WO2015009177A2

WO2015009177A2 - Mixture for the production of vibroinsulation materials to protect railways and roads

Info

Publication number: WO2015009177A2
Application number: PCT/PL2014/000078
Authority: WO
Inventors: Cezary DEBEK; Jan ADAMCZYK; Jan TARGOSZ
Original assignee: Instytut Inzynierii Materialow Polimerowych I Barwnikow; Eko-Kon Sp. Z O.O.
Priority date: 2013-07-18
Filing date: 2014-07-15
Publication date: 2015-01-22
Also published as: WO2015009177A3; PL233756B1; WO2015009177A4; PL404772A1

Abstract

The mixture for the production of vibroinsulation materials to protect railways and roads for motor vehicles according to the invention consists of a rubber granules, preferably with granulation of about 1-10 mm, in quantity of 90 - 50% by weight and bituminous materials modified with thermoplastic, thermoelastoplastic polymers or rubbers in quantity of 10 - 30% by weight Modified bituminous materials operate as a binder of rubber granules. In addition, the mixture may contain modifiers in the form of mineral fillers, fabrics or resins in quantity of up to 30% by weight against the weight of the total mixture. granules made of used car tyres, waste tapes and / or belts or production waste are preferably used as rubber granules. Asphalt modified with thermoplastic, thermoelastoplastic polymers or rubbers is preferably used as a modified bituminous binder. Ethylene polymers or ethylene-propylene copolymers are preferably used as thermoplastic polymers. Block copolymers of styrene-butadiene-styrene, styrene-isoprene- styrene, styrene-ethylene/butylene-styrene, styrene-ethylene/propylene-styrene are used as thermoelastoplastic polymers. Polyester or basalt fibres, natural and synthetic resins, preferably rosin, high-styrene resin, mineral fillers of different granulation, preferably quartz are used as modifiers for improving mechanical properties, rheology and hardness.

Description

Mixture for the production of vibroinsulation materials to protect railways and roads

The present invention is a mixture for the production of vibroinsulation materials, based on material recycling using rubber granules, intended for vibroinsulation railways and roads for motor vehicles.

The civilisation development in recent dozens of years on the one hand has brought to the humanity the innovative solutions it is difficult today to live without, but on the other hand it is the cause of the increased severity of the phenomena threatening the human health and life.

A significant part of this threat is intensively developing both railway (rail, tram) and road transport (car). It involves the continuous development of the road and rail networks, which more and more often is the cause of the protests of people exposed to the harmful effects of vibration resulting from noise of the transport structures.

The rail transport (rail, tram) and the road transport, which are the source of vibration and noise, has a negative impact on the human environment. Noise and vibration are a problem affecting the whole society; they exist in all areas of the human activity, affect all citizens, adversely affect the human health and hinder rest and rejuvenation, by reducing the effects of human work and increasing the likelihood of accidents. The residents of large urban agglomerations are particularly exposed to vibrations.

The transportation is inherently associated with dynamic impact on the environment causing mechanical vibrations of foundations, ground and engineering structures, thus the need to minimize their harmful effects is understandable and in recent years it is generally taken into account in engineering solutions.

Reducing the impact of transport as a source of noise and vibration can be achieved by changing the design of vehicles (by minimising backlash, by improving the balancing of rotating elements, minimising mutual collisions of the associated components) and by introducing systems for reducing vibration (vibration dampers, vibroisolators). You can also use the damping the vibrations in the way of their propagation, which can be achieved, for example, by introducing a dilatation between the trackway or road and the environment.

For this purpose vibroinsulation materials in various forms and technologies, such as anti-vibration mats made of rubber or rubber granules as well as thermoelastoplastic materials (PU), washers made of rubber or thermoplastic rubber, rubber rail inserts, are used. The vibration and noise reduction structures described above are characterized by high efficiency, however the cost of their execution is very high. A good way to reduce financial expenditures is to use cheaper raw materials from recycling, e.g. granules made of car tyres and conveyors. These are the materials made from quality raw materials worn as a product, which have virtually preserved the parameters of the input materials and can be successfully used for suppression of vibration and noise. Rubber is a multiphase viscoelastic material; and therefore it is able to effectively dissipate the variable forces applied in a fairly wide range of frequencies, amplitudes and environments.

The vibroinsulation solutions exist in the market, which are used in road and railway transport as well as in construction and industry and which make use of special vulcanized rubber compounds (rubbers), thermoelastoplastic materials and composites obtained in the recycling. In Poland, for example, the anti-vibration mats for trackway vibroinsulation made of vulcanised rubber are manufactured; but they expensive. Also the vibroinsulation mats, which are based on tyre rubber granules and are by 40% cheaper, are manufactured. The granules are combined (glued) with polyurethane adhesives applied in a quantity of about 20- 30%. The disadvantage of this solution is the use a significant amount of polyurethane adhesives, which in the working conditions (humidity) can be quite rapidly hydrolysed and irreversibly lose their performance, causing the need for an expansive replacement, which hinders the traffic flow.

An obstacle to the wider use of vibroinsulation materials in the construction of roads and railways is undoubtedly their too high price and lack of solutions that allow achieving all the desired characteristics of the final product in a single article. Rubber mats and glued granules have good strength parameters, but vibration damping is not at the highest level. Furthermore, it is believed that the more rubber is in the properties of the final product, the better are vibroinsulation characteristics. For this reason, most often mats of rubber or polyurethane glued rubber granules with high rubber content in the product are being used. The present invention reduces the known problems of road vibroinsulation systems. The mixture for the production of vibroinsulation materials to protect railways and roads for motor vehicles according to the invention consists of a rubber granules, preferably with granulation of about 1-10 mm in quantity of 90 - 50% by weight and bituminous materials modified with thermoplastic, thermoelastoplastic polymers or rubbers in quantity of 10 - 30% by weight. Modified bituminous materials operate as a binder of rubber granules. In addition, the mixture may contain modifiers in the form of mineral fillers, fabrics or resins in quantity of up to 30% by weight against the weight of the total mixture.

The granules made of used car tyres, waste tapes and / or belts or production waste are preferably used as rubber granules. Asphalt modified with thermoplastic, thermoelastoplastic polymers or rubbers is preferably used as a modified bituminous binder.

Ethylene polymers or ethylene-propylene copolymers are preferably used as thermoplastic polymers. Block copolymers such as styrene-butadiene-styrene (SBS), styrene- isoprene-styrene (SIS), styrene-ethylene butylene-styrene (SEBS), styrene- ethylene/propylene-styrene (SEPS) are preferably used as thermoelastoplastic polymers. Fibres, such as polyester or basalt fibres, natural and synthetic resins, such as rosin, high- styrene resin, mineral fillers of different granulation, such as inexpensive quartz, are preferably used as modifiers for improving mechanical properties, rheology and hardness.

In our own research it unexpectedly turned out that cheap bituminous binders modified with small quantities of polymers (elastomers) can be used for bonding rubber granules in place of an expensive polyurethane adhesive, especially if the composition is enriched with small quantities of additives: fibres, resins and mineral fillers modifying mechanical properties, rheology and hardness. Rubber materials - bituminous materials obtained from the mixture according to the invention do not cause the above-mentioned technological problems. They are easily obtainable in the temperature of about 170 °C by non-pressurised mixing: bitumen dampens the granules very well; the mixture is easily dozed and formed into desired shapes at low pressure. It can be applied on-site with methods used in road construction, like hot pouring. The technology of obtaining is completely waste-free: the material can be repeatedly processed and the technological waste recycled. After being used, the composites can be subject to product or material recycling.

Rubber materials - bituminous materials obtained from the mixture according to the invention have good mechanical and dynamic properties: permanent deformation under compression below 25%, relative damping (hysteresis) about 35% and above. Materials can be successfully used in the vibroinsulation solutions related to railways and roads for motor vehicles. They can be formed on site in a technology similar to that used for asphalt-mineral mixture.

The developed materials are at least twice cheaper than currently commercially available materials offering similar functionality. They can be produced from a mixture according to the invention in the form of ready-made vibroinsulation boards or in the form of a mixture to be applied on-site. Application of the vibroinsulation layers on-site is another advantage of the invention, since the delivery of finished, large sheets or mats requires transport and storage under the appropriate conditions and forms. Rolling them is not advisable. So the possibility to execute a vibroinsulation layer on-site is a desirable extra feature.

Despite the reduction in amount of rubber in the final product, the performance characteristics of materials made from the mixture according to the invention are at the same level in terms of the hardness and permanent deformation as polyurethane-glued granules. However their relative damping and resistance to moisture are at a higher level and in the tasks related to vibroinsulation it is one of the essential parameters. It can be supposed that the way of propagation of vibration in the material, in which single rubber granules are separated from each other with a layer of modified bituminous materials, is different and more favourable than in rubber products or glued granules.

Furthermore, because the mixture is thermoelastoplastic, the products made of it are fully recyclable. Vulcanised rubber and polyurethane glued granules do not have this feature. As compared to the most similar product already existing in the market, that is, granules- polyurethane mixtures, the invention provides a greatly improved resistance to ageing in the working conditions (acidic moisture).

Another feature which gives an advantage over the known materials is that the can be applied directly on-site with the road construction equipment, (granules-polyurethane mixtures can be applied by "pouring", but not with the road construction equipment). In addition, they are cross-linked with moisture from the air, so the dependence on the weather conditions causes problems with repeatability.

The invention is further illustrated in the implementation examples. Example 1. 210 g of rubber granules originating from used tyres with granulation of 1-6 mm and 90 g of bituminous binder modified with SBS (triblock copolymer of styrene- butadiene-styrene) thermoelastoplast were introduced into a cylindrical vessel with a volume of 1 litre heated in an oil bath up to 170 °C. After melting the binder, the input material was mixed with mechanical stirrer. The composition was heated for another half an hour, stirring now and then. Then a portion of the hot mixture was introduced into a steel ring with a diameter of 150 mm and a button closed with a steel plate; it was closed from the top with a piston with diameter of 146 mm and pressed with force of 100 N.

After cooling in the ambient temperature, this way about 25 mm thick plates of material were obtained, which were cut with a rotary knife into plugs with a diameter of 35 mm for testing the hysteresis and with a diameter of 29 mm for testing the permanent deformation under compression. The results of the performed tests are shown in Table 1

Example 2. 270 g of rubber granules originating from used conveyor belts with granulation of 1-6 mm and 30 g of bituminous binder modified with natural rubber were introduced into a cylindrical vessel with a volume of 1 litre heated in an oil bath up to 170 °C. After melting the binder, the input material was mixed with mechanical stirrer. The composition was heated for another half an hour, stirring now and then. Then a portion of the hot mixture was introduced into a steel ring with a diameter of 150 mm and a button closed with a steel plate; it was closed from the top with a piston with diameter of 146 mm and pressed with force of 100 N.

Example 3. 150 g of rubber granules originating from used tyres and waste from production of conveyor belts with granulation of 1-10 mm and 60 g of bituminous binder modified with SEBS (styrene-ethylene/butylene-styrene copolymer) thermoelastoplast, 30 g of rosin, 30 g of high-styrene resin, 3 g of waste polyester fibres and 27 g of quartz with granulation of 0.5-2 mm were introduced into a cylindrical vessel with a volume of 1 litre heated in an oil bath up to 170 °C. After melting the binder, the input material was mixed with mechanical stirrer. The composition was heated for another half an hour, stirring now and then. Then a portion of the hot mixture was introduced into a steel ring with a diameter of 150 mm and a button closed with a steel plate; it was closed from the top with a piston with diameter of 146 mm and pressed with force of 100 N.

Example 4. 120 g of rubber granules originating from used tyres with granulation of 1-6 mm, 120 g of rubber granules of the same origin with granulation of 4-10 mm, 45 g of bituminous binder modified with thermoplast, that is, ethylene-propylene copolymer, 9 g of rosin and 3 g of basalt fibres were introduced into a cylindrical vessel with a volume of 1 litre heated in an oil bath up to 170 °C. After melting the binder, the input material was mixed with mechanical stirrer. The composition was heated for another half an hour, stirring now and then. Then a portion of the hot mixture was introduced into a steel ring with a diameter of 150 mm and a button closed with a steel plate; it was closed from the top with a piston with diameter of 146 mm and pressed with force of 100 N.

Example 5. 120 g of rubber granules originating from used tyres with granulation of 1-6 mm, 120 g of rubber granules contaminated with fibres originating from used conveyor belts with granulation of 1-8 mm and 60 g of bituminous binder modified with SIS (triblock copolymer of styrene-isoprene-styrene) thermoelastoplast were introduced into a cylindrical vessel with a volume of 1 litre heated in an oil bath up to 170 °C. After melting the binder, the input material was mixed with mechanical stirrer. The composition was heated for another half an hour, stirring now and then. Then a portion of the hot mixture was introduced into a steel ring with a diameter of 150 mm and a button closed with a steel plate; it was closed from the top with a piston with diameter of 146 mm and pressed with force of 100 N. After cooling in the ambient temperature, this way about 25 mm thick plates of material were obtained, which were cut with a rotary knife into plugs with a diameter of 35 mm for testing the hysteresis and with a diameter of 29 mm for testing the permanent deformation under compression. The results of the performed tests are shown in Table 1

Example 6. 240 g of rubber granules originating from used tyres with granulation of 1-6 mm, 45 g of bituminous binder modified with styrene-ethylene/propylene-styrene (SEPS) and 15 g of rosin were introduced into a cylindrical vessel with a volume of 1 litre heated in an oil bath up to 170 °C. After melting the binder, the input material was mixed with mechanical stirrer. The composition was heated for another half an hour, stirring now and then. Then a portion of the hot mixture was introduced into a steel ring with a diameter of 150 mm and a button closed with a steel plate; it was closed from the top with a piston with diameter of 146 mm and pressed with force of 100 N.

Example 7. 240 g of rubber granules originating from used tyres with granulation of 1-6 mm, 45 g of bituminous binder modified with low-density polyethylene and 15 g of high- styrene resin were introduced into a cylindrical vessel with a volume of 1 litre heated in an oil bath up to 170 °C. After melting the binder, the input material was mixed with mechanical stirrer. The composition was heated for another half an hour, stirring now and then. Then a portion of the hot mixture was introduced into a steel ring with a diameter of 150 mm and a button closed with a steel plate; it was closed from the top with a piston with diameter of 146 mm and pressed with force of 100 N.

After cooling in the ambient temperature, this way about 25 mm thick plates of material were obtained, which were cut with a rotary knife into plugs with a diameter of 35 mm for testing the hysteresis and with a diameter of 29 mm for testing the permanent deformation under compression. The results of the performed tests are shown in Table 1 Example 9. A mat made of vulcanised rubber - a comparative study is given in Table 1.

Example 10. A mat made of rubber granules glued with polyurethane adhesive - a comparative study is given in Table 1.

Table 1. Results of testing permanent deformation, hardness and hysteresis of composites.

Hardness in IRH scale, according to ISO 48:2010 met.n.

Permanent deformation under compression, 24 h., ambient temp., 25%, according to PN-ISO 815:1998, with exception concerning sample thickness.

Relative damping, hysteresis, according to PN-87/C-04289, with exception concerning sample thickness.

* hardness in the ShA scale

Although the invention was clarified by using selected examples of its implementation, it is understood that it is possible to have multiple modifications, falling within the scope of protection of the patent claims.

Claims

1. The mixture for the production of vibroinsulation materials to protect railways and roads for motor vehicles based on rubber granules and binder, characterized in that it consists of rubber granules n quantity of 90 - 50% % by weight and bituminous materials modified with thermoplastic, thermoelastoplastic polymers or rubbers in quantity of 10 - 30% by weight.

2. The mixture according to claim 1, characterized in that it contains the modifiers in the form of mineral fillers, fabrics or resins in quantity of up to 30% by weight against the weight of the total mixture.

3. The mixture according to claim 1 or 2, characterized in that it contains the rubber granules with granulation of 1-10 mm.

4. The mixture according to claim 1 or 2, characterized in that granules made of used car tyres, waste tapes and / or belts or production waste are used as rubber granules.

5. The mixture according to claim 1 or 2, characterized in that Asphalt modified with thermoplastic, thermoelastoplastic polymers or rubbers is used as a modified bituminous binder.

6. The mixture according to claim 1 or 2, characterized in that ethylene polymers and ethylene-propylene copolymers are used as thermoplastic polymers.

7. The mixture according to claim 1 or 2, characterized in that block copolymers of styrene-butadiene-styrene, styrene-isoprene-styrene, styrene-ethylene/butyl ene- styrene, styrene-ethylene/propylene-styrene are used as thermoelastoplastic polymers.

8. The mixture according to claim 1 or 2, characterized in that polyester or basalt fibres, natural and synthetic resins, preferably rosin, high-styrene resin, mineral fillers of different granulation, preferably quartz are used as modifiers for improving mechanical properties, rheology and hardness.