CN222513086U - One-piece synthetic sleeper and preparation device - Google Patents
One-piece synthetic sleeper and preparation device Download PDFInfo
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- CN222513086U CN222513086U CN202420533830.XU CN202420533830U CN222513086U CN 222513086 U CN222513086 U CN 222513086U CN 202420533830 U CN202420533830 U CN 202420533830U CN 222513086 U CN222513086 U CN 222513086U
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- 241001669679 Eleotris Species 0.000 title claims abstract description 118
- 238000002360 preparation method Methods 0.000 title claims abstract description 12
- 239000003365 glass fiber Substances 0.000 claims abstract description 113
- 229920005749 polyurethane resin Polymers 0.000 claims abstract description 83
- 239000004744 fabric Substances 0.000 claims abstract description 56
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 17
- 239000011159 matrix material Substances 0.000 claims abstract description 15
- 239000002131 composite material Substances 0.000 claims description 107
- 239000003292 glue Substances 0.000 claims description 35
- 238000002347 injection Methods 0.000 claims description 27
- 239000007924 injection Substances 0.000 claims description 27
- 239000000463 material Substances 0.000 claims description 26
- 238000002156 mixing Methods 0.000 claims description 24
- 238000007598 dipping method Methods 0.000 claims description 23
- 239000000835 fiber Substances 0.000 claims description 19
- 229920002635 polyurethane Polymers 0.000 claims description 11
- 239000004814 polyurethane Substances 0.000 claims description 11
- 230000002787 reinforcement Effects 0.000 claims description 10
- 238000005470 impregnation Methods 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 4
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- 238000005336 cracking Methods 0.000 abstract description 7
- 238000004519 manufacturing process Methods 0.000 description 19
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- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 5
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- 238000001125 extrusion Methods 0.000 description 4
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- 239000012779 reinforcing material Substances 0.000 description 4
- 229920005830 Polyurethane Foam Polymers 0.000 description 3
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- 239000011248 coating agent Substances 0.000 description 2
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- 238000009827 uniform distribution Methods 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 229920002748 Basalt fiber Polymers 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
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- 238000009413 insulation Methods 0.000 description 1
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 description 1
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- 238000005259 measurement Methods 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
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Abstract
The utility model provides an integrally formed synthetic sleeper and a preparation device, which comprise a polyurethane resin matrix, wherein continuous glass fibers are longitudinally arranged in the polyurethane resin matrix and used for longitudinally reinforcing the synthetic sleeper, the surface of the polyurethane resin matrix is provided with a reinforcing layer consisting of glass fiber fabrics and polyurethane resin, the thickness of the reinforcing layer is 1-10 mm, and the integral strength of the synthetic sleeper can be remarkably improved and transverse cracking is avoided.
Description
Technical Field
The utility model relates to the technical field of rail transit, in particular to an integrally formed composite sleeper and a preparation device.
Background
The sleeper is an important accessory in the field of rail transit, can uniformly transfer the load transferred by the train to the track bed, and plays an important role in the stable and safe operation of the rail transit. At present, the most widely used sleeper is a wood sleeper and a reinforced concrete sleeper in the global scope, but the wood sleeper has the problems of easy decay and aging, uneven strength, high water absorption rate and the like, and the reinforced concrete sleeper has the problems of higher later maintenance cost, short service life, poor toughness, heavy weight, difficult installation, difficult on-site punching processing and the like, so in recent years, the novel composite sleeper is widely studied in all countries of the world.
The polyurethane foam synthetic sleeper is a composite material synthetic sleeper formed by glass fiber reinforced polyurethane foam, is widely applied because of the advantages of light weight, high strength, corrosion resistance, insulation, good weather resistance, high production and installation efficiency and the like, but the synthetic sleeper in the prior art also has the problems of unidirectional continuous glass fiber reinforcement, transverse non-fiber reinforcement, transverse cracking risk in the use process, smooth demoulding of the sleeper by spraying a release agent on the surface of a die sleeper when the synthetic sleeper is produced, polishing and spraying paint on the surface of a product after demoulding, complex production procedures and more VOC and dust pollution.
Disclosure of utility model
In view of the above, the utility model aims to provide an integrally formed composite sleeper and a preparation device, one of the problems is that unidirectional continuous glass fiber reinforcement is used for the composite sleeper in the prior art, no fiber reinforcement exists in the transverse direction, the risk of transverse cracking exists in the use process, and the other problem is that a release agent needs to be sprayed on the surface of the sleeper to enable the sleeper to be smoothly demolded during production, polishing and paint spraying are needed on the surface of a product after demolding, the production process is complex, and more VOC and dust pollution are generated.
In order to achieve the above purpose, the technical scheme of the utility model is realized as follows:
The integrated forming composite sleeper comprises a polyurethane resin matrix, wherein continuous glass fibers are longitudinally arranged in the polyurethane resin matrix and used for longitudinal reinforcement of the composite sleeper, the surface of the polyurethane resin matrix is provided with a reinforcing layer consisting of glass fiber fabrics and polyurethane resin, and the thickness of the reinforcing layer is 1-10 mm.
The glass fiber fabric is a composite felt with set color, which is used for producing the composite sleeper with the required color, reduces the painting links, lightens the pollution to the environment, can customize the color of the composite sleeper according to the requirements, meets the individual requirements of different customers, ensures that the color of the composite sleeper is consistent in the whole production process, is beneficial to improving the appearance quality of products, and increases the attractiveness and consistency of the products.
Further, the surface density of the glass fiber fabric is 300-1500 g/m 2.
The arrangement is convenient for adjusting the surface density of the glass fiber fabric according to the practical application working condition, can produce the composite sleeper with different surface reinforcing layer thicknesses, and expands the application range of the composite sleeper.
Further, the glass fiber fabric is made of composite felt with set colors and is used for producing the composite sleeper with the required colors. The paint spraying link is reduced, the pollution to the environment is lightened, the color of the composite sleeper 100 can be customized according to the requirement, the personalized requirements of different customers are met, the color of the composite sleeper 100 can be ensured to be consistent in the whole production process, the appearance quality of products is improved, the attractiveness and consistency of the products are improved, the composite felt is used as the material of the glass fiber fabric 511, the composite sleeper has better durability and ageing resistance, and the color of the composite sleeper 100 can be ensured to be still bright and stable after long-time use.
The application also provides a preparation device of the integrated composite sleeper, which is used for preparing the integrated composite sleeper and comprises a creel, a closed dipping box, a glue injection machine, a felt guide, a felt frame, a crawler belt machine and a sawing machine which are sequentially arranged, wherein the felt guide comprises a first felt guide and a second felt guide, the felt frame comprises the first felt frame and the second felt frame, the creel is used for placing continuous glass fibers, the closed dipping box is used for uniformly dipping polyurethane resin into the continuous glass fibers, the glue injection machine is used for conveying the polyurethane resin into the closed dipping box, the first felt frame is used for placing glass fiber fabrics, the first felt guide is used for guiding the glass fiber fabrics to be coated on the surfaces of the continuous glass fibers, the second felt frame is used for placing release paper, the second guide is used for guiding the release paper to be coated on the surfaces of the glass fiber fabrics, the crawler belt machine is provided with a die, and the die is used for heating and pressurizing the continuous glass fibers coated with the polyurethane resin, so that the polyurethane resin is solidified to form the fiber reinforced polyurethane composite sleeper, and the sawing machine is used for cutting the fiber reinforced polyurethane composite sleeper.
The arrangement can greatly improve the production efficiency and ensure the quality and consistency of the composite sleeper.
Further, the crawler comprises a lower crawler and an upper crawler, baffles are arranged on the left side and the right side of the crawler, the baffles are matched with the upper crawler and the lower crawler to form a mold cavity, the composite sleeper is solidified and formed in the mold cavity, and the composite sleeper is automatically separated from the mold cavity along with rotation of the crawler.
The arrangement can accurately control the shape and the size of the composite sleeper, ensure the consistency and the quality of products, and improve the production efficiency and the operation convenience.
Further, the injecting glue machine includes A component material jar, B component material jar, mixes rifle head and shunt, A component material jar and B component material jar are respectively through pipeline and mixing rifle head intercommunication, and mixing rifle head is through pipeline and shunt intercommunication, and the shunt is through reposition of redundant personnel injecting glue pipe and seal the gum dipping box intercommunication, A component material jar is used for storing polyurethane resin A, and B component material jar is used for storing polyurethane resin B, and mixing rifle head is used for mixing polyurethane resin A and polyurethane resin B, and the shunt is used for equally dividing the mixed polyurethane resin that mixes rifle head output and input seal the gum dipping box.
The arrangement can ensure that the polyurethane resin A and the polyurethane resin B are fully mixed to form uniform mixed polyurethane resin, and the uniform mixed polyurethane resin is uniformly distributed on the surface of the continuous glass fiber, so that the quality and the strength of the composite sleeper are improved.
Further, the creel is provided with a yarn dividing plate for dividing the continuous glass fiber.
The arrangement can ensure the quantity and the uniform distribution of each layer of fibers, improve the fiber reinforcement uniformity of the composite sleeper and strengthen the strength and the stability of the product.
Further, the closed gum dipping box is provided with a plurality of gum injecting holes, the mixing gun head is connected with a flow divider, and the flow divider is connected with the gum injecting holes through a plurality of flow dividing gum injecting pipes.
The arrangement is convenient for controlling the flow of polyurethane resin, ensures uniform impregnation of continuous glass fibers, and improves the quality and performance of the composite sleeper.
Further, the second felt frame is used for placing release cloth.
The release cloth has higher strength and durability, can better protect the surface of the composite sleeper from damage, can be reused after being properly cleaned and maintained, saves cost and reduces waste generation.
Compared with the prior art, the integrated composite sleeper and the preparation device have the following advantages:
1) The overall strength of the composite sleeper can be obviously increased, and transverse cracking is avoided;
2) The links of spraying release agent, surface painting and polishing are reduced, VOC and dust pollution in the production process are reduced, and the pollution to the environment is reduced.
Drawings
FIG. 1 is a schematic view of the overall structure of an integrally formed composite tie making apparatus according to an embodiment of the present utility model;
FIG. 2 is a schematic view of the felt guide of FIG. 1;
Fig. 3 is a schematic structural view of a composite sleeper according to an embodiment of the present utility model.
Reference numerals illustrate:
1. Creel, 11, continuous glass fiber, 2, a closed gum dipping box, 3, a glue injection machine, 31, a component material tank, 32, a component material tank, 33, a mixing gun head, 34, a diverter, 35, a diversion glue injection pipe, 4, a felt guide, 41, a first felt guide, 42, a second felt guide, 5, a felt rack, 51, a first felt rack, 511, glass fiber fabrics, 52, a second felt rack, 521, release paper, 6, a crawler, 61, a lower crawler, 62, an upper crawler, 7, a sawing machine, 100, a synthetic sleeper, 101, a polyurethane resin matrix, 102 and a reinforcing layer.
Detailed Description
In order that the above objects, features and advantages of the utility model will be readily understood, a more particular description of the utility model will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings.
The specific implementation mode is as follows:
As shown in fig. 1-3, an integrally formed composite sleeper includes a polyurethane resin matrix 101, continuous glass fibers 11 are longitudinally arranged in the polyurethane resin matrix 101 for longitudinal reinforcement of the composite sleeper 100, a glass fiber fabric 511 and a reinforcing layer 102 formed by polyurethane resin are arranged on the surface of the polyurethane resin matrix 101, the thickness of the reinforcing layer 102 is 1-10 mm, the overall density is 0.64-1.4 g/cm 3, wherein the polyurethane resin accounts for 35-50% of the total weight of the composite sleeper 100, the continuous glass fibers 11 account for 35-60% of the total weight of the composite sleeper 100, and the glass fiber fabric 511 accounts for 3-10% of the total weight of the composite sleeper 100.
Specifically, the continuous glass fiber 11 is longitudinally arranged in the polyurethane resin matrix 101, so that the overall strength and stability of the composite sleeper 100 can be improved, the reinforced layer 102 is arranged on the surface of the polyurethane resin matrix 101, the overall strength of the composite sleeper 100 can be remarkably improved, transverse cracking is avoided, the thickness range of the reinforced layer 102 is 1-10 mm, a proper thickness can be flexibly selected according to specific application scenes, the application range is enlarged, and the material proportion in the application can further improve the performance and quality of the composite sleeper 100.
Preferably, the continuous glass fiber 11 is made of alkali-free glass fiber direct yarn or ply yarn, and has a linear density of 4800-19200 tex.
Preferably, the glass fiber fabric 511 is a composite felt with a set color, which is used for producing the composite sleeper 100 with a required color, so that paint spraying links are reduced, environmental pollution is lightened, the color of the composite sleeper 100 can be customized according to the requirement, individual requirements of different customers are met, the color of the composite sleeper 100 can be ensured to be consistent in the whole production process, the appearance quality of a product is improved, the aesthetic degree and consistency of the product are improved, and the composite felt is used as a material of the glass fiber fabric 511, has better durability and ageing resistance, and can ensure that the color of the composite sleeper 100 is still bright and stable after long-time use.
Preferably, the glass fiber fabric 511 is one or more of glass fiber, carbon fiber, basalt fiber or nylon fiber, continuous felt made of polyester fiber, stitch-bonded felt, chopped strand felt, mesh cloth and biaxial cloth.
As a preferable example of the utility model, the polyurethane resin is compounded by a component A and a component B in a weight ratio of 100:100-150, wherein the component A is a polyol combination material, and the component B is isocyanate.
Specifically, the polyol has good elasticity and flexibility, can increase durability and impact resistance of the composite sleeper 100, can provide proper viscosity and fluidity, is beneficial to processing and molding of polyurethane resin, and the isocyanate can control hardness, strength and durability of the polyurethane resin, so that the composite sleeper 100 has proper rigidity and strength, the arrangement can ensure performance and quality of the polyurethane resin, and the overall strength and stability of the composite sleeper 100 are improved.
As a preferable example of the utility model, the average hydroxyl value of the component A is 300-500 mgKOH/g, the viscosity at 25 ℃ is 500-2000 mPa.s, the functionality is 3-6, the isocyanate content of the component B is 30-32%, the viscosity at 25 ℃ is 200-600 mPa.s, and the functionality is 2-3.
Specifically, the average hydroxyl value range is 300-500 mgKOH/g, enough reactivity can be provided, the polyurethane resin is formed by reacting with isocyanate of the component B, moderate viscosity is beneficial to processing and mixing of the component A, the preparation of the polyurethane resin is facilitated, the higher the functionality is, the higher the crosslinking degree of the polyurethane resin is, the hardness and strength are increased, the hardness and strength of the composite sleeper are improved, the sufficient reactivity and viscosity can be provided, the polyurethane resin is formed by reacting the component A with the component B, and the hardness and strength of the composite sleeper can be improved.
As a preferred example of the present utility model, the glass fiber fabric 511 has an areal density of 300 to 1500g/m 2, which may be one or more layers
Specifically, the greater the areal density of the glass fiber fabric, the greater the number of layers, the thicker the reinforcement layer formed, and the higher the transverse strength of the composite tie, but the slightly reduced longitudinal strength. The surface density of the glass fiber fabric 511 can be adjusted according to the actual application conditions, and composite sleepers with different surface reinforcing layer thicknesses can be produced.
The application also provides a preparation process of the integrated composite sleeper, which is used for preparing the integrated composite sleeper and comprises the following steps:
Step S1, calculating the number of continuous glass fibers 11 according to the density and the glass fiber content of the composite sleeper 100;
Step S2, layering the continuous glass fibers 11 according to the calculation result;
Step S3, uniformly impregnating the layered continuous glass fibers 11 with polyurethane resin;
Step S4, coating the glass fiber fabric 511 and the release paper 521 outside the continuous glass fiber 11 impregnated with polyurethane resin in sequence;
Step S5, heating the continuous glass fibers 11 coated with the glass fiber fabrics 511 and the release paper 521 and polyurethane resin, and curing the polyurethane resin to form the fiber reinforced polyurethane composite sleeper 100;
And S6, cutting and segmenting the cured and molded fiber reinforced polyurethane composite sleeper 100 according to the size requirement to obtain a finished product of the composite sleeper 100.
Specifically, by calculating the number of layers of the continuous glass fibers 11, the number of suitable fiber layers can be determined according to the density and the glass fiber content of the composite sleeper 100, so that the strength and the stability of the composite sleeper 100 are controlled, the layered continuous glass fibers 11 can be better combined with polyurethane resin, the overall strength and the stability of the composite sleeper 100 are improved, the surface strength of the composite sleeper can be improved by coating the glass fiber fabric 511, transverse cracking is avoided, the demolding paper 521 is coated outside the glass fiber fabric 511, the demolding of a product is facilitated, the spraying of a demolding agent and the surface polishing are not needed, and the VOC and dust pollution in the production process are reduced.
The application also provides a preparation device of the integrated composite sleeper, which is used for preparing the integrated composite sleeper, and comprises a creel 1, a closed dipping box 2, a glue injection machine 3, a felt guide 4, a felt frame 5, a crawler 6 and a sawing machine 7 which are sequentially arranged, wherein the felt guide 4 comprises a first felt guide 41 and a second felt guide 42, the felt frame 5 comprises a first felt frame 51 and a second felt frame 52, the creel 1 is used for placing continuous glass fibers 11, the closed dipping box 2 is used for uniformly dipping polyurethane resin into the continuous glass fibers 11, the glue injection machine 3 is used for conveying polyurethane resin into the closed dipping box 2, the first felt frame 51 is used for placing a glass fiber fabric 511, the first felt guide 41 is used for guiding the glass fiber fabric 511 to be coated on the surface of the continuous glass fibers 11, the second felt frame 52 is used for placing release paper 521, the second felt guide 42 is used for guiding the release paper to be coated on the surface of the glass fiber fabric 511, the crawler 6 is provided with a die which is used for heating and pressurizing the continuous glass fibers 11 coated with the polyurethane resin, the polyurethane resin is used for enabling the polyurethane resin to be uniformly dipped into the continuous glass fibers 11, and the polyurethane resin is used for cutting the polyurethane synthetic sleeper 100 to be cured by the sleeper 100.
Specifically, the creel 1 is provided with a yarn dividing plate for layering the continuous glass fibers 11, so as to ensure the quantity and the uniform distribution of each layer of fibers, improve the fiber reinforcement uniformity of the composite sleeper 100, strengthen the strength and the stability of products, in actual production, the continuous glass fibers 11 are led out from the creel 1, sequentially pass through the yarn dividing plate, the closed gum dipping box 2, the first felt guide 41 and the second felt guide 42 from front to back, enter the crawler 6, and the continuous glass fibers 11 move backwards under the extrusion traction of the crawler 6.
Preferably, the second felt frame 52 is used for placing a release paper/cloth, and the release paper/cloth at least comprises one of a polyethylene release film, a polypropylene release film, a polytetrafluoroethylene release film, a polyester release film, a laminated release paper and a non-woven fabric.
As a preferred example of the present utility model, the crawler 6 includes a lower crawler 61 and an upper crawler 62, the left and right sides of the crawler 6 are provided with baffles, the baffles cooperate with the upper crawler 62 and the lower crawler 61 to form a mold cavity, and the composite sleeper 100 is cured and formed in the mold cavity and is automatically separated from the mold cavity along with the rotation of the crawler 6.
In particular, this arrangement can accurately control the shape and size of the composite tie 100, ensure the consistency and quality of the product, and also improve the production efficiency and the operation convenience.
As a preferred example of the present utility model, the glue injector 3 includes an a-component material tank 31, a B-component material tank 32, a mixing gun 33 and a diverter 34, wherein the a-component material tank 31 and the B-component material tank 32 are respectively communicated with the mixing gun 33 through pipelines, the mixing gun 33 is communicated with the diverter 34 through pipelines, the diverter 34 is communicated with the closed glue dipping box 2 through a diversion glue injection pipe 35, the a-component material tank 31 is used for storing polyurethane resin a, the B-component material tank 32 is used for storing polyurethane resin B, the mixing gun 33 is used for mixing polyurethane resin a and polyurethane resin B, and the diverter 34 is used for equally dividing the mixed polyurethane resin output by the mixing gun 33 and inputting the same into the closed glue dipping box 2.
Specifically, through the mixing of the mixing gun head 33, the polyurethane resin A and the polyurethane resin B can be ensured to be fully mixed to form uniform mixed polyurethane resin, so that the uniform mixed polyurethane resin has better fluidity and wettability, the consistency and quality of the composite sleeper 100 are improved, the mixed polyurethane resin output by the mixing gun head 33 is evenly input into the closed dipping box 2 through the diverter 34, the mixed polyurethane resin can be ensured to be uniformly distributed on the surface of the continuous glass fiber 11 in the glue injection process, the quality and strength of the composite sleeper 100 are improved, the arrangement can ensure that the polyurethane resin A and the polyurethane resin B are fully mixed to form uniform mixed polyurethane resin and are uniformly distributed on the surface of the continuous glass fiber 11, and the quality and strength of the composite sleeper 100 are improved.
Preferably, the closed dipping box 2 is provided with a plurality of glue injection holes, the mixing gun head 33 is connected with the flow divider 34, and the flow divider 34 is connected with the glue injection holes through a plurality of flow dividing glue injection pipes 35, so that the flow of polyurethane resin is conveniently controlled, the uniform dipping of the continuous glass fibers 11 is ensured, and the quality and performance of the composite sleeper 100 are improved.
As a preferable example of the utility model, the traction speed of the die is 0.3-1.0 m/min, the die temperature is 40-90 ℃, and the curing time of the composite sleeper 100 in the die is 40-60 min.
Specifically, by controlling the drawing speed, the mold temperature, and the curing time, the composite tie 100 can be sufficiently cured in the mold, improving the quality and production efficiency of the product.
Example 1
The hydroxyl value of the component A of the polyurethane composite material is 320+/-20 mgKOH/g, the viscosity is 1200mPas, the component B adopts polymeric MDI, the isocyanate index is 31.2%, the mass ratio of the component A to the component B is set to be 100:100, and the component A and the component B are pumped into a glue injection machine in advance for standby;
By changing the position of the baffle plate and the distance between the lower crawler 61 and the upper crawler 62, the size of the cavity of the crawler 6 was adjusted to 200mm (width) ×140mm (height), and according to the product density of 0.70±0.04g/cm 3 and the glass fiber content of 50%, 9600tex of continuous glass fiber 11 direct yarns were used as reinforcing materials, 1030 bundles were used, the continuous glass fiber 11 was fed into the mold through the closed dipping box 2 and fed into the crawler cavity under the extrusion traction of the crawler 6, the glass fiber fabric 511 was used as a continuous felt 2 layer having a width of 700mm and a surface density of 600g/m 2, the felt guide 4 was used as a release paper 521 having a width of 720mm and a surface density of 90g/m 2, and the continuous glass fiber was sequentially wrapped with the glass fiber fabric 511 and the release paper 521 and fed into the mold.
When the temperature of the mould of the crawler machine 6 is preheated to 50 ℃, the glue injection machine 3 is started to inject glue, the glass fiber fabric 511 and the demoulding paper 521 are sequentially coated outside the continuous glass fiber 11 impregnated with polyurethane resin, the resin flow of the glue injection machine 3 is timely adjusted to ensure that the continuous glass fiber 11 and the fiber fabric 511 are uniformly impregnated with the polyurethane resin, the production speed is controlled to be 0.75m/min, the mould is started to demould after the product is solidified in the mould for 40min, after the product is demoulded, the product is sawed according to the set length, the demoulding paper 521 is cleaned after sawing, the finished product of the synthetic sleeper 100 can be obtained, and the thickness of the glass fiber fabric reinforcing layer 102 on the surface of the finished product of the synthetic sleeper 100 is 1.5mm.
Example 2
The hydroxyl value of the component A of the polyurethane composite material is 400+/-20 mgKOH/g, the viscosity is 800mPas, the component B adopts polymeric MDI, the isocyanate index is 31.2%, the mass ratio of the component A to the component B is set to be 100:120, and the component A and the component B are pumped into a glue injection machine in advance for standby;
By changing the position of the baffle plate and the distance between the lower crawler 61 and the upper crawler 62, the size of the die cavity of the crawler 6 was adjusted to 230mm (width) ×140mm (height), and according to the product density of 0.80±0.04g/cm 3 and the glass fiber content of 50%, a continuous glass fiber ply yarn of 13800tex was used as the reinforcing material, the number of 840 bundles was used, the continuous glass fiber 11 was fed into the die through the closed dipping box 2 and fed into the crawler die cavity under the extrusion traction of the crawler 6, the width of the glass fiber 511 was 750mm, a polyester stitch-bonded composite felt of 3-layer density 600g/m 2 and a glass fiber mesh+1-layer density 450g/m 2 was used, the polyester felt was black, the guide 4 was used as the release paper felt 521 with a width 770mm, the surface density 120g/m 2, and the continuous glass fiber 521 was sequentially wrapped up into the die.
When the temperature of the mould of the crawler machine 6 is preheated to 60 ℃, the glue injection machine 3 is started to inject glue, the glass fiber fabrics 511 and the demoulding paper 521 are sequentially coated outside the continuous glass fiber 11 impregnated with polyurethane resin, the resin flow of the glue injection machine 3 is timely adjusted to ensure that the continuous glass fiber 11 and the fiber fabrics 511 are uniformly impregnated with the polyurethane resin, the production speed is controlled to be 0.6m/min, the mould is started to be demoulded after the product is solidified in the mould for 50min, after the product is demoulded, the product is sawed according to the set length, the demoulding paper 521 is cleaned after sawing, the black synthetic sleeper 100 finished product can be obtained, and the thickness of the glass fiber fabric reinforcing layer 102 on the surface of the synthetic sleeper 100 finished product is 3mm.
Example 3
The hydroxyl value of the component A of the polyurethane composite material is 480+/-20 mgKOH/g, the viscosity is 700mPas, the component B adopts polymeric MDI, the isocyanate index is 31.2%, the mass ratio of the component A to the component B is set to be 100:140, and the component A and the component B are pumped into a glue injection machine in advance for standby;
By changing the position of the baffle plate and the distance between the lower crawler 61 and the upper crawler 62, the cavity size of the crawler 6 was adjusted to 240mm (width) ×240mm (height), a continuous glass fiber ply yarn of 19200tex was used as the reinforcing material, a number of 1990 bundles were used as the glass fiber content 55% in terms of the product density of 1.20±0.06g/cm 3, the continuous glass fiber 11 was fed through the closed dipping box 2 into the mold and fed into the crawler cavity under the extrusion traction of the crawler 6, the glass fiber fabric 511 was used as a continuous felt of 0 °/90 ° glass fiber biaxial cloth +1 layer density 450g/m 2 of width of 980mm, the 6 layer density 600g/m 2, the felt guide 4 was used as the release paper 521, the width was 1000mm, the glass fiber fabric 511 and the release paper 521 were sequentially wrapped with the continuous glass fiber into the mold.
When the temperature of the mould of the crawler belt machine 6 is preheated to 60 ℃, the glue injection machine 3 is started to inject glue, the glass fiber fabrics 511 and the demoulding paper 521 are sequentially coated outside the continuous glass fiber 11 impregnated with polyurethane resin, the resin flow of the glue injection machine 3 is timely adjusted to ensure that the continuous glass fiber 11 fiber fabrics 511 are uniformly impregnated with the polyurethane resin, the production speed is controlled to be 0.55m/min, the mould is started to demould after the product is solidified in the mould for 50min, after the product is demoulded, sawing is carried out on the product according to the set length, the demoulding paper 521 is cleaned after sawing, the finished product of the synthetic sleeper 100 can be obtained, and the thickness of the glass fiber fabric reinforcing layer 102 on the surface of the finished product of the synthetic sleeper 100 is 6mm.
Comparative example 1
The reinforced material is totally made of 9600tex continuous glass fiber direct yarns, the arrangement number is 1120 bundles, and the surface is not reinforced by glass fiber fabrics;
Other molding process parameters were the same as "example 1".
Comparative example 2
13800Tex continuous glass fiber yarns are used as the reinforcing material, the arrangement quantity is 900 bundles, and the surface is not reinforced by glass fiber fabrics;
Other molding process parameters were the same as "example 2".
Comparative example 3
The reinforced material is totally made of 9600tex continuous glass fiber direct yarns, the arrangement number is 2180 bundles, and the surface is not reinforced by glass fiber fabrics;
other molding process parameters were the same as "example 3".
Performance measurement
In the above examples and comparative examples, the density measurement was carried out according to GB/T1463-2005 "fiber reinforced plastics density and relative density test method", examples 1, 2 and comparative examples 1, 2 were tested with respect to the mechanical properties of CJ/T3992012 "polyurethane foam composite sleeper", and examples 3 and comparative example 3 were tested with respect to the mechanical properties of TJ/GW161-2018 "railway steel beam HFFP composite bridge sleeper" under the temporary technical conditions.
The fiber reinforced polyurethane composite material composite sleeper obtained in examples 1 to 3 and comparative examples 1 to 3 was tested, and the specific results are shown in table 1.
TABLE 1 comparison of the properties of the example and comparative composite sleeper products
Note 1. Compressive strength was sampled from the surface of the product;
2. the fiber-extending direction is vertical, and the vertical fiber direction is horizontal.
As shown by the test results in the table 1, for the example and the comparative example products with similar density, the performances of the example products such as the transverse compressive strength, the screw spike pulling resistance and the finished product bending area load are larger than those of the comparative example, and the surface reinforcing layer can obviously increase the integral strength of the composite sleeper, so that the surface reinforcing layer has obvious advantages in performance compared with the traditional unidirectional fiber reinforced composite sleeper.
In summary, the integrated composite sleeper and the preparation device have the advantages that 1, the integral strength of the composite sleeper 100 can be remarkably improved, transverse cracking is avoided, 2, a spray painting link is reduced, environmental pollution is lightened, the color of the composite sleeper 100 can be customized according to requirements, personalized requirements of different customers are met, the color of the composite sleeper 100 can be ensured to be consistent in the whole production process, the appearance quality of products is improved, the durability and the ageing resistance are better, the color of the composite sleeper 100 can be ensured to be still bright and stable after long-time use, 3, the demolding of the products is facilitated, the spraying of a demolding agent and the surface polishing are not needed, and VOC and dust pollution in the production process are reduced.
Although the present utility model is disclosed above, the present utility model is not limited thereto. Various changes and modifications may be made by one skilled in the art without departing from the spirit and scope of the utility model, and the scope of the utility model should be assessed accordingly to that of the appended claims.
Claims (9)
1. The integrated composite sleeper is characterized by comprising a polyurethane resin matrix (101), wherein continuous glass fibers (11) are longitudinally arranged in the polyurethane resin matrix (101) and used for longitudinal reinforcement of the composite sleeper (100), a reinforcing layer (102) consisting of glass fiber fabrics (511) and polyurethane resin is arranged on the surface of the polyurethane resin matrix (101), and the thickness of the reinforcing layer (102) is 1-10 mm.
2. The integrally formed composite tie of claim 1, wherein the glass fiber fabric (511) has an areal density of 300-1500 g/m 2.
3. The integrally formed composite tie of claim 1, wherein said fiberglass fabric (511) is a composite mat of a predetermined color for producing a composite tie (100) of a desired color.
4. An integrally formed synthetic sleeper preparation device for preparing an integrally formed synthetic sleeper according to any one of claims 1-3, characterized by comprising a creel (1), a closed impregnation box (2), a glue injection machine (3), a felt guide (4), a felt support (5), a crawler machine (6) and a sawing machine (7) which are sequentially arranged, wherein the felt guide (4) comprises a first felt guide (41) and a second felt guide (42), the felt support (5) comprises a first felt support (51) and a second felt support (52), the creel (1) is used for placing continuous glass fibers (11), the closed impregnation box (2) is used for uniformly impregnating polyurethane resin into the continuous glass fibers (11), the glue injection machine (3) is used for conveying polyurethane resin into the closed impregnation box (2), the first felt support (51) is used for placing a glass fiber fabric (511), the first felt guide (41) is used for guiding the glass fiber fabric (511) to be coated on the surface of the continuous glass fibers (11), the second felt support (52) is used for placing a demolding support (6) and a demolding support (521) is used for guiding the glass fiber fabric (521) to be coated on the surface of the continuous glass fibers (11) by a pressurizing mould, the polyurethane resin is solidified to form the fiber reinforced polyurethane composite sleeper (100), and the sawing machine (7) is used for cutting the fiber reinforced polyurethane composite sleeper (100).
5. The device for preparing the integrated composite sleeper according to claim 4, wherein the crawler machine (6) comprises a lower crawler machine (61) and an upper crawler machine (62), baffles are arranged on the left side and the right side of the crawler machine (6), the baffles are matched with the upper crawler machine (62) and the lower crawler machine (61) to form a mold cavity, the composite sleeper (100) is solidified and molded in the mold cavity, and the composite sleeper is automatically separated from the mold cavity along with the rotation of the crawler machine (6).
6. The device for preparing the integrated composite sleeper according to claim 4, wherein the glue injection machine (3) comprises an A component material tank (31), a B component material tank (32), a mixing gun head (33) and a flow divider (34), the A component material tank (31) and the B component material tank (32) are respectively communicated with the mixing gun head (33) through pipelines, the mixing gun head (33) is communicated with the flow divider (34) through pipelines, the flow divider (34) is communicated with the closed dipping box (2) through a flow dividing glue injection pipe (35), the A component material tank (31) is used for storing polyurethane resin A, the B component material tank (32) is used for storing polyurethane resin B, the mixing gun head (33) is used for mixing the polyurethane resin A and the polyurethane resin B, and the flow divider (34) is used for equally dividing the mixed polyurethane resin output by the mixing gun head (33) and inputting the mixed polyurethane resin into the closed dipping box (2).
7. The device for producing an integrally formed synthetic sleeper according to claim 4, characterized in that the creel (1) is provided with a yarn dividing plate for layering continuous glass fibers (11).
8. The device for preparing the integrated composite sleeper according to claim 6, wherein the closed impregnation box (2) is provided with a plurality of glue injection holes, the mixing gun head (33) is connected with a flow divider (34), and the flow divider (34) is connected with the glue injection holes through a plurality of split glue injection pipes (35).
9. The apparatus for making an integrally formed composite tie as claimed in claim 4, wherein said second felt mount (52) is adapted to receive a release cloth.
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