A plastic track plate and its preparation process, and railway track structure

Abstract

The present invention provides a plastic track plate, including plastic particles, synthetic resin, natural resin and additives, wherein the mass percentage of the plastic particles is 20% to 30%; the mass percentage of the synthetic resin is 20% to 45%; the mass percentage of the natural resin is 30% to 40%; the mass percentage of the additive is 10% to 20%; the present invention also provides a preparation process of the plastic track plate, including the steps of mixing, drying, injection molding, and molding, and the present invention also provides a railway track structure, including a base bed, a support layer, a damping layer, a plastic track plate and a rail laid in sequence from bottom to top. The plastic track plate in the present invention is not only low in cost, light in weight, short in manufacturing cycle, convenient in transportation and easy to install, and improves construction efficiency, but also has better elasticity than the steel-concrete structure, can optimize the stiffness of the ballastless track system, is conducive to optimizing the dynamic response of the wheel and rail, and can play a role in reducing vibration and noise, which is conducive to reducing the workload of maintenance and repair.

Description

Technical Field

[0001] The invention relates to the technical field of plastic railway tracks, and in particular to a plastic track plate and a preparation process thereof, and a railway track structure. Background Art

[0002] With the expansion of urban scale and the increase of urban population, the problem of urban traffic congestion has become increasingly prominent. Rail transit has become an effective means of transportation to solve the problem of urban congestion with its characteristics of "convenient, fast, safe and comfortable, large passenger volume, low pollution, and no ground space occupation". While traditional urban rail transit brings convenience to society, it also causes environmental vibration and noise pollution that cannot be ignored in people's living and working environment. When the running of trains causes environmental vibration in the surrounding area, it will affect nearby buildings and people, especially when the tunnel is shallow and passes directly under the building, the vibration impact is more prominent. With the improvement of material living standards, people's requirements for the quality of living and working environment are getting higher and higher. The environmental vibration and noise problems caused by train operation have received widespread attention since the construction of rail transit began.

[0003] Plastic vibration damping products have unique advantages such as free choice of shape, adjustable formula and hardness. With the development of the railway transportation industry, the demand for vibration damping products for railway locomotives and railway plastic sleepers is increasing, which is a product with great potential for development. Traditional track structures often use concrete as the main material, and the vibration response is large under the action of trains. Once the steel-concrete structure of the track plate is severely damaged, it will be scrapped and cannot be recycled. Therefore, proposing a new plastic track plate and its preparation process, as well as a railway track structure to solve the problems existing in the existing technology is bound to be a new idea for realizing the green development of my country's rail transportation.

[0004] In summary, there is an urgent need for a plastic track plate and a preparation process thereof, as well as a railway track structure to solve the problems existing in the prior art. Summary of the invention

[0005] The present invention aims to provide a plastic track plate and a preparation process thereof, as well as a railway track structure, so as to solve the problem of vibration reduction and noise reduction of the railway track.

[0006] To achieve the above-mentioned purpose, the present invention provides a plastic track plate including plastic particles, synthetic resin, natural resin and additives; the mass percentage of the plastic particles is 20%~30%; the mass percentage of the synthetic resin is 20%~45%; the mass percentage of the natural resin is 30%~40%; the mass percentage of the additive is 10%~20%.

[0007] Preferably, the plastic particles include at least one of PVC plastic particles and ABS plastic particles.

[0008] Preferably, the synthetic resin consists of phenolic resin and polyethylene.

[0009] Preferably, the natural resin includes at least one of rosin and shellac.

[0010] Preferably, the additives include fillers, curing agents, stabilizers, plasticizers, colorants and lubricants; the fillers include at least one of graphite, asbestos fiber, asbestos powder, mica powder and molybdenum disulfide; the curing agent includes at least one of hexamethylenetetramine, ethylenediamine and maleic anhydride; the plasticizer is a liquid or low-melting-point solid organic compound; the plasticizer is dibutyl phthalate; the stabilizer is an antioxidant, phenolic or amine organic substance to resist aging of the track plate under frequent driving.

[0011] The present invention also provides a process for preparing a plastic track plate, comprising the following steps:

[0012] Step 1: Put the plastic pellets, synthetic resin, natural resin and additives into the mixer according to the required percentage by mass and mix them evenly;

[0013] Step 2: Dry the mixed plastic raw materials with an electric drying machine;

[0014] Step 3: Use an injection molding machine to process the dried plastic material into the designed shape;

[0015] Step 4: Trim and surface treat the formed plastic track plate.

[0016] The present invention also provides a railway track structure, including a base bed, a supporting layer, a damping layer, a plastic track plate and a steel rail; the base bed, the supporting layer, the damping layer, the plastic track plate and the steel rail are laid in sequence from bottom to top; the base bed and the damping layer are both embedded with phononic crystals.

[0017] Preferably, vertical high-strength plastic fibers are pre-embedded inside the base bed, and the vertical high-strength plastic fibers are arranged perpendicular to the surface of the phononic crystal base bed; the support layer and the base bed are connected together by the pre-embedded vertical high-strength plastic fibers; and the support layer and the base bed are both provided with expansion joints.

[0018] Preferably, high-strength plastic fibers are arranged in the plastic track plate, including longitudinal high-strength plastic fibers and transverse high-strength plastic fibers; the longitudinal high-strength plastic fibers are arranged in two layers, and the transverse high-strength plastic fibers are arranged in the middle layer between the two layers of longitudinal high-strength plastic fibers.

[0019] As another preferred scheme, high-strength plastic fibers are arranged in the plastic track plate, including longitudinal high-strength plastic fibers and transverse high-strength plastic fibers; the longitudinal high-strength plastic fibers and transverse high-strength plastic fibers are arranged in two layers, the longitudinal high-strength plastic fibers and the transverse high-strength plastic fibers form a planar mesh structure.

[0020] The application of the technical solution of the present invention has the following beneficial effects:

[0021] (1) Conventional track structures often use concrete as the main material, and the vibration response is large under the action of trains. The present invention adopts an integral plastic railway track structure and embeds phononic crystal materials with excellent vibration and noise reduction performance therein to achieve excellent vibration and noise reduction effects.

[0022] (2) The plastic track plate in the present invention is not only low in cost, light in weight, short in manufacturing cycle, convenient in transportation and easy to install, which improves construction efficiency, but also has better elasticity than steel-concrete structure, can optimize the stiffness of the ballastless track system, is conducive to optimizing the dynamic response of the wheel and rail, and can play a role in reducing vibration and noise, which is conducive to reducing the workload of maintenance and repair. In addition, the plastic track plate itself is a polymer material with good insulation properties. Its quality is not easy to degrade in a humid or hot and humid environment, and it has good corrosion resistance. The plastic track plate can also be recycled. Unlike the track plate with steel-concrete structure, it will be scrapped once it is severely damaged. The plastic track plate can be processed and reused after damage, thereby solving the problems of high cost, high weight, non-recyclability and high carbon emissions during construction of the steel-concrete structure track plate in the prior art.

[0023] (3) The plastic railway track of the present invention has the advantages of light weight, resistance to vibration and impact, and high specific strength. It also has the characteristics of friction reduction, wear resistance, self-lubrication, shock absorption and noise reduction.

[0024] (4) The present invention utilizes the rich band gap structure of phononic crystals. The higher-order dispersion curve of the band gap structure will show multiple straight bands, thereby showing multiple relatively continuous band gaps. The present invention designs a stacked square columnar phononic crystal unit cell with good band gap characteristics. In this way, when a train passes by, the elastic waves with vibration frequencies within the band gap range can be greatly attenuated, and the vibration reduction effect is significant.

[0025] (5) The present invention utilizes high-strength plastic fibers to replace the steel structure in the traditional track structure, which is beneficial to reducing the amount of steel used, reducing the weight and cost of the track plate, reducing the engineering transportation cost, facilitating the on-site laying of the track plate, and having good engineering application value.

[0026] In addition to the above-described purposes, features and advantages, the present invention has other purposes, features and advantages. The present invention will be further described in detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The drawings constituting a part of this application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0028] Figure 1 is a schematic diagram of a railway track structure;

[0029] Figure 2 It is a schematic diagram of a longitudinal section structure of a railway track structure;

[0030] Figure 3 It is a structural schematic diagram of the support layer of the present invention;

[0031] Figure 4 for Figure 3 A top view of

[0032] Figure 5 is a schematic diagram of the structure of the damping layer;

[0033] Figure 6 for Figure 5 A top view of

[0034] Figure 7 This is a schematic diagram of the first arrangement structure of high-strength plastic fibers in a plastic track slab;

[0035] Figure 8 for Figure 7 Schematic diagram of longitudinal section;

[0036] Fig. 9 It is a schematic diagram of the second arrangement structure of high-strength plastic fibers in the plastic track slab;

[0037] Fig.10 for Fig. 9 Schematic diagram of longitudinal section;

[0038] Fig.11 Schematic diagram of the process flow for preparing plastic track slabs.

[0039] In the figure: 1. base bed, 11. vertical high-strength plastic fiber, 12. expansion joint, 2. support layer, 3. damping layer, 4. plastic track plate, 41. longitudinal high-strength plastic fiber, 42. transverse high-strength plastic fiber, 5. rail. DETAILED DESCRIPTION

[0040] The embodiments of the present invention are described in detail below with reference to the accompanying drawings, but the present invention can be implemented in many different ways as defined and covered by the claims. Embodiment 1:

[0041] A plastic track plate 4 includes plastic particles, synthetic resin, natural resin and additives; the mass percentage of the plastic particles is 20%; the mass percentage of the synthetic resin is 20%; the mass percentage of the natural resin is 40%; the mass percentage of the additive is 20%. The plastic track plate produced by the ratio of this embodiment has the advantages of light weight, vibration and impact resistance, high specific strength, and also has the characteristics of friction reduction, wear resistance, self-lubrication, shock absorption and noise reduction.

[0042] The plastic particles are composed of PVC plastic particles and ABS plastic particles, and the mass percentage thereof is 1:1.

[0043] The synthetic resin is prepared from phenolic resin and polyethylene, with a mass percentage of 1:1.

[0044] The natural resin is composed of rosin and shellac in a mass percentage of 1:1.

[0045] The additives include filler, curing agent, stabilizer, plasticizer, colorant and lubricant; the mass percentage thereof is 1:1:1:1:1.

[0046] The filler includes graphite, asbestos fiber, asbestos powder, mica powder and molybdenum disulfide; the mass percentage thereof is 1:1:1:1:1.

[0047] The curing agent comprises hexamethylenetetramine, ethylenediamine and maleic anhydride; the mass percentage thereof is 1:1:1.

[0048] The plasticizer is a liquid or low-melting-point solid organic compound; the plasticizer is dibutyl phthalate;

[0049] The stabilizer is an anti-oxidant substance, phenols, amines or other organic substances to resist the aging of the plastic track plate under frequent driving. In this embodiment, the stabilizer is 2,6-di-tert-butyl-4-methylphenol.

[0050] The plastic track plate in this example can also use existing plastic products.

[0051] like Fig.11 As shown, the preparation process of the above-mentioned plastic track plate includes the following steps:

[0052] Step 1: Put plastic pellets, synthetic resin, natural resin and additives into a mixer according to the required mass percentage of 1:1:2:1 and mix them evenly;

[0053] Step 2: Dry the mixed plastic raw materials with an electric drying machine;

[0054] Step 3: Use an injection molding machine to process the dried plastic material into the designed shape;

[0055] Step 4: Trim and surface treat the formed plastic track plate.

[0056] The preparation process of the plastic track plate of this embodiment can also be prepared using existing process technology.

[0057] like Figure 1 to Figure 10 As shown, a railway track structure includes the above-mentioned plastic track plate, and also includes a base bed 1, a supporting layer 2, a damping layer 3, and a rail 5; the base bed 1, the supporting layer 2, the damping layer 3, the plastic track plate 4 and the rail 5 are laid in sequence from bottom to top; the base bed 1 and the damping layer 3 are both embedded with phononic crystals.

[0058] Phononic crystals are a new type of functional material formed by periodically arranging elastic solids in another solid or fluid medium. By analogy with photonic crystals, people have found that when elastic waves propagate in a periodic elastic composite medium, elastic wave band gaps similar to photonic band gaps will also be generated, thus proposing the concept of phononic crystals. By utilizing the rich band gap structure of phononic crystals, the higher-order dispersion curves of the band gap structure will have multiple straight bands, thereby resulting in multiple relatively continuous band gaps. The present invention designs a stacked square columnar phononic crystal unit cell with good band gap characteristics, so that when a train passes by, the elastic waves with vibration frequencies within the band gap range can be greatly attenuated, and the vibration reduction effect is significant.

[0059] The base bed 1 is pre-buried with vertical high-strength plastic fibers 11 with a diameter of 16 mm, which are arranged in a row at a longitudinal interval of 0.6 m. The vertical high-strength plastic fibers 11 are arranged perpendicular to the surface of the base bed; the support layer 2 and the base bed 1 are connected together by the pre-buried vertical high-strength plastic fibers 11; the support layer 2 and the base bed 1 are both provided with expansion joints 12.

[0060] The longitudinal length of the support layer 2 is 5.6m, the width of the support layer 2 is 3.1m, the thickness of the support layer 2 is 0.28m, and two concave terraces 21 are symmetrically arranged on the upper surface of the support layer 2. The length of the two concave terraces 21 is 0.7m, the width of the two concave terraces is 1m, and the depth of the two concave terraces is 0.1m.

[0061] The damping layer 3 is provided with a boss 31 whose size matches the concave platform 21; the supporting layer 2 and the damping layer 3 are connected together through the concave platform and the boss; the length of the damping layer 3 is 5.6m, the width of the damping layer 3 is 2.5m, the thickness of the damping layer 3 is 0.1m, and the length, width and height of the plastic track plate 4 are 5.6m, 2.5m and 0.21m respectively.

[0062] The plastic track plate is provided with high-strength plastic fibers, including longitudinal high-strength plastic fibers 41 and transverse high-strength plastic fibers 42; Figure 7 , Figure 8As shown, the longitudinal high-strength plastic fibers 41 are arranged in two layers, the transverse high-strength plastic fibers 42 are arranged in the middle layer between the two layers of longitudinal high-strength plastic fibers; the diameter of the longitudinal high-strength plastic fibers 41 is 13 mm, and the number is 8; the diameter of the transverse high-strength plastic fibers 42 is 13 mm, and the number is 12.

[0063] Another arrangement of high-strength plastic fibers in plastic track slabs, such as Fig. 9 , Fig.10 As shown in the figure, the longitudinal high-strength plastic fibers 41 and the transverse high-strength plastic fibers 42 are arranged in two layers, the longitudinal high-strength plastic fibers 41 and the transverse high-strength plastic fibers 42 form a planar mesh structure. The diameter of the longitudinal high-strength plastic fibers 41 is 14 mm, and the number is 24; the diameter of the transverse high-strength plastic fibers 42 is 10 mm, and the number is 48.

[0064] In this embodiment, the vertical direction refers to the direction perpendicular to the surface of the plastic track plate, the longitudinal direction refers to the length direction along the rail, and the transverse direction refers to the length direction perpendicular to the rail in the horizontal plane. Embodiment 2:

[0065] The difference between this embodiment and embodiment 1 is that the plastic track plate 4 includes plastic particles, synthetic resin, natural resin and additives; the mass percentage of the plastic particles is 25%; the mass percentage of the synthetic resin is 30%; the mass percentage of the natural resin is 35%; and the mass percentage of the additive is 10%.

[0066] The plastic track plate produced by the ratio of this embodiment has the advantages of light weight, vibration and impact resistance, high specific strength, etc., and also has the characteristics of friction reduction, wear resistance, self-lubrication, shock absorption and noise reduction. Its effect is equivalent to that of embodiment 1. Embodiment 3:

[0067] The difference between this embodiment and embodiment 1 is that the plastic track plate 4 includes plastic particles, synthetic resin, natural resin and additives; the mass percentage of the plastic particles is 20%; the mass percentage of the synthetic resin is 40%; the mass percentage of the natural resin is 30%; and the mass percentage of the additive is 10%.

[0068] The plastic track plate produced by the ratio of this embodiment has the advantages of light weight, vibration and impact resistance, high specific strength, etc., and also has the characteristics of friction reduction, wear resistance, self-lubrication, shock absorption and noise reduction. Its effect is equivalent to that of embodiment 1.

[0069] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A railway track structure, It is characterized in that The invention comprises a base bed (1), a support layer (2), a damping layer (3), a plastic track plate (4) and a steel rail (5); the base bed (1), the support layer (2), the damping layer (3), the plastic track plate (4) and the steel rail (5) are laid in sequence from bottom to top; the base bed (1) and the damping layer (3) are both embedded with phononic crystals; The base bed (1) is pre-buried with vertical high-strength plastic fibers (11), and the vertical high-strength plastic fibers (11) are arranged perpendicular to the surface of the base bed; the support layer (2) and the base bed (1) are connected together via the pre-buried vertical high-strength plastic fibers (11); The plastic track plate (4) comprises plastic particles, synthetic resin, natural resin and additives; the mass percentage of the plastic particles is 20% to 30%; the mass percentage of the synthetic resin is 20% to 45%; the mass percentage of the natural resin is 30% to 40%; and the mass percentage of the additive is 10% to 20%; The preparation process of the plastic track plate includes the following steps: Step 1: Put the plastic pellets, synthetic resin, natural resin and additives into the mixer according to the required percentage by mass and mix them evenly; Step 2: Dry the mixed plastic raw materials with an electric drying machine; Step 3: Use an injection molding machine to process the dried plastic material into the designed shape; Step 4: Trim and surface treat the formed plastic track plate.

2. A railway track structure according to claim 1, It is characterized in that The plastic particles include at least one of PVC plastic particles and ABS plastic particles.

3. A railway track structure according to claim 1, It is characterized in that The synthetic resin consists of phenolic resin and polyethylene.

4. A railway track structure according to claim 1, It is characterized in that The natural resin includes at least one of rosin and shellac.

5. A railway track structure according to claim 1, It is characterized in that The additives include fillers, curing agents, stabilizers, plasticizers, colorants and lubricants; The filler comprises at least one of graphite, asbestos fiber, asbestos powder, mica powder and molybdenum disulfide; The curing agent includes at least one of hexamethylenetetramine, ethylenediamine and maleic anhydride; The plasticizer is a liquid or low-melting-point solid organic compound; the plasticizer is dibutyl phthalate; The stabilizer is an anti-oxidant substance, phenolic or amine organic matter, so as to resist the aging of the plastic track plate under the action of frequent driving.

6. A railway track structure according to any one of claims 1 to 5, It is characterized in that The support layer (2) and the base bed (1) are both provided with expansion joints.

7. A railway track structure according to claim 6, It is characterized in that The plastic track plate is provided with high-strength plastic fibers, including longitudinal high-strength plastic fibers (41) and transverse high-strength plastic fibers (42); the longitudinal high-strength plastic fibers (41) are arranged in two layers, upper and lower, and the transverse high-strength plastic fibers (42) are arranged in the middle layer between the two layers of longitudinal high-strength plastic fibers.

8. A railway track structure according to claim 6, It is characterized in that The plastic track plate is provided with high-strength plastic fibers, including longitudinal high-strength plastic fibers (41) and transverse high-strength plastic fibers (42); the longitudinal high-strength plastic fibers (41) and transverse high-strength plastic fibers (42) are arranged in two layers, upper and lower, and the longitudinal high-strength plastic fibers (41) and transverse high-strength plastic fibers (42) form a planar mesh structure.

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