RU82714U1 - WATER DRAIN - Google Patents

Abstract

1. A drainage tray made of composite materials, characterized by a frontal body with a docking broadening at one of its ends, consisting of a concave bottom and side flat walls with drainage holes made therein, transverse stiffeners located at a certain distance from each other, longitudinal ribs stiffnesses made externally along the upper edge of the walls along the entire length of the tray, and anchor plates, characterized in that the walls and transverse stiffeners are made of different-module thermoplastic tichnoy material. ! 2. Drainage tray according to claim 1, characterized in that the transverse ribs are made of thermoplastic based on a reinforcing filler and a polymer binder. ! 3. Drainage tray according to claim 2, characterized in that glass and carbon fibers are used as a reinforcing filler. ! 4. The drainage tray according to claim 3, characterized in that polyolefins or polyamides are used as the polymer binder. ! 5. Drainage tray according to claim 4, characterized in that the amount of reinforcing fiber in the thermoplastic is from 10 to 50 wt.%. for polyolefins. ! 6. Drainage tray according to claim 4, characterized in that the amount of reinforcing fiber in the thermoplastic is from 10 to 40 wt.% For polyamides. ! 7. Drainage tray according to claim 4, characterized in that, depending on the depth of the tray, the elastic modulus of the material of each rib is respectively from 2500 to 20,000 MPa. ! 8. The drainage tray according to claim 4, characterized in that the shell of the housing and the ribs are made of dissimilar thermoplastics, while the rib material is made of thermoplastic with a higher elastic modulus than the material

Description

The proposed technical solution relates to the engineering equipment of road communications, and specifically to drainage structures used to divert surface and groundwater from a railway embankment. The inventive design can also find application for the drainage of roads, airfields, urban facilities.

Known drainage tray - structures made of reinforced concrete (AS USSR No. 1320323, publ. 30.06.87).

Known drainage tray (RF Patent ПМ №58134, publ. 10.11.06), made of a prefabricated thin-walled polymer shell and containing metal spacers placed inside the shell.

Known drainage tray (RF Patent ПМ №40059, publ. 27.08.04), in which the body and stiffeners are made of structural thermoplastic, which are used as mineral-filled polypropylene and polyamide.

The listed drainage trays during installation are installed in trenches, which are then covered with soil. The conditions of their operation determine the basic requirements for the strength and elasticity of the walls of the drainage trays, which must withstand constant loads caused by the pressure of the surrounding soil on the walls, as well as periodic loads of varying intensity, arising as a result of seasonal climatic movements, especially water-saturated soil, and when passing railway (or automobile) transport.

The required operational characteristics of the drainage trays of the above structures are achieved due to the wall thickness, the use of spacers, the creation of massive stiffeners or the presence of a large number of them, which take a significant part of the load on themselves, which

leads to an increase in the weight of finished products, the need to use special equipment during their assembly, as well as a significant increase in the cost of both the products themselves and their installation and dismantling.

Known adopted for the prototype drainage tray made of composite material (RF Patent for the invention No. 2285766, publ. 20.10.06), which is made on the basis of fiberglass and consists of walls with drainage holes made in them and a concave bottom, transverse stiffeners made outside on forming walls and bottom along the entire length of the tray except for the ends, longitudinal stiffeners, made outside the upper edge of the walls and transverse stiffeners, as well as anchor plates located horizontally between the pop with stiffened ribs.

A significant drawback of this technical solution is that the material for the manufacture of the tray is limited to only one class of composite materials - fiberglass, which provides an excess margin of safety without the need for all the elements of the tray made by the prototype.

It is known that fiberglass has a high strength characteristics, the performance of which linearly depends on the amount of reinforcing filler, with maximum values corresponding to 50-70% weight. filler ("Chemical Encyclopedia", t.4, M., 1995). Therefore, the replacement of fiberglass with another composite material, in particular, with a lower filler content (while maintaining the operational characteristics shown by the current specifications for drainage trays) should lead to a decrease in the weight of the finished product, expanding the choice of technological operations for manufacturing the tray and the possibility of re-processing and use of the material ( recycling).

In addition, the replacement of fiberglass is associated with insufficient environmental friendliness of the methods of its production. So, precisely in connection with the solution of this technical problem, a drainage tray was created according to the aforementioned RF patent

at PM No. 40059, where structural thermoplastic is used instead of fiberglass.

The technical task of the proposed solution is the creation of drainage trays with the optimal combination of strength characteristics of structural elements by expanding the range of polymer-filled materials used to manufacture the tray.

To achieve the named technical result, the drainage tray is made of composite thermoplastic material and is a jelly-like body consisting of flat walls with drainage holes made in them and a concave bottom, transverse stiffeners made outside along the walls and bottom along the entire length of the tray except the ends, longitudinal stiffeners made externally along the upper edge of the walls and transverse stiffeners, as well as anchor plates located horizontally outside the tray between the transverse ribs, and wherein the bottom of the tray at one end are mounted for telescoping with one another broadening. The walls are tilted outward at an angle of 24 ° to 45 ° C. Additionally, to ensure the possibility of changing the shape of the route of the drainage channel in terms of the tray can be performed with a rotation, which is advisable to perform with an angle of 30 ° or 45 °. In some cases, to ensure the possibility of operating the trays and cleaning, the bottom is made thicker, and the width is made on the basis of the conditions for the passage of attendants.

Common with the proposed technical solution are the following essential features - the drainage tray is made of composite material, the housing consists of walls with drainage holes and a concave bottom, transverse stiffeners made outside along the generatrix of the walls and the bottom along the entire length of the tray except for the ends, longitudinal stiffeners, made outside the upper edge of the walls and transverse stiffeners, as well as anchor plates.

A distinctive essential feature of the proposed

drainage tray is its implementation of a composite material based on thermoplastics, in which the casing and transverse ribs are made of multimodular thermoplastic materials.

At the same time, in the proposed technical solution, multimodularity refers to differences in the elastic-strength properties of composite thermoplastic materials, determined by the amount of reinforcing filler in the polymer binder, which begin to appear when the filler content is from 10% by mass, and are characterized by a difference in the elastic modulus of the material of the structural elements, ribs and the body of the tray, at 1000 MPa and at their melting temperature, differing by at least 10 ° C.

The manufacture of the elements of the hydrocrack from multimodular thermoplastics allows, with minimal means, to purposefully strengthen those places of its construction that are subjected to the greatest deformation load.

Due to the presence of these distinctive features, together with the known ones, the following technical result is achieved: due to the manufacture of power elements from multimodular thermoplastic materials, a tray is obtained that corresponds to the requirements of TU in terms of strength and resistance to bending of the structure, but does not have technological limitations and physico-mechanical defects of fiberglass and single-module thermoplastics. In this case, the thermoplastics for the elements and the body itself can be both homogeneous and heterogeneous (i.e., differing in chemical structure and / or structure).

As a result of a search by sources of patent and scientific and technical information, the totality of signs characterizing the proposed drainage tray was not found. Thus, the proposed device meets the eligibility criteria for the object "utility model".

The design of the proposed drainage tray is illustrated by drawings (figures 1-2), which depict a section of the tray made of thermoplastic materials, while its length is determined by the capabilities

equipment of the manufacturer, but must not contain less than 2 ribs.

Fig. 1-2, the drainage tray consists of a concave bottom 1, the radial shape of which (the shape of the bottom can be made as a radius that can be greater than or equal to half the width of the tray at the bottom, and by pairing several radii or a curve described by the equation second order) contributes to the effect of self-cleaning of the trays due to the gradient of flow rates, flat walls of the housing 2 inclined outwardly with drainage holes 3 made therein, transverse stiffeners 4 made outside along the generatrix of the walls 2 and bottom 1 and the entire length of the tray except the ends, longitudinal stiffeners 5, made outside the upper edge of the walls 2 and transverse stiffeners 4, as well as anchor plates 6 located horizontally between the transverse stiffeners 4 on the outside of the tray, preventing the soil from being ejected by the tray, with the bottom 1 and the walls 2 of the tray on one of the ends have telescopic broadening 7. Anchor plates are installed on both sides of the tray in several or all sections between the ribs 4. At the same time, drainage holes are prevented from silting the tray Section 3 can be made lattice, in particular, a grid 8 of polymeric materials.

The ribs are made of a material with a higher modulus of elasticity than the material of the body, and are connected to the walls of the body by welding or mechanical locking connection. The housing (lining) has a broadening at one of its ends to ensure the connection of the tray sections into a single channel: for a more reliable connection of the trays and to exclude the longitudinal movement of the tray sections, it is also possible to lock them 9.

The drain tray works as follows. A trapezoidal trench digs, corresponding in size to the installed trays and design documentation. Then the installation of the trays in the trench begins with the laying of each subsequent section of the tray in broadening 7 of the previous one. If necessary, lay the tray section, the length of which is less than the whole

tray, it is trimmed to the required size, for example, with a hacksaw so that the cut line is away from the transverse rib 3. Next, the assembly is performed as usual. If necessary, trays with rotation are used. After assembling the trays into a single system, the formed gutter is backfilled, and then the trays are closed from above with plates - covers (concrete or from polymeric materials). To ensure the removal of groundwater in areas of long length (more than 100 m), with a slope of at least 0.002 m, trays of various dimensions in depth (height) are used. The slope ensures the discharge of water coming through the drainage holes into the sewer.

Experimental tests of statically loaded trays were carried out at a specialized test bench for trays OLAD.01.00.00 according to the "Methodology for conducting static tests of drainage trays made of composite materials during acceptance and periodic tests of LAD.0101.000 M1".

Control of physical and mechanical parameters of the material of the tray during periodic and type tests is carried out in accordance with TU2296-008-39790001-2004.

Thermoplastic materials were used as composites: the binder is polypropylene (PP) filled with glass fibers with a content of 10-50% by weight. (PPSV) and carbon fibers (or basalt) with a content of 10-50% of the mass. (UPP) - for the manufacture of ribs, a copolymer of PP with polyethylene (Balen brand 02015), sheet, block - for the walls (shells) of the body, a binder - polyamide (PA-6) filled with carbon fibers (UKN brand) or glass fibers with a content 10-40% by weight (UPA or PASV) - for the manufacture of ribs, polyamide (PA-6), sheet, block - for the walls of the body.

The content of fillers in prolipropylene and polyamide may be greater than the above, but this will lead to higher prices for products.

The shell of the body is made of thermoplastic by vacuum drawing, the ribs are injection molded, and the ribs are connected to the body by welding or mechanical locking. The ribs at the junction with the body have a shaped thickening.

The calculation of the number of ribs (n) for a given length of the tray (1) was performed according to the formula:

;

where E, J, F, r is the elastic modulus, moment of inertia, cross-sectional area, distance from the center of gravity of the section to the neutral axis of the rib, respectively, for the ith rib. The calculation is based on the well-known “finite element method” known in sopromat.

Examples of the implementation of the proposed technical solution:

Example 1

Production of a drainage tray with a depth of 0.5 m with stiffeners and shell walls of the casing from heterogeneous and heterogeneous thermoplastic materials.

By injection molding at a temperature of 230 ° C, ribs of 5 mm thickness are made from polyamide filled with 10% by mass with chopped glass fiber (grade PA-6 CB10).

On a Taura-Phoenix vacuum molding machine, at a temperature of 165 ° C, the shell walls of the casing are made of sheet block thermoplastics representing a copolymer of polyethylene with polypropylene (Balen grade 02015), 5 mm thick.

Put the shell of the tray body on the frame of the slipway, install the ribs with a pre-calculated step of 120 mm and weld the ribs to the surface of the outer wall along the entire length (perimeter) of the tray using the Olmax welding machine and a filler rod made of polypropylene.

In this case, the index of ultimate strength of the tray rib bending was 125 MPa (for unfilled polyamide grade PA-6, the tensile strength is 105 MPa), while this value for the body was 35 MPa.

Example 2

Production of a drainage tray with a depth of 0.75 m with stiffeners and shell walls of the housing from homogeneous thermoplastic materials of different modules.

By injection molding at a temperature of 235 ° C, 3 mm thick ribs are made from PA-6 polyamide filled with 40% by weight with carbon fiber (UPA-40 grade).

On a Taura-Phoenix vacuum molding machine, at a temperature of 220 ° C, the shell walls of a casing are made of sheet block polyamide 4 mm thick.

Put the shell of the tray body on the frame of the slipway, install the ribs with a pre-calculated step of 500 mm and weld the ribs to the surface of the outer wall along the entire length (perimeter) of the tray using the Olmax welding machine and a filler rod of polyamide with a diameter of 3 mm.

In this case, the index of the ultimate strength of the tray rib for bending was 250 MPa, while this value for the casing was about 100 MPa.

According to the above technology, trays were made from the above thermoplastic materials taken for walls and stiffeners in various combinations and various thicknesses. So for a 10% polypropylene (PPCB) tray filled with fiberglass, the indicator of the flexural strength of the rib was 45 MPa, (elastic modulus 2500 MPa, Tm = 175 ° C), for a 30% filled with carbon fibers - 100 MPa (Tm = 181 ° C), for 40% CB - filled - 135 MPa (MP = 185 ° C), for 50% CB - filled - 140 MPa (elastic modulus 12000 MPa, MP = 187 ° C).

As a control, a tray made using the traditional technology of mineral-filled polypropylene of the PP-403M and PPMN-50-1 t grades with a thickness of ribs and case equal to 6 mm and the number of ribs equal to 10 per 1 m of the length of the tray was taken.

The obtained experimental data are shown in tables 1-3.

In table 1: with constant for the claimed materials the thickness of the ribs - 4 mm and the thickness of the walls of the body - 5 mm., But for different depths of the trays. With a design load for depths of 0.5-0.75-1.0 m according to TU 3185-006-39790001-04.

Table 2: for different rib thicknesses and constant shell thickness and tray depth of 0.5 m.

Table 3: material characteristics of drainage tray elements.

As can be seen from the obtained data, the stated technical task is to strengthen the claimed drainage tray made of composite materials, characterized by a gutter-shaped housing with a butt broadening at one of its ends, consisting of a concave bottom and side flat walls with drainage holes made therein, transverse stiffeners located on a certain distance from each other, longitudinal stiffeners made outside along the upper edge of the walls along the entire length of the tray and anchor plates, is achieved the fact that its walls and transverse stiffeners are made of different-module thermoplastic material. In this case, the transverse ribs are made of thermoplastic based on a reinforcing filler and a polymer binder. Glass and carbon fibers are used as a reinforcing filler, and polyolefins or polyamides are used as a polymer binder. The hardening effect of the product begins for polyamides and polyolefins (for example, polypropylene and polyethylene) with the same 10% content of glass (CB) or carbon (Y) fibers in them and appears up to 40% and 50%, respectively. Raise the concentration of reinforcing fillers higher

it does not make sense since the effect remains at the same level. In this case, the bending elastic modulus for the material of the ribs can vary depending on the depth of the tray in the range for polyolefins from 2500 MPa (depth 0.5 m) to 12000 MPa (depth 1.0 m) and for polyamides from 3300 MPa (0.5 m) up to 20,000 MPa (1.0 m). In the case where the shell of the body and the ribs are made of heterogeneous thermoplastics, the material of the rib is made of thermoplastic with a higher elastic modulus than the material of the body, while the melting temperature of the material of the rib is higher than the melting temperature of the material of the body by at least 10 ° C. For the case when the shell of the body and the ribs are made of a homogeneous thermoplastic, the shell is made of sheet thermoplastic, and the ribs are made of filled thermoplastic with a higher modulus of elasticity than the material of the body, and the melting temperature of the material of the rib is higher than the melting temperature of the material of the body by at least 10 ° C.

The data presented convincingly prove the advantages of manufacturing the body and stiffeners from different-module thermoplastics in comparison with the same, but single-module materials, which, together with the structural features of the claimed solution, makes it possible to achieve the technical task: creating a drainage tray that meets the technical requirements of the technical and mechanical characteristics, but without technological limitations and disadvantages of structural materials used for these purposes Mr. art.

Table 1. No. Depth of tray, m The modulus of elasticity of the material. MPa Rib spacing 1 m with constant rib thickness, mm Transverse narrowing of the tray at a constant load, mm Permissible according to TU 3185-006-39790001-04 PP-403M 0.5 2200 110 35 twenty UPP-30 0.5 10,000 450 fifteen twenty PA-SV40
0.75 15,000 450 45 fifty UPA-40 1.0 20000 450 60 70 Table 2. No. Tray Depth, 0.5 m Rib Thickness, MM Modulus of elasticity, MPa Rib spacing, mm Weight kg / m PP-403M 6 2200 110 9,600 UPP-30 5 10,000 400 7,650 UPA-40 four 20,000 -
const 480 7,825 3 300 7,997 2 210 8,169

Table 3 Indicators Ribs Body Counter. experience PASV -
30-3M PASV -
50-1 PPSV -
40-1 SCP - 30 UPA - 40 PA-6 block. PP Block. PP-403 M Ppl
-50-1 t Bending Strength, MPa 260 290 135 one hundred 250 105 32 thirty thirty Flexural modulus, MPa 9600 12000 7200 10. twenty. 3300 1000 2200 3000 000 000 Density kg / m3 1400-1460 1530-1540 1220-1260 970 1300 1150-1160 910 1220-1280 1350-1450 Melting point, ° С 238 248 185 180 183 220 165

Claims (11)

1. A drainage tray made of composite materials, characterized by a frontal body with a docking broadening at one of its ends, consisting of a concave bottom and side flat walls with drainage holes made therein, transverse stiffeners located at a certain distance from each other, longitudinal ribs stiffnesses made externally along the upper edge of the walls along the entire length of the tray, and anchor plates, characterized in that the walls and transverse stiffeners are made of different-module thermoplastic tichnoy material. 2. Drainage tray according to claim 1, characterized in that the transverse ribs are made of thermoplastic based on a reinforcing filler and a polymer binder. 3. Drainage tray according to claim 2, characterized in that glass and carbon fibers are used as a reinforcing filler. 4. The drainage tray according to claim 3, characterized in that polyolefins or polyamides are used as the polymer binder. 5. Drainage tray according to claim 4, characterized in that the amount of reinforcing fiber in the thermoplastic is from 10 to 50 wt.%. for polyolefins. 6. Drainage tray according to claim 4, characterized in that the amount of reinforcing fiber in the thermoplastic is from 10 to 40 wt.% For polyamides. 7. Drainage tray according to claim 4, characterized in that, depending on the depth of the tray, the elastic modulus of the material of each rib is respectively from 2500 to 20,000 MPa. 8. The drainage tray according to claim 4, characterized in that the shell of the body and the ribs are made of dissimilar thermoplastics, while the material of the rib is made of thermoplastic with a higher elastic modulus than the material of the body, and the melting temperature of the material of the rib is higher than the melting temperature of the material of the body, at least 10 ° C. 9. The drainage tray according to claim 4, characterized in that the shell of the body and the ribs are made of homogeneous thermoplastic, the shell is made of sheet thermoplastic, and the ribs are made of filled thermoplastic with a higher elastic modulus than the material of the body and the melting temperature of the rib material is higher the melting temperature of the body material, at least 10 ° C. 10. Drainage tray according to claim 1, characterized in that the ribs at the junction with the housing have a shaped thickening. 11. Drainage tray according to claim 10, characterized in that the shell of the housing is made of thermoplastic by vacuum drawing, the ribs are injection molded, and the ribs are connected to the housing by a welding method or mechanical locking connection.