WO2016095454A1 - 一种复合材料轨枕及其制造方法 - Google Patents

一种复合材料轨枕及其制造方法 Download PDF

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Publication number
WO2016095454A1
WO2016095454A1 PCT/CN2015/080860 CN2015080860W WO2016095454A1 WO 2016095454 A1 WO2016095454 A1 WO 2016095454A1 CN 2015080860 W CN2015080860 W CN 2015080860W WO 2016095454 A1 WO2016095454 A1 WO 2016095454A1
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fiber
resin
base profile
mats
cavity
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PCT/CN2015/080860
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English (en)
French (fr)
Inventor
赵沭通
张跃进
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赵沭通
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Priority claimed from CN201410799847.0A external-priority patent/CN104452485A/zh
Priority claimed from CN201420815713.9U external-priority patent/CN204417927U/zh
Application filed by 赵沭通 filed Critical 赵沭通
Publication of WO2016095454A1 publication Critical patent/WO2016095454A1/zh

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    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B3/00—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails
    • E01B3/46—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails made from different materials

Definitions

  • the invention relates to the field of composite materials, and is particularly suitable for composite sleepers supporting rails in railway lines.
  • Sleepers are an indispensable material in the field of railway transportation. Its role is to under the rail, to maintain the geometrical position of the gauge, horizontal, height and direction between two or more rails by interconnecting parts, and to distribute the various loads on the rail evenly on the track bed. basically. Therefore, the sleeper must have rigidity, durability and elasticity.
  • the sleepers used in railway construction projects are: wooden sleepers, reinforced concrete sleepers and steel sleepers.
  • the well-known wooden sleeper rails are widely used in special sections such as bridges and ballasts because of their advantages of good elasticity, easy processing, and ease of use.
  • the strength and durability of the wooden pillow are not uniform enough, and the wheel-rail dynamic force is increased, so that the service life of the wooden pillow is short.
  • the wooden pillows Under the open air conditions, affected by the environment and climate, the wooden pillows are easy to age, decay and chryscle.
  • the wood pillow anti-corrosion layer is destroyed during construction, this aging decay phenomenon will be significantly aggravated. Under the impact and rolling of long-term train load, it is easy to cause mechanical wear of the wooden pillow, shorten the service life and cause inconsistency in elasticity.
  • the nail hole on the wooden pillow will be slack due to the long-term use, and the nail holding ability will be reduced, resulting in a safety hazard of driving.
  • the quality of wood resources is relatively scarce, the supply of wood raw materials is decreasing, and it is increasingly incompatible with environmental protection and ecological protection requirements.
  • Reinforced concrete sleepers are also commonly used sleepers, which overcome the shortcomings of short life of wooden sleepers, and have the characteristics of long life and good stability. However, due to the high hardness of this type of sleeper, its elasticity is poor, and the sound absorption and damping effect is also Poor, cracks are prone to occur after a period of use, affecting the safe operation of the railway. Reinforced concrete sleepers are heavy and bulky compared to wooden sleepers, making them difficult to lay, maintain, and transport.
  • reinforced concrete and steel sleepers need to be insulated in the process of use, especially in electrified lines, the insulation requirements are higher. Further, it will emit large quantities of CO 2 in the preparation of the raw materials of cement and steel process, reported amount of CO 2 Preparation of cement and steel during the discharge, respectively 10-fold and 200-fold wooden sleepers, causing environmental pollution, does not comply with environmental, Low carbon requirements.
  • the present invention provides a composite sleeper comprising a base profile extending in a longitudinal direction, the base profile having a cavity extending therethrough.
  • the base profile is a fiber reinforced resin matrix composite comprising a resin and a fiber reinforcement, the fiber reinforcement comprising a fiber mat and a fiber yarn, and the fiber mat is in the base profile
  • the fiber yarn is laid around the cavity, and the fiber yarn includes a plurality of fibers distributed in the longitudinal direction in the vicinity of the fiber mat.
  • the fiber mat is laid in the base profile as a unit of fiber mat or a plurality of unit fiber mats arranged in order from the inner layer to the outer layer of the base profile, and the fiber mat of each unit comprises a plurality of pieces A fiber mat that is laid to wrap around the cavity.
  • the present invention also provides a method of manufacturing the above composite sleeper comprising the steps of: (1) providing a suitable amount of fiber reinforcement and resin, the fiber reinforcement comprising fiber yarn, fiber mat, and the reinforcing material Divided into groups; (2) guiding: a group of the fiber reinforcing materials are arranged in a layered structure in a predetermined pattern by a guiding device, and guided to a dipping device containing a resin at a predetermined speed; (3) impregnation: The layered structure of the fiber-reinforced material arranged in a predetermined pattern passes through the resin-containing impregnation apparatus at a predetermined speed; (4) preformed: the layered structure of the resin-impregnated fiber-reinforced material is predetermined The speed is drawn into the cavity of the preforming device, so that the resin is impregnated The fiber reinforced material removes excess resin, excludes bubbles, and shapes it close to the inlet shape of the forming mold; (5) repeats the above steps (2)-(4) for the other groups of the
  • the present invention has the following advantages:
  • the main production process of the composite sleeper with the filling material body in the core is the pultrusion process, which has high production efficiency, less waste of raw materials, good consistency of the integrity and cross-sectional shape, and unlimited length of the profile.
  • the sleeper is corrosion-resistant, does not require regular maintenance, causing environmental pollution and other problems, saving maintenance and protection costs, especially in some places with harsh working conditions.
  • the sleeper is modularized in the factory, which has less damage to the environment, convenient transportation and hoisting, and lower construction cost.
  • the sleeper can also be used for the sleeper to be repaired, that is, to replace the existing sleeper.
  • Figure 1 shows a schematic perspective view of a composite sleeper in accordance with one embodiment of the present invention
  • Figure 2 shows a cross-sectional view of the composite sleeper shown in Figure 1;
  • FIG. 3 is a view showing the internal structure of a fiber reinforced resin-based composite material of a composite sleeper according to an embodiment of the present invention
  • 4A, 4B, 4C, and 4D are diagrams showing internal structures of a fiber reinforced resin-based composite material of a composite sleeper according to still another embodiment of the present invention.
  • Figure 5 is a schematic view showing an example of a pipeline for manufacturing a composite sleeper according to the present invention.
  • Figure 6 shows a schematic view of another example of a pipeline for making a composite sleeper in accordance with the present invention.
  • Cross section means a section perpendicular to the "longitudinal” direction.
  • Figure 1 shows a schematic perspective view of a composite sleeper in accordance with one embodiment of the present invention.
  • the sleeper comprises a base profile 1 extending in the longitudinal direction (in the direction indicated by the arrow in Fig. 1).
  • the base profile 1 has a cavity that runs through in the longitudinal direction.
  • the cavity may be empty or may be filled with a core 2 to prevent moisture or the like from entering the cavity.
  • the base profile 1 of the sleeper shown in Fig. 1 has a rectangular cylindrical shape; that is, the base profile 1 can be regarded as forming a cylindrical body by hollowing out a smaller rectangular body in the longitudinal direction, the cylinder being The cross section is two rectangles nested.
  • Figure 2 shows a cross-sectional view of the composite sleeper of Figure 1 (the composite sleeper of Figure 2 has a core 2, which may also have no core).
  • X, Y in the figure are the thickness of the wall of the rectangular cylinder at two different positions. The thickness may be different at different locations or may be the same.
  • the aforementioned rectangular cylinders in addition to the four corners, have the same wall thickness, and the wall thickness is 8-25 mm.
  • the base profile 1 may be a fiber-reinforced resin-based composite material made of 60% to 85% by weight of a fiber reinforcing material and 15% to 40% of a resin.
  • the fiber-reinforced resin-based composite material includes a resin 5 including a fiber mat 6 (shown as a thick solid line in FIG. 3) and a fiber yarn 7 (as shown in FIG. 3). Point shown).
  • the fiber mat 6 is laid around the cavity in the base profile 1.
  • the fiber yarn 7 includes a plurality of fibers distributed in the longitudinal direction in the vicinity of the fiber mat 6.
  • the fiber yarn 7 provides tensile strength in the longitudinal direction.
  • fiber yarns generally have high strength only in the longitudinal direction and low strength in the transverse direction. If only fiber yarns are used, the resulting sleepers can only resist tensile stresses in the longitudinal direction and apply lateral or other stresses (for example, rails are mounted on rails, and when the train is running, the bolts are Overcoming the stress applied by the train to the sleepers in all directions), the sleepers will easily yield and break. Therefore, the composite material in the technical solution of the present invention is also reinforced with the fiber mat 6.
  • the fiber mat 6 may be a biaxial or multiaxial braided felt or mesh cloth, i.e., fibers are woven in more than two directions of its plane such that it has high mechanical properties in the plurality of directions described. .
  • the fiber mat 6 may be a fiberglass mat, a fiberglass mat, a fiberglass mat, a carbon fiber mat, an aramid cloth, a polyester cloth, or a mixture thereof.
  • the fiber mat 6 can be a three-axial series of felt mats. This three-axis normal angle is 0°/45°/-45° and 45°/90°/-45°. At the same time, the angle can be arbitrarily adjusted within ⁇ 20 to ⁇ 90°.
  • the total grammage of the fiber mat 6 can be selected from the range of 752 g/m 2 to 1242 g/m 2 .
  • the fiber mat 6 may have a radial breaking strength of 780 N/25 mm to 3000 N/25 mm and a latitudinal breaking strength of 650 N/25 mm to 2500 N/25 mm.
  • two fiber mats form a cavity in which the unit is wrapped around the base profile 1 in a cylindrical shape.
  • one skilled in the art can use one block as needed. It is also possible to use three, four or more fiber mats which are arranged in order from the inner layer to the outer layer of the base profile 1 like the two fiber mats shown in FIG.
  • the fiber mat may have a shape other than a cylindrical shape.
  • four planar fiber mats 61, 62, 63, 64 may be provided, and the fiber mats 61, 62, 63, 64 are respectively distributed on the four planar walls of the rectangular tubular base profile 1. in.
  • the four fiber mats surround the cavity of the base profile 1 so that the base profile 1 has the desired mechanical properties at various locations of its four walls and at various corners.
  • FIG. 4B there may be two fiber mats 65, 66.
  • the fiber mat 65 is folded into an inverted trough shape (having a cross section such as a "U" shape, as shown in FIG. 4B), covering an entire wall of the rectangular tubular base profile 1 and adjacent to the entire wall.
  • the fiber mat 66 is also folded into a trough shape (having a cross section such as a "U" shape, as shown in FIG.
  • planar fiber mats 67, 68, 69, 70 and two "U" shaped fiber mats 71, 72 there may be four planar fiber mats 67, 68, 69, 70 and two "U" shaped fiber mats 71, 72; wherein the planar fiber mats 67, 68, 69, 70 Located on the inner side of the "U” shaped fiber mats 71, 72, respectively distributed in the four planar walls of the rectangular tubular base profile 1, and the "U" shaped fiber mats 71, 72 are located in the planar fiber mats 67, 68.
  • the outer sides of 69, 70 respectively cover an entire wall of the rectangular tubular base profile 1 and about half of the walls adjacent to the entire wall; the two "U” shaped fiber mats 71, 72 are mutually “ “Bucking” covers the four walls of the base profile 1, that is, wraps around the cavity, which allows the base profile 1 to have the desired mechanical properties at various locations of its four walls and at various corners.
  • the planar fiber mats 67, 68, 69, 70 are shown on the inside of the "U" shaped fiber mats 71, 72, the former being located outside the latter. side.
  • FIG. 4D Yet another example of a fiber mat structure is shown in Figure 4D. As shown, it may have a planar fiber mat 73 and a "U" shaped fiber mat 74; wherein the planar fiber mat 73 is distributed in a planar wall of the rectangular tubular base profile 1; The "U" shaped fiber mats 74 are distributed in the three planar walls of the rectangular tubular base profile 1. The planar fiber mat 73 and the "U" shaped fiber mat 74 surround the cavity, which allows the base profile 1 to have the desired mechanical properties at various locations of its four walls and at various corners.
  • each such structure constitutes a "unit” in which a plurality of such "units" can be arranged in order from the inner layer to the outer layer of the base profile 1, as shown in the two tubular fiber mats shown in FIG.
  • one sleeper can have from one to four units, each unit comprising 1-3 layers of fiber mat laid to surround the cavity, such that there are about 1-10 layers of fiber mat. These units may be arranged in the same unit repeatedly, or different types of units may be sequentially arranged from the inside to the outside.
  • the "unit" of the fiber mat described in Figures 3, 4A, 4B, 4C and 4D has a plurality of fiber mats. These multiple fiber mats may be of the same type of fiber mat or different types of fiber mats, depending on the needs of the particular application.
  • the planar fiber mat 73 may be a fiberglass mat
  • the "U" fiber mat 74 may be a carbon fiber mat.
  • all of the fiber mats in the "unit” are made of the same type of fiber mat (for example, a glass fiber woven felt), different types of fiber mats having different strengths and weaves can be selected as needed.
  • the fiber mats 61, 62, 63, 64 shown in Fig. 4A may each be selected from fiber mats having a total gram weight in the range of 752 g/m 2 to 1242 g/m 2 , wherein the fiber mats 61 and 63 may be selected.
  • a 943 g/m 2 triaxial glass fiber woven felt, and fiber mats 62 and 64 may have a 934 g/m 2 triaxial fiberglass woven felt.
  • the fiber yarn 7 in the fiber reinforced material may be carbon fiber, glass fiber, aramid fiber, polyester fiber or a mixture thereof.
  • the fiber yarn 7 may be a glass fiber having a linear density of from 2400 tex to 9600 tex.
  • the tensile strength can be The tensile modulus of elasticity may be 7,000 MPa to 8000 MPa, and the elongation at break may be 1.5% to 4%.
  • the above resin 5 may be an unsaturated polyester resin (for example, a vinyl ester resin), a phenol resin, a polyurethane resin, an epoxy resin, or the like.
  • the fiber reinforcing material is a fiber yarn and a fiber mat, and the fiber reinforcing material is 60% to 70% by weight, an unsaturated polyester resin or a vinyl ester.
  • the resin is 30% to 40%.
  • the fiber reinforcement is a fiber yarn or a fiber yarn and a fiber mat, and the fiber reinforcement is 65% to 85% by weight, and the polyurethane resin is 15% to 35%.
  • the resin 5 is an epoxy resin
  • the fiber reinforcing material is a fiber yarn or a fiber yarn and a fiber mat, and the fiber reinforcing material is 65% to 85% by weight, and the epoxy resin is 15% to 35%.
  • the material of the core 2 may be selected from the group consisting of phenolic foam, polyurethane foam, polyvinyl chloride foam, polystyrene foam, recycled plastic, recycled plastic and wood chip mixture.
  • Figure 5 shows a schematic diagram of one example of a pipeline used to make a composite sleeper in accordance with the present invention.
  • One embodiment of a method of manufacturing the above composite sleeper according to the present invention will be described with reference to FIG. The method includes the following steps:
  • Pre-forming the layered structure of the resin-impregnated fiber-reinforced material is drawn into the cavity of the preforming device 26 at a predetermined speed to cause the resin impregnated fiber
  • the reinforcing material removes excess resin, eliminates bubbles, and shapes it close to the shape of the inlet of the forming mold;
  • Figure 6 shows a schematic view of another example of a pipeline used to make a composite sleeper in accordance with the present invention. Another embodiment of a method of manufacturing the above composite sleeper according to the present invention will be described with reference to FIG. The method is similar to the method described in the above embodiments, however, the fiber reinforcement material is divided into two groups, the first group of fiber reinforcement materials are laid in the inner layer of the base profile (1), and the second group of fiber reinforcement materials are laid. In the outer layer of the base profile 1.
  • the first set of fiber reinforcements are directed through a first set of guides 23 to a first set of impregnation apparatus 24, which are initially formed by impregnation of the resin through a first set of preforming apparatus 26; After being guided by the second group of guiding devices 23 to the second group of impregnation devices 24, after being impregnated with the resin, they are solidified together with the first group of impregnated fiber reinforcing materials through a second set of preforming equipment into the cavity of the forming mold.
  • the fiber mat is laid around the cavity in the base profile 1 into two units of fiber mats arranged in sequence from the inner layer to the outer layer of the base profile 1, the fiber mat of each unit being laid to wrap around the cavity A plurality of fiber mats of the body.
  • the fiber reinforcing materials are divided into two groups, which are respectively impregnated with a resin and subjected to preforming to form the fiber reinforcing material into two layers.
  • the fiber reinforcing materials may be divided into three groups, four groups or more as needed, respectively impregnating the resin and performing preforming to form the fiber reinforcing material into three, four or more Units arranged in order from the inside to the outside.
  • the molding die 27 has a length of 900 to 1200 mm.
  • the molding die 27 can be provided with two different heating zones, one zone having a temperature of 60-75 ° C, two The zone temperature is 80-120 °C.
  • the composite sleeper manufactured by the above method has no core.
  • the core 2 is added to the base profile 1 by the following two methods to obtain a core-filled composite sleeper: 1): a sleeper obtained by in-mold curing to obtain a composite of the base profile 1 and the core material; 2)
  • the rectangular cylinder of the base profile 1 is produced separately and then the cavity of the rectangular cylinder of the base profile 1 is filled with the core 2 material.

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Abstract

公开了一种复合材料轨枕及其制造方法。轨枕包括沿着纵向方向延伸的基础型材，基础型材具有沿着纵向方向贯通的腔体。基础型材是纤维增强树脂基复合材料，纤维增强树脂基复合材料包括树脂和纤维增强材料，纤维增强材料包括纤维毡和纤维纱，并且纤维毡在基础型材中绕腔体铺层，纤维纱包括多根，沿着纵向方向分布在纤维毡附近。并且，纤维毡在基础型材中铺设成一个单元的纤维毡或从基础型材的内层向外层依次排列的多个单元的纤维毡，每个单元的纤维毡包括多块纤维毡，多块纤维毡铺设成包绕腔体。

Description

一种复合材料轨枕及其制造方法 技术领域
本发明涉及复合材料领域，尤其适用于铁路线路中支撑钢轨的复合材料轨枕。
背景技术
轨枕是现在铁路交通运输领域中不可缺少的材料。其作用是承垫于钢轨之下，通过相互连接零件保持两股或多股钢轨之间的轨距、水平、高低和方向等几何形位，以及使钢轨所承受的各种载荷平均分布于道床基础上。因此轨枕必须具有坚固性、耐久性和弹性。
在铁路建设工程中所使用的轨枕有：木质枕木、钢筋混凝土枕木和钢质枕木等。
公知的木质枕轨由于具有弹性好、易于加工、使用方便等优点，在桥梁、道岔等特殊地段上得到广泛使用。但由于取材的原因，木枕的强度和耐久性不够均匀，会加大轮轨动力作用，使得木枕的使用寿命短。在露天条件下受环境和气候的影响，使木枕容易老化、腐朽及劈裂等，在施工过程中木枕防腐层一旦破坏，这种老化腐朽现象会明显加剧。在长期列车载荷的冲击和碾压下，易造成木枕机械磨损，缩短使用寿命，并引起弹性不一致。木枕上的道钉孔会因使用日久而松弛，持钉能力下降，造成行车安全隐患。另外，优质木材资源比较缺乏，木材原材料供应量日益减小，也越来越不符合环保和生态保护要求。
钢筋混凝土轨枕也属常用的轨枕，其克服了木制轨枕使用寿命短的缺陷，具有寿命长、稳定性好的特点，但是由于该类型轨枕硬度大，所以其弹性较差，消音减震效果也差，使用一段时间后容易出现裂纹的问题，影响铁路的安全运营。钢筋混凝土轨枕较之木制轨枕其重很大，体积笨重，使得其铺设、养护维修以及运输都很不方便。
钢制轨枕的制造成本很高，不能被广泛应用。铺设后与列车之间发生摩擦的噪音很大。
此外由于混凝土轨枕和钢制轨枕自身的绝缘性比较差，因此钢筋混凝土和钢制轨枕在使用过程中还需进行二次绝缘，特别是在电气化线路中，绝缘性要求更高。另外，在制备原材料水泥和钢筋过程中会排放大量的CO2，据报道，制备水泥和钢筋过程中排放的CO2量分别为木轨枕的10倍和200倍，造成环境污染，不符合环保、低碳的要求。
发明内容
为了克服现有技术的轨枕的上述不足，本发明提供了一种复合材料轨枕，所述轨枕包括沿着纵向方向延伸的基础型材，所述基础型材具有沿着所述纵向方向贯通的腔体。所述基础型材是纤维增强树脂基复合材料，所述纤维增强树脂基复合材料包括树脂和纤维增强材料，所述纤维增强材料包括纤维毡和纤维纱，并且所述纤维毡在所述基础型材中绕所述腔体铺层，所述纤维纱包括多根，沿着所述纵向方向分布在所述纤维毡附近。并且，所述纤维毡在所述基础型材中铺设成一个单元的纤维毡或从所述基础型材的内层向外层依次排列的多个单元的纤维毡，每个单元的纤维毡包括多块纤维毡，所述多块纤维毡铺设成包绕所述腔体。
本发明还提供了一种制造上述复合材料轨枕的方法，其包括以下步骤：(1)提供适当数量的纤维增强材料和树脂，所述纤维增强材料包括纤维纱、纤维毡，将所述增强材料分为多组；(2)导向：通过导向装置将所述纤维增强材料的一组按预定图案排列成层状结构，并以预定速度引导至盛装有树脂的浸渍设备；(3)浸渍：将按预定图案排列的纤维增强材料的所述层状结构以预定的速度通过所述盛装有树脂的浸渍设备；(4)预成型：使得浸渍过树脂的纤维增强材料的所述层状结构以预定的速度牵引进入预成型设备的型腔中，使浸渍了树脂 的纤维增强材料除去多余的树脂，排除气泡，并使其形状接近于成型模具的进口形状；(5)对所述多组纤维增强材料的其它组重复上述步骤(2)-(4)，使得所述多组纤维毡在所述基础型材中铺设成从所述基础型材的内层向外层依次排列的多个单元的纤维毡，每个单元的纤维毡包括铺设成包绕所述腔体的多块纤维毡；(6)成型固化：将浸渍过树脂的纤维增强材料经过预成型设备的型腔以预定的速度牵引进入成型模具，通过成型模具模内固化得到轨枕所需的基础型材的结构，并通过成型模具对所述纤维增强材料加热；(7)切割：将所述基础型材的结构切割成具有所需长度的基础型材。
与现有技术相比，本发明具有以下优点：
1、芯部具有填充材料体的复合材料轨枕主要生产工艺为拉挤工艺，此生产效率高，原材料浪费少，整体性和截面形状一致性好，型材长度不受限制。
2、自重轻、强度高，重量仅为钢材的1/3-1/4。
3、可设计性高：根据轨枕所要求承受的负荷，设计制造不同厚度、截面、形状、尺寸及不同强度的轨枕。
4、耐腐蚀性好：轨枕耐腐蚀，无须定期维护保养，造成环境污染等问题，节约了维修和防护费用，尤其在一些工作环境恶劣的地方使用。
5、热导率低、膨胀系数小，在有温差时所产生的热应力比金属多得多。
6、安装方便：轨枕在工厂中模块化生产，对于环境的破坏小，运输吊装方便，降低建造成本。
7、轨枕除了用于新建的铁路上，还可用于待维修的轨枕，即替换现有的轨枕。
附图说明
现在参照附图描述本发明的实施例，其中：
图1示出了根据本发明的一个实施例的复合材料轨枕的示意性立体图；
图2示出了图1所示的复合材料轨枕的横截面图；
图3示出了根据本发明的一个实施例的复合材料轨枕的纤维增强树脂基复合材料的内部结构图；
图4A、4B、4C和4D示出了根据本发明的另外四个实施例的复合材料轨枕的纤维增强树脂基复合材料的内部结构图；
图5示出了根据本发明的制造复合材料轨枕的流水线一个示例的示意图；
图6示出了根据本发明的制造复合材料轨枕的流水线另一个示例的示意图。
具体实施方式
在附图中使用的相同附图标记表示相同或者技术等效的元件。
术语“纵向”和“横向”分别规定元件沿着给定方向和在垂直于这个方向的平面中延伸。“横截面”指垂直于所述“纵向”方向的截面。
以下依次说明：(一)复合材料轨枕的实施方式；以及(二)制造该复合材料轨枕的方法的实施方式。
<复合材料轨枕>
参见图1。图1示出了根据本发明的一个实施例的复合材料轨枕的示意性立体图。轨枕包括沿着纵向方向(如图1中箭头所示方向)延伸的基础型材1。基础型材1具有沿着所述纵向方向贯通的腔体。腔体可以是空的，也可以填充有芯部2以防止潮气等进入腔体中。
图1中所示出的轨枕的基础型材1具有矩形筒形状；也即，基础型材1可以看作是将一个矩形体沿着纵向方向掏空一较小的矩形体而形成筒，该筒的横截面为嵌套的两个矩形。
图2示出了图1所示复合材料轨枕的横截面图(图2所示复合材料轨枕具有芯部2，其也可以不具有芯部)。图中的X、Y是矩形筒在两个不同位置处的壁的厚度。该厚度在不同位置处的值可以不同，也可以相同。在图2中，除四个角附近，前述矩形筒具有相同的壁厚，该壁厚为8-25mm。
基础型材1可以是由60％-85％重量比的纤维增强材料和15％-40％的树脂制成的纤维增强树脂基复合材料。
图3是根据本发明的一个实施例的复合材料轨枕的横截面图，其示出轨枕的基础型材1的纤维增强树脂基复合材料的内部结构图。如图3所示，纤维增强树脂基复合材料包括树脂5和纤维增强材料，所述纤维增强材料包括纤维毡6(如图3中粗实线所示)和纤维纱7(如图3中的点所示)。纤维毡6在基础型材1内绕前述腔体铺层。纤维纱7包括多根，沿着纵向方向分布在纤维毡6附近。
纤维纱7提供了纵向方向的拉伸强度。然而，纤维纱通常只在纵向方向具有高的强度，在横向方向的强度较低。若只使用纤维纱，则所获得的轨枕只能较好地抵抗在纵向方向的拉伸应力，对其施加横向方向或其它方向的应力(例如，轨枕安装上铁轨，列车在运行时，螺栓为克服列车运行对轨枕施加各个方向的应力)，则轨枕会很容易屈服断裂。因此，本发明的技术方案中的复合材料还使用纤维毡6进行增强。纤维毡6可以是双轴向或多轴向的编织毡或网格布，即在其平面的两个以上的方向编织有纤维，从而使得其在所述的多个方向上具有高的力学性质。
纤维毡6可以是玻璃纤维毡、玻璃纤维编织毡、玻璃纤维网格布、碳纤维毡、芳纶布、涤纶布或其混合物。作为示例，纤维毡6可以是三轴向系列的编织毡。此三轴向常规角度为0°/45°/-45°和45°/90°/-45°。同时角度可在±20～±90°内任意调整。纤维毡6的总克重可在752g/m2～1242g/m2范围内选用。纤维毡6的径向断裂强度可以是780N/25mm～3000N/25mm，其纬向断裂强度可以是 650N/25mm～2500N/25mm。
在图3中，两块纤维毡构成一个单元呈筒状包绕基础型材1的腔体。然而，本领域技术人员可以根据需要采用1块。也可以采用3块、4块或更多块纤维毡，这些纤维毡如图3所示的两块纤维毡一样从基础型材1的内层向外层依次排列。
此外，纤维毡可以具有筒状之外的形状。例如，如图4A所示，可以具有4块平面状纤维毡61、62、63、64，纤维毡61、62、63、64分别分布在矩形筒状的基础型材1的4个平面状的壁中。这4块纤维毡包绕基础型材1的腔体，从而使得基础型材1在其4壁的各个位置处以及各个角落处都具有所需的力学性质。
再例如，如图4B所示，可以具有2块纤维毡65、66。其中，纤维毡65被折成的倒置的槽形(其横截面如“U”形，如图4B所示)，覆盖矩形筒状的基础型材1的一整个壁以及与该整个壁相邻的两个壁的约半个壁；而纤维毡66也被折成的槽形(其横截面如“U”形，如图4B所示)，覆盖矩形筒状的基础型材1的一整个壁以及与该整个壁相邻的两个壁的约半个壁；两块“U”形纤维毡65、66相互“扣合”，覆盖基础型材1的四壁，也即，包绕腔体，这使得基础型材1在其4壁的各个位置处以及各个角落处都具有所需的力学性质。
又例如，如图4C所示，可以具有4块平面状纤维毡67、68、69、70和两块“U”形纤维毡71、72；其中，平面状纤维毡67、68、69、70位于“U”形纤维毡71、72的内侧，分别分布在矩形筒状的基础型材1的4个平面状的壁中；而“U”形纤维毡71、72位于平面状纤维毡67、68、69、70的外侧，分别覆盖矩形筒状的基础型材1的一整个壁以及与该整个壁相邻的两个壁的约半个壁；两块“U”形纤维毡71、72相互“扣合”，覆盖基础型材1的四壁，也即，包绕所述腔体，这使得基础型材1在其4壁的各个位置处以及各个角落处都具有所需的力学性质。在图4C中，平面状纤维毡67、68、69、70被示出为位于“U”形纤维毡71、72的内侧，前者也可位于后者的外 侧。
如图4D示出了纤维毡结构的又一示例。如图所示，可以具有1块平面状纤维毡73和一块“U”形纤维毡74；其中，平面状纤维毡73分布在矩形筒状的基础型材1的1个平面状的壁中；而“U”形纤维毡74分布在矩形筒状的基础型材1的3个平面状的壁中。该平面状纤维毡73和该“U”形纤维毡74包绕所述腔体，这使得基础型材1在其4壁的各个位置处以及各个角落处都具有所需的力学性质。
上述图3、4A、4B、4C和4D中描述了“一层”(图4A和图4B)或“两层”(图3和图4C)纤维毡结构。每个这种结构构成一个“单元”，多个这样的“单元”可以从基础型材1的内层向外层依次排列，如图3所示的两块筒状纤维毡一样。通常，一个轨枕可具有1-4个单元，每个单元包括铺设成包绕腔体的1-3层纤维毡，这样共有约1-10层纤维毡。这些单元可以是同一种单元反复排列，也可以是不同种类的单元依次从内向外排列。
如上所述，在图3、4A、4B、4C和4D描述的纤维毡的“单元”具有多块纤维毡。根据具体应用的需要，这些多块纤维毡可以是相同种类的纤维毡，也可以是不同种类的纤维毡。例如，在如图4D所图示的纤维毡“单元”中，平面状纤维毡73可以是玻璃纤维编织毡，而“U”形纤维毡74可以是碳纤维毡。此外，即使该“单元”中的所有纤维毡都采用同一种类的纤维毡(例如玻璃纤维编织毡)，也可以根据需要选用不同型号的具有不同强度和织法的纤维毡。例如，图4A所示的纤维毡61、62、63、64均可以在总克重在752g/m2～1242g/m2范围内的纤维毡中选用，其中，纤维毡61和63可选择约943g/m2的三轴向玻璃纤维编织毡，而纤维毡62和64可选择934g/m2的三轴向玻璃纤维编织毡。
纤维增强材料中的纤维纱7可以是碳纤维、玻璃纤维、芳纶纤维、涤纶纤维或者其混合物。作为示例，纤维纱7可以是玻璃纤维，其线密度可在2400tex～9600tex范围内选用。其拉伸强度可以是 100MPa～300MPa，拉伸弹性模量可以是7000MPa～8000MPa、断裂时的伸长率可以是1.5％～4％。
上述树脂5(参见图3)可以是不饱和聚酯树脂(例如，乙烯基酯树脂)、酚醛树脂、聚氨酯树脂、环氧树脂等。
以下为树脂和纤维增强材料的成分和配比的示例。
树脂5是不饱和聚酯树脂、乙烯基酯树脂或酚醛树脂时，纤维增强材料为纤维纱和纤维毡，按重量比纤维增强材料为60％-70％，不饱和聚酯树脂或乙烯基酯树脂为30％-40％。树脂5是聚氨酯树脂复合时，纤维增强材料为纤维纱或者纤维纱和纤维毡，按重量比纤维增强材料为65％-85％，聚氨酯树脂为15％-35％。树脂5是环氧树脂时，纤维增强材料为纤维纱或者纤维纱和纤维毡，按重量比纤维增强材料为65％-85％，环氧树脂为15％-35％。
芯部2的材料可以选自以下材料组成的组：酚醛泡沫、聚氨酯泡沫、聚氯乙烯泡沫、聚苯乙烯泡沫、再生塑料、再生塑料与木屑混合物。
<制造复合材料轨枕的方法>
图5示出了根据本发明的制造复合材料轨枕的所使用的流水线的一个示例的示意图。参照图5说明根据本发明的制造上述复合材料轨枕的方法一个实施例。该方法包括以下步骤：
(1)提供适当数量的纤维增强材料和树脂，所述纤维增强材料包括纤维纱21、纤维毡22，通过导向装置23将所述纤维增强材料按预定图案排列成层状结构，并以预定速度引导至盛装有树脂的浸渍设备24；
(2)浸渍：将按预定图案排列的纤维增强材料的所述层状结构以预定的速度通过所述盛装有树脂的浸渍设备24；
(3)预成型：使得浸渍过树脂的纤维增强材料的所述层状结构以预定的速度牵引进入预成型设备26的型腔中，使浸渍了树脂的纤 维增强材料除去多余的树脂，排除气泡，并使其形状接近于成型模具的进口形状；
(4)成型固化：将浸渍过树脂的纤维增强材料经过预成型设备26的型腔以预定的速度牵引进入成型模具27，通过成型模具27模内固化得到轨枕所需的结构，并通过成型模具对所述纤维增强材料加热；
(5)切割：将所述结构切割成具有所需长度的轨枕。
图6示出了根据本发明的制造复合材料轨枕的所使用的流水线的另一个示例的示意图。参照图6说明根据本发明的制造上述复合材料轨枕的方法另一个实施例。该方法与上述实施例中所述的方法类似，但是，所述纤维增强材料被分为两组，第一组纤维增强材料铺设在基础型材(1)的内层，第二组纤维增强材料铺设在基础型材1的外层。在该方法中，将第一组纤维增强材料经过第一组导向装置23导向到第一组浸渍设备24，经浸渍树脂后通过第一组预成型设备26初步成型；同时第二组纤维增强材料经过第二组导向装置23导向到第二组浸渍设备24，经浸渍树脂后与第一组浸渍过的纤维增强材料一齐经过第二组预成型设备进入成型模具型腔内固化。这样，纤维毡在基础型材1内绕腔体铺设成从所述基础型材1的内层向外层依次排列的两个单元的纤维毡，每个单元的纤维毡包括铺设成包绕所述腔体的多块纤维毡。
在上述实施例中，将纤维增强材料分为两组，分别对其浸渍树脂和实施预成型，以便将纤维增强材料形成为两层。实际上，可以根据需要将纤维增强材料分为三组、四组或更多组，分别对其浸渍树脂和实施预成型，以形成将纤维增强材料形成为三个、四个或更多个从内向外依次排列的单元。
在上述实施例中，所述成型模具27的长度为900-1200mm。成型模具27可以设置有两个不同的加热区，一区温度为60-75℃，二 区温度为80-120℃。
以上方法所制造的复合材料轨枕没有芯部。通过以下两种方法在基础型材1中加入芯部2从而获得填充有芯部的复合材料轨枕：1)：经过模内固化得到基础型材1与芯部材料一起复合而成的轨枕；2)先单独生产出基础型材1的矩形筒然后再对基础型材1的矩形筒的腔体填充芯部2材料。
以上所述的实施例仅仅是对本发明的优选实施方式进行描述，并非对本发明的范围进行限定，在不脱离本发明设计精神的前提下，本领域普通技术人员对本发明的技术方案做出的各种变形和改进，均应落入本发明权利要求书确定的保护范围内。

Claims (18)

  1. 一种复合材料轨枕，所述轨枕包括沿着纵向方向延伸的基础型材(1)，所述基础型材(1)具有沿着所述纵向方向贯通的腔体，
    其特征在于：所述基础型材(1)是纤维增强树脂基复合材料，所述纤维增强树脂基复合材料包括树脂(5)和纤维增强材料，所述纤维增强材料包括纤维毡(6)和纤维纱(7)，并且所述纤维毡在所述基础型材中绕所述腔体铺层，所述纤维纱包括多根，沿着所述纵向方向分布在所述纤维毡附近，
    并且，所述纤维毡在所述基础型材(1)中铺设成一个单元的纤维毡或从所述基础型材(1)的内层向外层依次排列的多个单元的纤维毡，每个单元的纤维毡包括多块纤维毡，所述多块纤维毡铺设成包绕所述腔体。
  2. 根据权利要求1所述的复合材料轨枕，其特征在于，所述基础型材(1)是矩形筒形，所述矩形筒形的四个壁的相对的两个壁的厚度(x)是8-25mm，所述矩形筒形的四个壁的另两个壁的厚度(y)是8-25mm。
  3. 根据权利要求1所述的复合材料轨枕，其特征在于，所述基础型材(1)中铺设有1-4个单元的纤维毡。
  4. 根据权利要求1所述的复合材料轨枕，其特征在于，至少一个单元的纤维毡的多块纤维毡中，至少有一块纤维毡的强度和织法不同于其它的纤维毡。
  5. 根据权利要求1所述的复合材料轨枕，其特征在于，所述基础型材(1)是矩形筒形，所述一个或多个单元的纤维毡中的至少一个单元包括4块平面状纤维毡(61、62、63、64)，所述4块平面状纤维毡(61、62、63、64)分别分布在矩形筒形的基础型材(1)的4个平面状的壁中。
  6. 根据权利要求1所述的复合材料轨枕，其特征在于，所述基 础型材(1)是矩形筒形，所述一个或多个单元的纤维毡中的至少一个单元包括2块“U”形纤维毡(65、66)，其中，一块“U”形纤维毡(65)覆盖矩形筒形的基础型材(1)的一整个壁以及与该整个壁相邻的两个壁的约半个壁，而另一块“U”纤维毡(66)覆盖矩形筒状的基础型材1的一整个壁以及与该整个壁相邻的两个壁的约半个壁，两块“U”形纤维毡(65、66)相互“扣合”。
  7. 根据权利要求1所述的复合材料轨枕，其特征在于，所述基础型材(1)是矩形筒形，所述一个或多个单元的纤维毡中的至少一个单元包括4块平面状纤维毡(67、68、69、70)和两块“U”形纤维毡(71、72)，其中，所述平面状纤维毡(67、68、69、70)位于所述“U”形纤维毡(71、72)的内侧或外侧，分别分布在所述矩形筒形的基础型材(1)的4个平面状的壁中；而所述“U”形纤维毡(71、72)位于所述平面状纤维毡(67、68、69、70)的外侧或内侧，分别覆盖矩形筒状的基础型材(1)的一整个壁以及与该整个壁相邻的两个壁的约半个壁，所述两块“U”形纤维毡(71、72)相互“扣合”。
  8. 根据权利要求1所述的复合材料轨枕，其特征在于，所述基础型材(1)是矩形筒形，所述一个或多个单元的纤维毡中的至少一个单元包括1块平面状纤维毡(73)和一块“U”形纤维毡(74)，其中，所述平面状纤维毡(73)分布在所述矩形筒状的基础型材(1)的1个平面状的壁中，而“U”形纤维毡(74)分布在所述矩形筒状的基础型材(1)的其它3个平面状的壁中。
  9. 根据权利要求1-8之一所述的复合材料轨枕，其特征在于，所述树脂是不饱和聚酯树脂、酚醛树脂、环氧树脂或者聚氨酯树脂。
  10. 根据权利要求1-8之一所述的复合材料轨枕，其特征在于，所述纤维毡是玻璃纤维毡、玻璃纤维编织毡、玻璃纤维网格布、碳纤维毡、芳纶布、涤纶布或其混合物。
  11. 根据权利要求1-8之一所述的复合材料轨枕，其特征在于， 所述纤维纱是碳纤维、玻璃纤维、芳纶纤维、涤纶纤维或者其混合物。
  12. 根据权利要求1-8之一所述的复合材料轨枕，其特征在于，所述基础型材(1)由60％-85％重量比的纤维增强材料和15％-40％的树脂制成。
  13. 根据权利要求1-8之一所述的复合材料轨枕，其特征在于：所述腔体中填充有芯部(2)，所述芯部(2)的材料选自以下材料组成的组：酚醛泡沫、聚氨酯泡沫、聚氯乙烯泡沫、聚苯乙烯泡沫、再生塑料、再生塑料与木屑混合物。
  14. 一种制造根据权利要求1-12之一所述的复合材料轨枕的方法，其特征在于，包括以下步骤：
    (1)提供适当数量的纤维增强材料和树脂，所述纤维增强材料包括纤维纱(21)、纤维毡(22)，通过导向装置(23)将所述纤维增强材料按预定图案排列成层状结构，并以预定速度引导至盛装有树脂的浸渍设备(24)；
    (2)浸渍：将按预定图案排列的纤维增强材料的所述层状结构以预定的速度通过所述盛装有树脂的浸渍设备(24)；
    (3)预成型：使得浸渍过树脂的纤维增强材料的所述层状结构以预定的速度牵引进入预成型设备(26)的型腔中，使浸渍了树脂的纤维增强材料除去多余的树脂，排除气泡，并使其形状接近于成型模具的进口形状；
    (4)成型固化：将浸渍过树脂的纤维增强材料经过预成型设备(26)的型腔以预定的速度牵引进入成型模具(27)，通过成型模具模内固化得到轨枕所需的基础型材(1)的结构，并通过成型模具对所述纤维增强材料加热；
    (5)切割：将所述基础型材(1)的结构切割成具有所需长度的基础型材(1)。
  15. 一种制造根据权利要求1-12之一所述的复合材料轨枕的方法，其特征在于，包括以下步骤：
    (1)提供适当数量的纤维增强材料和树脂，所述纤维增强材料包括纤维纱(21)、纤维毡(22)，将所述增强材料分为多组；
    (2)导向：通过导向装置(23)将所述纤维增强材料的一组按预定图案排列成层状结构，并以预定速度引导至盛装有树脂的浸渍设备(24)；
    (3)浸渍：将按预定图案排列的纤维增强材料的所述层状结构以预定的速度通过所述盛装有树脂的浸渍设备(24)；
    (4)预成型：使得浸渍过树脂的纤维增强材料的所述层状结构以预定的速度牵引进入预成型设备(26)的型腔中，使浸渍了树脂的纤维增强材料除去多余的树脂，排除气泡，并使其形状接近于成型模具的进口形状；
    (5)对所述多组纤维增强材料的其它组重复上述步骤(2)-(4)，使得所述多组纤维毡在所述基础型材(1)中铺设成从所述基础型材(1)的内层向外层依次排列的多个单元的纤维毡，每个单元的纤维毡包括铺设成包绕所述腔体的多块纤维毡；
    (6)成型固化：将浸渍过树脂的纤维增强材料经过预成型设备(26)的型腔以预定的速度牵引进入成型模具(27)，通过成型模具模内固化得到轨枕所需的基础型材(1)的结构，并通过成型模具对所述纤维增强材料加热；
    (7)切割：将所述基础型材(1)的结构切割成具有所需长度的基础型材(1)。
  16. 一种制造根据权利要求13所述的复合材料轨枕的方法，其特征在于，包括以下步骤：
    (1)提供适当数量的纤维增强材料和树脂，所述纤维增强材料包括纤维纱(21)、纤维毡(22)，将所述增强材料分为多组；
    (2)导向：通过导向装置(23)将所述纤维增强材料的一组按预定图案排列成层状结构，并以预定速度引导至盛装有树脂的浸渍设备(24)；
    (3)浸渍：将按预定图案排列的纤维增强材料的所述层状结构以预定的速度通过所述盛装有树脂的浸渍设备(24)；
    (4)预成型：使得浸渍过树脂的纤维增强材料的所述层状结构以预定的速度牵引进入预成型设备(26)的型腔中，使浸渍了树脂的纤维增强材料除去多余的树脂，排除气泡，并使其形状接近于成型模具的进口形状；
    (5)对所述纤维增强材料的其它组重复上述步骤(2)-(4)，使得所述多组纤维毡在所述基础型材(1)中铺设成从所述基础型材(1)的内层向外层依次排列的多个单元的纤维毡，每个单元的纤维毡包括铺设成包绕所述腔体的多块纤维毡；
    (6)成型固化：将浸渍过树脂的纤维增强材料经过预成型设备(26)的型腔以预定的速度牵引进入成型模具(27)，通过成型模具模内固化得到轨枕所需的基础型材(1)的结构，并通过成型模具对所述纤维增强材料加热；
    (7)切割：将所述基础型材(1)的结构切割成具有所需长度的基础型材(1)。
    (8)填充：对所述基础型材(1)的腔体填充芯部(2)材料。
  17. 一种制造根据权利要求13所述的复合材料轨枕的方法，其特征在于，包括以下步骤：
    (1)提供适当数量的纤维增强材料和树脂，所述纤维增强材料包括纤维纱(21)、纤维毡(22)，将所述增强材料分为多组；
    (2)导向：通过导向装置(23)将所述纤维增强材料的一组按预定图案排列成层状结构，并以预定速度引导至盛装有树脂的浸渍设备(24)；
    (3)浸渍：将按预定图案排列的纤维增强材料的所述层状结构以预定的速度通过所述盛装有树脂的浸渍设备(24)；
    (4)预成型：使得浸渍过树脂的纤维增强材料的所述层状结构以预定的速度牵引进入预成型设备(26)的型腔中，使浸渍了树脂的 纤维增强材料除去多余的树脂，排除气泡，并使其形状接近于成型模具的进口形状；
    (5)对所述纤维增强材料的其它组重复上述步骤(2)-(4)，使得所述多组纤维毡在所述基础型材(1)中铺设成从所述基础型材(1)的内层向外层依次排列的多个单元的纤维毡，每个单元的纤维毡包括铺设成包绕所述腔体的多块纤维毡；
    (6)成型固化：将浸渍过树脂的纤维增强材料经过预成型设备(26)的型腔以预定的速度牵引进入成型模具(27)，通过成型模具模内固化得到轨枕所需的基础型材(1)的结构，并通过成型模具对所述纤维增强材料加热，与此同时，芯部(2)材料与基础型材(1)的结构一起复合而成；
    (7)切割：将与芯部(2)一起复合而成的所述基础型材(1)的结构切割成具有所需长度的轨枕。
  18. 根据权利要求14-17之一所述的方法，其特征在于，所述成型模具的长度为900-1200mm，所述成型模具设置有两个个不同的加热区，一区温度为60-75℃，二区温度为80-120℃。
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