JP3340799B2 - Rust prevention rail - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel rustproof rail. More specifically, the present invention relates to a rust-preventive rail for preventing a rail from shortening its service life due to corrosion such as salt damage corrosion and environmental corrosion.

[0002]

2. Description of the Related Art A railroad is a vehicle for transporting passengers and cargo by driving a vehicle guided by a track by power. Of these, the rail, which is the most basic component of the track, has a direct and significant effect on the running safety and riding comfort of the train due to its shape change and damage.

The main controlling factor of the rail life due to such rail wear is wear, and in a general environment, the influence of corrosion wear on the life is small. However, in severe corrosive environments such as undersea tunnels, corrosion depletion is a dominant factor in rail life. In addition, it has been reported that the stronger the corrosiveness of the environment, the greater the amount of wear increases (Toshimitsu Miyamoto, Kato Watanabe (1980), track-track design and management, p. 43-).
73, p133-166).

[0004] Therefore, rails are required to have sufficient strength against dynamic loads, and measures to prevent rusting of the rails in corrosive environments are also important. Therefore, wear resistance, corrosion resistance, weldability and the like are required. Required.

As the working rail made based on such a design concept, a high carbon steel (C: 0.6 to 0.82%,
(Mn: 1.1% or less) other than ordinary rails for general use, heat-treated hard-headed rails, which are used for the outer rails having a sorbite structure by hardening and tempering the heads of the ordinary rails, and the ordinary rails The heat treatment rails used at the joints are used.

[0006] However, even with a working rail having such abrasion resistance, corrosion resistance, weldability, etc., a rail in a Shinkansen tunnel of a Shinkansen that is constantly exposed to an extremely severe corrosive environment, etc. Due to salt, high humidity, etc., a great deal of corrosion has occurred. As a result, especially in places with bad conditions, hitting the abdomen of the rail with a hammer or the like causes the corroded portion of the rail to peel off and fall off, and the maximum wear of the rail is a constant amount of wear (usually, 14 to 15 mm) during normal rail life. In the current situation, the rails are replaced at the time of replacement. However, at present, the rails are quickly replaced due to corrosion prior to the wear of the rails (however, the top surface of the rails may be ground to correct the wavy wear of the rails. In some cases, it may be exchanged in about three to five years). Further, in recent years, the improvement of the rail itself has been progressing and the wear resistance of the rail has been improving, and therefore, an improvement in earlier replacement due to corrosion has been desired.

[0007]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a novel rustproof rail.

Another object of the present invention is to provide a rust-preventive rail having excellent anticorrosion performance and long-term durability against corrosion such as salt damage corrosion and environmental corrosion, and capable of preventing shortening of rail life due to corrosion. Is to do.

[0009]

Means for Solving the Problems In order to achieve the above objects, the present inventors have conducted intensive studies on a novel rust-preventive rail, and as a result, the rail has been subjected to corrosion such as salt corrosion and environmental corrosion. On the other hand, from the viewpoint of providing excellent corrosion protection performance, an organic coating with rust prevention performance is formed on the rail base to improve the adhesion to the rail base and to prevent the penetration of corrosive substances from the outside. Film performance is obtained, and from the viewpoint of providing long-term durability on the organic coating, a strong anti-corrosion material is applied to the rail shape by applying an anticorrosion material in which a resin compound containing a rust-proof pigment is supported on a base material. Can form thickness,
Furthermore, they learned that they could follow the expansion and contraction of the rail, and based on this finding, completed the present invention.

That is, an object of the present invention is to provide an organic coating layer formed by applying a rust-preventive paint composition on a rail substrate, and a liquid composition containing a rust-preventive pigment on the organic coating layer is carried on a substrate. The present invention can be achieved by a rust-preventive rail having a rust-preventive material layer formed by applying a corrosion-resistant material formed as described above.

[0011]

The rust-preventive rail of the present invention has an organic coating layer formed by applying a rust-preventive paint composition on a rail substrate, and a resin compound containing a rust-preventive pigment is formed on the organic coating layer as a base material. It is characterized by having a rust preventive material layer formed by carrying a supported anticorrosive material. Hereinafter, the present invention will be described in detail.

First, the rail used in the present invention is not particularly limited, and can be applied to all rails currently used. For example, a high carbon steel (C: 0.6 to 0) .82%, Mn: 1.1% or less), a heat-treated hard-headed rail used for a sharply curved outer rail having a sorbite structure by quenching and tempering the head of the ordinary rail. Heat treatment near the both ends of the rail to make a fine pearlite structure. It is often used for the heat treatment of the end head used for the joint track and the crossing of the turnout using austenitic manganese steel (C: 1%, Mn: 13%). High manganese rope crossing.

Next, before forming the organic coating layer on the rail base, it is preferable that the base of the rail is appropriately adjusted for base. The base adjustment removes dirt such as oils and fats, water and the like adhering to the metal surface prior to coating. That is, the presence of dirt hinders normal formation of a coating film and hinders adhesion of the coating film to a metal surface. Examples of the base adjustment include treatment with a degreasing agent (such as an alkali type or an emulsion type) and solvent. Steam cleaning,
It is desirable to perform a degreasing cleaning such as cleaning with a cloth.

Further, if rust is present on the surface to be coated, it causes corrosion under the coating film, and the durability of the anticorrosion coating film is reduced. Therefore, it is desirable to completely remove it before coating. As a base adjustment for removing such rust, keren and blasting are highly reliable among mechanical rust removing methods. Above all, vacuum blast, wet blast, water jet method, etc., which can reduce harm of dust, are preferable. In addition, as a chemical treatment method, an acid washing method such as hydrochloric acid, sulfuric acid, phosphoric acid, or the like can be used. Further, when blasting is not possible as in the case of the rail laying site, rust may be removed by a power tool or a hand tool (such as a wire brush).

[0015] Further, it is preferable that an appropriate rust treatment is applied to the rail base after the base adjustment. The rust treatment is to convert existing rust into high-quality rust. Examples of the rust treatment include a method of applying a rust conversion agent such as Lastol B (trade name, manufactured by Lastec Co., Ltd.). .
The thickness of the coating film formed by applying the rust converting agent is usually 15 to 50 μm, preferably 30 to 50 μm,
More preferably, it is in the range of 35 to 50 μm. When the thickness of the coating is less than 15 μm, a sufficient rust treatment effect cannot be obtained due to poor film formation.

Next, the rust-preventive coating composition that can be used for the organic coating layer formed on the rail substrate is not particularly limited as long as it has adhesion to the rail substrate, waterproofness, and corrosion resistance. Instead, the resin component, the solvent, and the pigment are essential components, and additives are included as necessary.

The resin component is not particularly limited as long as it is a conventionally known resin component used in a paint used for the purpose of preventing rust and corrosion. Examples of the resin component include alkyd resins, aminoalkyd resins, and acrylic resins. , Vinyl resin,
Epoxy resin, tar epoxy resin, polyurethane resin, phenol resin, polyester resin, rubber resin,
Silicon resin, fluorine resin and the like can be mentioned.

Although the content of the resin component is not particularly limited, it is generally 57 to 70% by weight, preferably 60 to 70% by weight, more preferably 60 to 70% by weight, based on the whole components of the coating composition. It is used in the range of 60 to 64% by weight. If the content of the resin component is less than 50% by weight, the setting time is undesirably long. On the other hand, if the content of the resin component exceeds 70% by weight, it is not preferable because of poor coating due to high viscosity.

Next, the solvent used in the rust preventive coating composition of the present invention is not particularly limited as long as it can dissolve the resin component, and conventionally known solvents can be used alone or in combination. Examples of the solvent include alcohols such as methanol, ethanol, butanol, isopropyl alcohol and diacetyl alcohol, toluene, xylene, n
Aromatic hydrocarbons such as hexane; ketones and esters such as acetone, ethyl acetate, butyl acetate and cellosolve acetate; and glycol ethers such as ethylel cellosolve and butyl cellosolve. The type and the mixing ratio of the solvent are appropriately selected depending on the type of the resin component used and the like.

Although the content of the solvent is not particularly limited, it is usually 2% with respect to all the constituent components of the coating composition.
It is used in an amount of 8 to 42% by weight, preferably 30 to 40% by weight, more preferably 32 to 40% by weight. If the amount of the solvent is less than 28% by weight, it is not preferable because of poor coating due to high viscosity. On the other hand, when the amount of the solvent exceeds 42% by weight, it is not preferable because of generation of armpits.

The pigment used in the rust-preventive coating composition of the present invention is added for the purpose of improving the function of a coating film that blocks the entry of corrosive substances from the outside. It is necessary to have a rust preventive pigment.

The rust preventive pigment is not particularly limited, and examples thereof include leadtan, lead suboxide, basic lead chromate,
Basic pigments such as basic lead silicate chromate, cyanamide lead, calcium lead acid, and basic lead sulfate; soluble pigments such as zinc chromate, strontium chromate, barium chromate, and calcium chromate; metal powder pigments such as zinc dust And the like. These rust-preventive pigments are usually appropriately determined depending on the combination of the resin component used, the solvent, and the like.

Although the content of the rust preventive pigment is not particularly limited, it is usually 5 to 10% by weight, preferably 7 to 10% by weight, more preferably 7 to 10% by weight, based on the whole components of the coating composition. It is used in an amount of 8 to 10% by weight. If the rust-preventive pigment is less than 5% by weight, the rust-preventive effect is not sufficiently exhibited, which is not preferable. On the other hand, when the amount of the rust-preventive pigment exceeds 10% by weight, the rust-preventive effect corresponding to the added amount cannot be improved, which is not economically preferable.

In the present invention, other than the above-mentioned rust preventive pigments, conventionally known pigments can be used alone or in combination as required. Examples of the pigment include a color pigment, an extender pigment, mica-like iron oxide powder, aluminum powder, and glass flake.

The coloring pigment used in the rust preventive coating composition of the present invention includes, for example, titanium white, zinc white, graphite, ocher, titanium yellow, hansa yellow, chrome vermillion, bengara, toluidine red, synchasia red. ,
Navy blue, cyanine blue, chrome green, chromium oxide,
Examples thereof include cyanine green, carbon black, and iron oxide black. However, since long-term durability is required, a pigment having high weather fastness is preferable, and the color tone is desirably determined in consideration of this point.

Although the content of the coloring pigment is not particularly limited, it is usually 2 to 2 with respect to the whole components of the coating composition.
5% by weight, preferably 3-5% by weight, more preferably 3%
Used in an amount of ４4% by weight. 2% by weight of the coloring pigment
If it is less than 1, the color tone and weather fastness are not sufficiently exhibited, which is not preferable. On the other hand, if the content of the coloring pigment is more than 5% by weight, the effect corresponding to the added amount cannot be improved, which is not economically preferable.

The extender used in the rust preventive coating composition of the present invention includes, for example, calcium carbonate, barium sulfate, clay, talc, silica and the like. These are usually used for preparing coating properties and coating film properties. It is added for the purpose.

Although the content of the extender pigment is not particularly limited, it is usually 30 parts by weight based on the whole components of the coating composition.
It is used in an amount of up to 45% by weight, preferably 35 to 45% by weight, more preferably 35 to 40% by weight. If the extender is less than 30% by weight, the coating properties and physical properties of the coating film cannot be sufficiently controlled, which is not preferable. On the other hand, when the extender exceeds 45% by weight, the effect of the preparation cannot be improved in proportion to the amount added, which is not economically preferable.

The mica-like iron oxide powder, aluminum powder and glass flake used in the rust preventive coating composition of the present invention are:
Both are scaly and arranged in parallel with the coating surface to improve the shielding function of the coating, and further, mica-like iron oxide powder,
Has the effect of ensuring interlayer adhesion, glass flakes,
In combination with unsaturated polyester resin, epoxy resin, etc., it can be used for flake coating to obtain a film thickness close to that of resin lining and anti-corrosion performance by spray coating, roll coating, etc.

As the additive used in the rust preventive coating composition of the present invention, as a dispersant used for dispersing the above resin component, for example, formic acid in the case of a cationic resin component,
Examples include acids such as acetic acid, lactic acid, and sulfamic acid; bases such as ammonia, amine, and inorganic alkali in the case of an anionic resin component; and surfactants.

The organic coating layer formed on the rail substrate by appropriately selecting the above-mentioned rust-preventive coating composition may be at least a single layer, and the organic coating layer is an object of the present invention. Because the performance required to achieve a wide variety of, it is unlikely that a single paint can achieve the purpose,
Usually, several kinds of paints are often applied repeatedly.

When the organic coating layer is a single layer, the single layer needs to have adhesion to a rail base, rust prevention performance and long-term durability, so that a thick film coating may be required. In many cases, the film thickness is usually 35 to 500 μm, preferably 150 to 500 μm, more preferably 400 to 50 μm.
The range is 0 μm. If the thickness is less than 35 μm, sufficient long-term durability cannot be obtained, and 500
When the thickness exceeds μm, the required coating film performance can be obtained,
It is not preferable because workability such as coating, drying and curing is reduced.

In the case where the organic coating layer is composed of a plurality of layers, the most common mode is an undercoat layer having adhesion to a rail base material and rust prevention performance, and a rust prevention material layer on the undercoat layer. This is to laminate an intermediate coating layer for the purpose of promoting adhesion to the undercoat layer, increasing rust prevention performance, and improving physical properties of the coating film. In this case, the thickness of the undercoat layer is usually 15 to 40 μm, preferably 30 to 40 μm, more preferably 35 to 40 μm.
Range. When the film thickness is less than 15 μm, sufficient anticorrosion performance cannot be obtained due to poor film formation, and when it exceeds 40 μm, necessary coating film performance can be obtained.
It is not preferable because workability such as drying and curing is reduced.
The thickness of the overcoat layer is usually in the range of 20 to 45 μm, preferably 30 to 45 μm, and more preferably 35 to 45 μm. When the film thickness is less than 20 μm, sufficient long-term durability cannot be obtained. When the film thickness is more than 45 μm, required coating film performance can be obtained. Is undesirably reduced.

Examples of the method of applying the rust preventive coating composition include brush coating, roller coating, spray coating, electrostatic coating, electrodeposition coating, roll coater, curtain flow coater, and powder coating. It is necessary to appropriately select the rail in consideration of the shape and size of the rail.

In the case of painting at a rail laying site, the use of a heat-curable paint is practically impossible. Therefore, the use of a room-temperature-curable paint and a quick-drying solvent-evaporable paint is suitable. The coating material is applied using a coating method such as brush coating, roller coating, or spray coating. In this case, if the installation site is inside a tunnel,
It is necessary to particularly consider the coating environment such as the solvent used.

Next, the liquid composition used for the anticorrosion material constituting the rust preventive material layer applied on the organic coating layer has adhesion to the organic coating layer, waterproofness, corrosion resistance, and weather resistance. The liquid composition is not particularly limited as long as it is a liquid composition containing a resin component, a solvent, and a pigment containing at least one type of rust-preventive pigment as essential components, and optionally containing additives.

Accordingly, the resin component, solvent, pigment containing at least one kind of rust-preventive pigment and additives used in the liquid composition include, for example, the rust-preventive paint composition which can be used in the above-mentioned organic coating layer. A liquid composition obtained by appropriately selecting and combining the components used for the resin component, the solvent, the pigment, and the additive, which are the components described above, can be used.

In this case, the content of the resin component is not particularly limited, but it is usually 50 to 68% by weight, preferably 60 to 68% by weight, and more preferably, 60% by weight based on the whole components of the liquid composition. It is used in the range of 60 to 64% by weight. If the content of the resin component is less than 50% by weight, the setting time is undesirably long. On the other hand, if the content of the resin component exceeds 68% by weight, it is not preferable because the base material is not sufficiently supported by impregnation with a high viscosity.

Although the content of the solvent is not particularly limited, it is usually 30 parts with respect to all the constituents of the liquid composition.
It is used in an amount of ５０50% by weight, preferably 30-40% by weight, more preferably 32-40% by weight. The solvent is
If the amount is less than 30% by weight, the support by impregnation of the base material due to high viscosity is not sufficient, which is not preferable. On the other hand, when the amount of the solvent exceeds 50% by weight, it is not preferable because of generation of armpits.

The content of the rust-preventive pigment is not particularly limited, but is usually 6 to 10% by weight, preferably 8 to 10% by weight, more preferably 8 to 10% by weight, based on the whole components of the liquid composition. It is used in the range of ９9% by weight. If the rust-preventive pigment is less than 6% by weight, the rust-preventive effect is not sufficiently exhibited, which is not preferable. On the other hand, when the amount of the rust-preventive pigment exceeds 10% by weight, the rust-preventive effect corresponding to the added amount cannot be improved, which is not economically preferable.

The content of the color pigment is not particularly limited, but is usually 3 to 5% by weight, preferably 3 to 4% by weight, more preferably 3 to 3% by weight, based on the whole components of the liquid composition. It is used in an amount of 0.5% by weight. The coloring pigment is
When the amount is less than 3% by weight, the color tone and the weather fastness are not sufficiently exhibited, which is not preferable. On the other hand, if the content of the coloring pigment is more than 5% by weight, the effect corresponding to the added amount cannot be improved, which is not economically preferable.

The content of the extender pigment is not particularly limited.
Usually 30 to 50% by weight, preferably 35 to 45% by weight,
More preferably, it is used in an amount of 35 to 40% by weight. If the extender is less than 30% by weight, the coating properties and physical properties of the coating film cannot be sufficiently controlled, which is not preferable. Also,
If the extender exceeds 50% by weight, the effect of the preparation cannot be improved in proportion to the amount added, which is not economically preferable.

Next, as the base material used for the anticorrosive material constituting the rust preventive material layer applied on the organic coating layer, a nonwoven fabric, woven fabric, paper, film, synthetic fiber, natural fiber, etc. Alternatively, a tape-like material can be used.

The raw material for the substrate is not particularly limited, and may be, for example, polyolefin, polyester,
Nonwoven fabrics, woven fabrics, papers, films and the like made of polyamide, polyacrylonitrile, polycarbonate, cellulose and the like can be mentioned. Among them, a long-fiber non-woven fabric sheet such as polyester or polyacrylonitrile produced by a spun bond method is preferable in terms of mechanical strength, waterproof performance, rust prevention performance, and non-biodegradability.

Next, the anticorrosive material constituting the rust preventive material layer applied on the organic coating layer is formed by supporting the liquid composition on one surface, both surfaces and / or voids of the base material to form a composite. Thus, it can be used as an anticorrosive material having good workability, long-term durability and high rust prevention performance.

The method for supporting the liquid composition on a substrate to form an anticorrosive material is not particularly limited. For example, after adding a surfactant or the like to the liquid composition as necessary,
Non-woven fabric, woven fabric, paper, coated on one or both sides of a sheet or tape-like substrate such as a film, or impregnated with the liquid composition and carried on the substrate, and if necessary, the sheet- or tape-like substrate Is cut into an appropriate width to obtain a sheet-shaped or tape-shaped anticorrosive material.

The viscosity of the liquid composition when supported on the above-mentioned anticorrosive material varies greatly depending on the above-mentioned supporting method and the like.
~ 15 cp, preferably 5-15 cp, more preferably 5-11 cp. When the viscosity is less than 3 cp, it can be sufficiently impregnated into the substrate, but it is difficult to support it in the substrate due to its low viscosity. When the viscosity exceeds 15 cp, the impregnation takes a long time, and when used, the flexibility of the anticorrosion material is poor, so that the workability may be deteriorated. Is not preferred.

Next, the weight of the liquid composition supported on the substrate of the anticorrosive material of the present invention is usually 480 to 6 as a dry weight.
00 g / m ² , preferably 480-560 g / m ² , more preferably 480-544 g / m ² . If the weight of the liquid composition is less than 480 g / m ² , the obtained anticorrosive may not have sufficient long-term durability.
On the other hand, if the supporting amount exceeds 600 g / m ² , the obtained anticorrosive material will have poor flexibility, and therefore, the workability will be poor.

The method of applying the anticorrosion material thus obtained is not limited at all, but it is preferred that the rust-preventive coating composition for forming the organic coating layer be used in order to further enhance the adhesion to the organic coating layer. After applying the product, the coating composition is adhered to the rail shape in a wet state, and at room temperature,
A method of curing and fixing by natural drying is one of the preferable construction methods.

The dry film thickness of the thus obtained rust preventive material layer after application is usually 300 to 500 μm, preferably 300 to 500 μm.
It is 400 μm, more preferably 300 to 350 μm. When the film thickness is less than 300 μm, a strong film thickness cannot be obtained, and sufficient mechanical strength, long-term durability and corrosion resistance cannot be imparted, which is not preferable. However, this is not economically preferable.

Further, in the present invention, an overcoat layer formed by applying a rust-preventive paint composition for the purpose of imparting weather resistance and corrosion resistance may be formed on the above-mentioned rust-preventive material layer, if necessary. desirable. Examples of the rust preventive paint composition that can be used for the overcoat layer include, for example, resin components, solvents, and pigments that are components of the rust preventive paint composition that can be used for the organic coating layer formed on the rail substrate described above. And what is obtained by appropriately selecting and combining components used for additives can be used.

The above-mentioned method for the organic coating layer can be applied to the method for applying the overcoat layer.

Further, the coating thickness of the above-mentioned overcoat layer is usually 15 to 50 μm, preferably 30 to 50 μm,
More preferably, it is 35 to 50 μm. The film thickness is 15μ
If less than m, it is not preferable because sufficient corrosion resistance and water resistance cannot be imparted.
A sufficient effect corresponding to this cannot be obtained, which is not preferable from an economic viewpoint.

Next, the total thickness of the rust-proofed portion of the rust-proof rail obtained by the present invention is usually 350 to 350.
It is 500 μm, preferably 400 to 500 μm, more preferably 400 to 450 μm. The film thickness is 350 μm
If it is less than 50 μm, a sufficient rust-preventing effect cannot be obtained, which is not preferable. If it exceeds 500 μm, a sufficient effect corresponding thereto can be obtained, but it is not preferable from an economic viewpoint.

Further, the adhesion between the layers of the multilayer film (including the base material) structure portion of the part subjected to the rustproofing treatment thus obtained must be good, but the adhesion between the layers closer to the rail base surface must be good. It is necessary to select the material of each layer so that the strength is high. This is because, when a strong destructive force is applied to the multilayer structure portion, the upper layer film is peeled off so that the entire multilayer film is peeled and the rail base is exposed and corrosion does not occur, thereby weakening the force. This is to make it remain.

Next, the places to be constructed on the rustproof rail of the present invention will be described with reference to the drawings.

FIG. 1 is an enlarged schematic sectional view showing each embodiment of the rustproof rail of the present invention in a section perpendicular to the rail axis direction.

In FIG. 1 (A), assuming that only the abdomen of the rail 1 is used as a construction site in the rust preventive rail, the surface of the abdomen base of the rail 1 is prepared and a rust treatment agent is applied as a rust treatment. On the rust-treating agent layer 2 formed, an organic coating layer 5 composed of two layers of an undercoat layer 3 and an intermediate coating layer 4 is sequentially formed, and a liquid composition is formed on the organic coating layer 5 on a tape base material. The anticorrosive material carrying the anticorrosive material is adhered along the rail axis direction, dried and cured to form a rust preventive material layer 6, and finally, an overcoat layer 7 is formed on the rust preventive material layer 6, and It is assumed that. The rust preventive rail is suitable for construction in a place where the frequency of occurrence of corrosion due to salt and high humidity due to seawater is low as compared with the case described below.

In FIG. 1 (B), both the abdomen and the bottom of the rail 1 are used as construction locations on the rust-preventive rail. A rust-treating agent is applied to form a rust-treating agent layer 2, and then an organic coating layer 5 composed of two layers of an undercoat layer 3 and an intermediate coating layer 4 is sequentially formed, and a tape is formed on the organic coating layer 5. An anticorrosive material in which a liquid composition is carried on a substrate is bonded or wound along the rail axis direction, dried and cured to form a rust preventive material layer 6, and finally on the rust preventive material layer 6. An overcoating layer 7 is formed on the rust-proof rail. The rustproof rail is suitable for construction in a place where the frequency of occurrence of corrosion due to salt, high humidity or the like due to seawater is extremely high.

Further, in FIG. 1 (C), the organic coating layer 5 composed of two layers, that is, the preparation of the base material, the formation of the rust treatment agent layer 2, the undercoat layer 3 and the intermediate coating layer 4, is used as a work place on the rust prevention rail. The formation is performed on both the abdomen and the bottom of the rail, and the formation of the rust preventive material layer 6 and the formation of the overcoat layer 7 are performed only on the abdomen of the rail (or any one of the bottom (not shown)). It is. The rust prevention rail is
It is suitable when the frequency of occurrence of corrosion is about the middle between FIG. 1 (A) and FIG. 1 (B).

Further, in addition to the above description, in the present invention,
In the weld between the rails as well,
The construction may be performed in the order shown in any of (A) to (C) of FIG. In this case, in particular, it is necessary to sufficiently remove a substance that causes a decrease in adhesion and causes corrosion, such as welding burn, by preparing a substrate.

[0062]

Next, the method of the present invention will be described in more detail with reference to examples.

Example 1 (N1) A rustproof rail shown in FIG. 1 (C) was manufactured over 40 m on site using the working rail of Shinkanmon Tunnel of Sanyo Shinkansen for slab track one month after laying. went.

First, the abdomen base surface of the abdomen and the bottom of the working rail 1 (Shinkansen 60 rail manufactured by Nippon Kokan Co., Ltd.) was degreased and cleaned with sandpaper and a wire sponge to prepare a base. quickly rust treatment agent at a brush or a roller as rust treatment (Rasutekku Co., Rasutoru -B) to form a rust treatment agent layer 2 is applied in measure of about 300 g / m ^2. The dry thickness of the rust treating agent layer 2 was about 30 μm.

Next, after applying the rust-treating agent, the rust-preventive coating composition for undercoating is applied to the rust-treating agent layer 2 with a brush or a roller after 30 minutes to 1 hour (the masking treatment was performed during this time). (Last Tech Co., Night Primer NP
100S) was applied at a standard of about 300 g / m ² to form an undercoat layer 3. The dry film thickness of the undercoat layer 3 is about 35 μm.
Met.

Subsequently, 30 minutes to 1 hour after the undercoating, about 300 g of a rust-preventive paint composition for intermediate coating (manufactured by Lastec Co., Ltd., Night Primer NP100) was applied on the undercoating layer 3 with a brush or a roller. m ² was applied to form an intermediate coating layer 4 and an organic coating layer 5 was formed. The dry thickness of the intermediate coating layer 4 was about 30 μm.

Thereafter, the above-mentioned rust-preventive coating composition for intermediate coating is applied to only the abdomen of the current rail 1 in a wet state, and is manually applied onto the organic coating layer 5 to form a liquid composition on the tape-like base material. Anticorrosive material (Lastec Co., Ltd., night tape NT105, tape width of 100 mm) is applied along the rail axis direction, dried and cured to form a rust preventive material layer 6
Was formed. The dry film thickness of the rust preventive material layer 6 was about 300 μm.

Finally, after applying the anticorrosive material, after confirming dryness to the touch, a rust-preventive paint composition (manufactured by Lastec Co., Ltd., Knight) was applied on the rust-preventive material layer 6 with a brush or a roller. Primer NP 100S) was applied at a standard of about 400 g / m ² to form an overcoat layer 7 to obtain a desired rustproof rail (1). The dry film thickness of the overcoat layer 7 was about 35 μm. The time required for the construction was 3 hours in total.
The composition and properties of the rust treatment agent, the rust preventive paint composition for the undercoat, the rust preventive paint composition for the intermediate coat, the anticorrosive material and the rust preventive paint composition for the top coat used in the present Example are shown in Table 1. 1
Shown in

Example 2 (N2) In Example 1, instead of the anticorrosion material (Lastec Co., Night Tape NT 105, 100 mm tape width), an anticorrosion material (Lastec Co., Night Tape NT 100, A rust-preventive material layer 6 having a dry film thickness of 400 μm was formed using a tape having a width of 100 mm), and instead of a rust-preventive paint composition for top-coating (Lastec Co., Ltd., Night Primer NP 100S), A desired rust-preventive rail (2) was obtained in the same manner as in Example 1 except that the overcoat layer 7 was formed using a rust-preventive coating composition (Lastec Co., Ltd., Night Primer NP 100). The time required for the construction was 2 hours and 40 minutes in total. The composition and properties of the rust treatment agent, the rust preventive paint composition for the undercoat, the rust preventive paint composition for the intermediate coat, the anticorrosive material and the rust preventive paint composition for the top coat used in the present Example are shown in Table 1. It is shown in FIG.

[0070]

[Table 1]

COMPARATIVE EXAMPLE 1 (C1) In the same manner as in Example 1, rust-preventive rails were manufactured over a length of 40 m using a working rail for general use one month after the installation.

First, the abdomen base surface of the abdomen and the bottom of the working rail is degreased and cleaned with sandpaper and a wire sponge to prepare a base. After the base is prepared, a brush or roller is placed on the base prepared layer. Thick epoxy resin for low underground treatment surface (China Paint Co., Ltd., Univan H
S) was applied at a standard of about 160 g / m ² to form a coating layer, and a desired rustproof rail (3) was obtained. The dry film thickness of the coating layer was about 70 μm. The time required for the construction was 3 hours in total.

Comparative Example 2 (C2) In Comparative Example 1, a thick-film type tar epoxy resin (Viscon HS, manufactured by Chugoku Paint Co., Ltd.) was used instead of the thick-film type epoxy resin for a low underground treatment surface at about 300 g / m ² . Except for forming a coating layer by applying as a guide, in the same manner as in Comparative Example 1,
The desired rustproof rail (4) was obtained. The dry film thickness of the coating layer was about 120 μm. The time required for construction is 3
It was time.

Comparative Example 3 (K1) In the same manner as in Example 1, rust-preventive rails were manufactured over a length of 40 m using a working rail for general use one month after the installation.

First, the abdomen base surface of the abdomen and the bottom of the working rail is degreased and cleaned using sandpaper and a wire sponge to prepare a base. After the base is prepared, lacquer is immediately applied as a rust preventive treatment with a brush or roller. About 300 g / m ² of rust-preventive oil (Kowa Kasei Co., Ltd., Kowasabi Top E, chelating group-containing epoxy resin)
To form a rust-proof layer to obtain a desired rust-proof rail (5). The thickness of the rust preventive layer was about 50 μm.
The time required for the construction was one hour in total.

Comparative Example 4 (K2) In Comparative Example 3, instead of the lacquer type rust preventive oil, about 500 g of a grease type rust preventive oil (manufactured by Kowa Kasei Co., Ltd., hot melt type waterproof oil G-3K). / M ² to obtain a desired rust-proof rail (6) in the same manner as in Comparative Example 3 except that a rust-proof layer was formed by coating. The thickness of the rust preventive layer was about 500 μm. The time required for the construction was 1.5 hours in total.

Comparative Example 5 (K3) In Comparative Example 3, instead of the lacquer type rust preventive oil, a transparent oil type rust preventive oil (Metalex S-250, manufactured by Kowa Kasei Co., Ltd., solvent-diluted rust preventive oil) ) Of about 300 g / m
^A desired rust-proof rail (7) was obtained in the same manner as in Comparative Example 3, except that the rust-proof rail (7) was applied and dried to form a rust-proof layer of a non-adhesive soft film. The thickness of the rust preventive layer was about 40 μm. The time required for the construction was 1.5 hours in total.

Comparative Example 6 (K4) In Comparative Example 3, a black oil-type rust-preventive oil (Metalex AP-1, manufactured by Kowa Kasei Co., Ltd., asphalt wax) was used instead of the lacquer-type rust-preventive oil. About 350
g / m ² was applied and dried to form a rust-proof layer of a black cured film, and a desired rust-proof rail (8) was obtained in the same manner as in Comparative Example 3. The thickness of the rust preventive layer was about 45 μm. The time required for the construction was 1.5 hours in total.

Example 3 Regarding the rustproof rails (1) to (8) obtained in Examples 1 and 2 and Comparative Examples 1 to 6, the corrosion progress during the actual use as a railroad rail was examined as a rustproof test. It was evaluated by visual observation.

Table 2 shows the results of the rust prevention test.

[0081]

[Table 2]

As a result of the above rust preventive test, the rust preventive rail of each of the rust preventive oil types of Comparative Examples 3 to 5 lost the rust preventive power in a shorter time than the other samples due to the flow of the rust preventive oil. Was confirmed. It is also possible to apply the rust preventive oil again by maintenance.However, it is considered that such rust preventive oil is not preferable because the rust preventive oil that has flowed out into the sea mixed with drainage may cause marine pollution. .

In addition, the resin paint type rust-preventive rails of Comparative Examples 1 and 2 can maintain the rust-preventive power more than the rust-preventive oil type, but have a shorter sustaining power as compared with the present invention. Was. Further, once rust is generated, internal corrosion may spread even if a resin coating is applied repeatedly like rust preventive oil, which is not preferable.

Table 3 shows the results of the stationary test conducted in the Railway Technical Research Institute (Kokubunji, Tokyo) at the same time as the above rust prevention test. In addition, the contents of the stationary test were performed using the working rails for general use and the above-described Examples 1-2 and Comparative Examples 1--2.
Rust prevention rails (1) to (8) were prepared in the same manner as the preparation method of the rust prevention rail of No. 6, and a rust prevention test was performed using these rails, and the progress of corrosion was evaluated by visual observation. .

[0085]

[Table 3]

The results shown in Table 3 also confirm that the rust-preventive rails of Examples 1 and 2 and the rust-preventive rails of Comparative Examples 1 to 6 have superior rust-preventive performance.

From the results in Tables 2 and 3, it can be seen that the rust-preventing rail of the present invention did not generate rust at all during the test period and had excellent rust-preventing performance and durability as compared with the comparative example. confirmed.

From the above results, in addition to having the main purpose of the rust-proof function, the rust-proof rail of the present invention has the following (1)
(4).

(1) Workability is good.

The workability is good even on existing rails, especially at night and in tunnels, even during several hours while train operation is stopped. Unlike ordinary painting, coating thickness control is easy and complete rust prevention is achieved. It is possible.

(2) Good durability.

[0092] The painted surface alone may be broken or peeled off by the vibration of the train due to the running vibration of the train, and is less durable than the present invention. However, the present invention does not peel off and is excellent in durability.

(3) It has anti-vibration properties.

The rust-preventive rail constructed on the side of the rail by the method of the present invention can be made of a corrosion-resistant material according to the shape of the rail to form a strong film, prevent the rail from resonating due to running vibration, and reduce running noise and creaking noise. In addition, it can also function as a soundproof rail.

(4) Corrosion-proof insulation of rails At railroad crossings, the lower surface of rails is wet,
Since electric corrosion may occur, it is possible to prevent the corrosion of the electric corrosion by performing the rail insulation according to the present invention.

[0096]

[Effect] The rust preventive rail of the present invention can be easily applied to the rail shape with any rust preventive material having a rust preventive function. In addition, it can follow the expansion and contraction of the rail, has excellent anticorrosion performance and long-term durability against salt damage corrosion, environmental corrosion, electric corrosion, etc., and can prevent shortening of the rail life due to corrosion.

Further, the rust preventive rail of the present invention does not elute the rust preventive material to the outside, has no danger of marine pollution, etc., is pollution-free and is environmentally friendly.

Further, the rust-preventive rail of the present invention is excellent in workability, and can be constructed in a short time on an existing rail already laid, and can be used in the existing Shinkanmon tunnel, Seikan tunnel, Shintanna tunnel. In addition to application to rails where salt corrosion and environmental corrosion are concerned, such as tunnels and Honshu-Shikoku Bridge, to prevent corrosion at the middle of mountain tunnels with old smoke exhaust ports, and to prevent electrical corrosion at railroad crossings, etc. Is applicable.

[Brief description of the drawings]

FIG. 1 is an enlarged schematic cross-sectional view showing each embodiment of a rust prevention rail of the present invention in a cross section perpendicular to the rail axis direction.
FIG. 1A is an enlarged schematic cross-sectional view of a case where only the abdomen of the rail is performed as a construction site in the rust-preventive rail.
FIG. 1 (B) is an enlarged schematic cross-sectional view showing both the abdomen and the bottom of the rust-prevention rail when the rust-prevention rail is used. In FIG. FIG. 4 is an enlarged schematic cross-sectional view showing a case where the formation of an agent layer and an organic coating layer is performed on both the abdomen and the bottom of the rail, and the formation of a rust preventive material layer and an overcoat layer is performed only on the abdomen of the rail.

[Explanation of symbols]

1 ... rail, 2 ... rust treatment layer, 3 ...
Undercoat layer, 4 ... Intercoat layer, 5: Organic coating layer, 6: Rust preventive material layer, 7: Overcoat layer.

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Noriji Abe 2-8 Hikaricho, Kokubunji-shi, Tokyo 38 Inside the Railway Technical Research Institute (72) Inventor Jin Hitoma 3534-1, Fukami, Yamato-shi, Kanagawa Green Pier 202 (72) Inventor Kazuma Ozawa 4-1-2 Motonakayama, Funabashi-shi, Chiba City Court Fudo Nakayama In-house (56) References JP-A-5-214701 (JP, A) JP-A-5 -280001 (JP, A) JP-A-4-203001 (JP, A) Japanese Utility Model Application No. Sho 53-109209 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) E01B 19/00 E01B 5/02 C23F 11/00

Claims (1)

(57) [Claims] An anticorrosion material comprising an organic coating layer formed by applying a rust-preventive coating composition on a rail substrate, and a liquid composition containing a rust-preventive pigment supported on a base material on the organic coating layer. A rust prevention rail having a rust prevention material layer by construction.