2 having a substantially rectangular cross-sectional shape, floating resistance Can be increased.

  Thereby, even when force is applied in the direction of lifting from the gravel due to vibration or the like, the protruding portion protruding from the side surface becomes a resistance, so that the lifting of the sleeper can be suppressed.

  Moreover, even if it is the structure which provided the protrusion part which protrudes in the width direction from the side surface like Examples 1-4, it is substantially equivalent to the comparative example 1 regarding bending bending, and is smaller than the comparative example 2. It was a result.

  Furthermore, compared with the comparative example 1 which has the same circumscribed rectangle as the sleeper of Examples 1-4, the usage-amount of glass fiber and a foaming curable resin can be reduced, and cost reduction can be aimed at.

  The sleeper of the present invention has an effect that even if it is a lighter sleeper, it is possible to effectively suppress the occurrence of misalignment (floating) in the substantially vertical direction due to vibration or the like. It is widely applicable as a sleeper.

10 sleeper 10a bottom 10b top 10c side 11 main body 12a, 12b projecting part 20 gravel 30 production device 31 hopper 31a filler 32 belt feeder 33 tank 33a first raw material 34 pump 35 mixing extruder 35a cylinder 35b screw 36 pump 37 tank 37a Second raw material 38 Pump 39 Spreading device 39a Foam curable resin composition 40a Reinforcing fiber 40b impregnated with foam curable resin composition Reinforcing fiber 41 Gripping plate 42 Impregnated plate 43 Molding passage 110 Sleeper 110c Side 112b Protrusion 210 Sleeper 210c Side surface 212a, 212b Protrusion part 310 Sleeper tree 310c Side face 312a, 312b, 312c Protrusion part 410 Sleeper part 410c Side face 412a-412c Protrusion part d1, d3 Maximum width d2 Minimum width

Claims (13)

A main body having a longitudinal direction and a width direction and made of resin;
A sleeper provided with projecting portions that project in the width direction of the main body from the side surfaces on both sides in the width direction of the main body.   The sleeper according to claim 1, wherein a ratio of the smallest width of the sleeper to the largest width of the sleeper in a direction parallel to the bottom surface of the main body is 0.60 to 0.95.   The sleeper according to claim 1 or 2, wherein the ratio of the width of the upper surface of the sleeper to the width of the bottom of the sleeper is 0.6 to 1.0.   The sleeper according to any one of claims 1 to 3, wherein the main body portion includes reinforcing fibers arranged along a longitudinal direction of the main body portion.   The sleeper tree according to claim 4, wherein the reinforcing fiber includes one of glass fiber, carbon fiber, and wood fiber.   The sleeper according to any one of claims 1 to 5, wherein the resin of the main body is a polyurethane resin.   The sleeper according to any one of claims 1 to 6, wherein the resin of the main body includes powder particles.   The sleeper tree according to claim 7, wherein the powdery particles are at least one selected from an inorganic powder and an organic powder.   The sleeper tree according to claim 8, wherein the inorganic powder is at least one selected from metal carbonates, minerals, sulfates, potassium salts, ash, clays, metal nitrides, titanium compounds, and sulfides. . It is a manufacturing method of the sleeper tree of any one of Claim 1 to 9,
A step of aligning a plurality of reinforcing fibers in a first direction and feeding the aligned reinforcing fibers along the first direction;
Impregnating the aligned reinforcing fibers with a foam curable resin composition obtained by mixing a first raw material containing compound A and a second raw material containing compound B that reacts with compound A;
A step of foaming and curing the foam curable resin composition while passing the reinforcing fiber impregnated with the foam curable resin composition through a molding passage, and obtaining a foam molded article;
A method for manufacturing a sleeper tree.   The method for manufacturing a sleeper according to claim 10, wherein the foamed molded product itself is obtained as a sleeper.   The method for manufacturing a sleeper according to claim 10, further comprising a step of bonding the plurality of foam molded bodies to obtain a sleeper.   The sleeper manufacturing method according to any one of claims 10 to 12, wherein a plurality of sleeper trees are manufactured continuously.

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