Composite material elastic sleeper and preparation method thereof

Abstract

Provided is an elastic rail sleeper of composite material and a preparation method thereof, comprising an elastic bottom layer and a rail sleeper body, wherein a nylon sleeve for connecting and fixing a rail with a mounting fastener is pre-embedded in the upper end face of the rail sleeper body, and an inner filler is provided in two symmetrically arranged cavities in the lower end face of the rail sleeper body, and the integrally formed rail sleeper body, the inner filler and the elastic bottom layer of the lower end face thereof form a conical structure whose upper end size is smaller than the lower end size. The present invention solves the drawbacks of high replacement cost and heavy weight of traditional rail sleepers by optimizing the structure and materials of the rail sleeper, significantly reduces the weight of the rail sleeper, ensures the structural strength of the rail sleeper, and effectively guarantees various functions of the rail sleeper in actual use by pre-embedding a nylon sleeve in the upper end face of the rail sleeper body, provides solid support for the safety and stability of railway transportation, can effectively reduce maintenance and replacement costs, has good elastic performance of the rail sleeper, has a short integral molding processing cycle, is low in cost, is highly efficient, and meets the high quality and high performance requirements of the rail sleeper.

Description

Technical Field

[0001] The invention belongs to the technical field of railway equipment, and in particular relates to an elastic sleeper of a composite material and a preparation method thereof. Background Art

[0002] Traditional wooden sleepers and concrete sleepers have many shortcomings, such as limited resources and easy corrosion of wooden sleepers. Their service life will be greatly shortened due to factors such as cargo flow, speed and load, and the replacement cost is high; concrete sleepers are heavy and inconvenient to install and replace. With the development of railway construction, the performance requirements for sleepers are constantly increasing. A new type of sleeper that has both good performance and can overcome the shortcomings of traditional sleepers is needed. FRP sleepers came into being. FRP, also known as glass fiber reinforced plastic, is a combination of glass fiber and synthetic resin. It has the advantages of light weight, high strength, corrosion resistance, fatigue resistance, and good insulation. The service life of sleepers made of it can reach more than 50 years, which can effectively reduce maintenance and replacement costs. Therefore, it is necessary to make improvements. Summary of the invention

[0003] The technical problem solved by the present invention is as follows: to provide an elastic sleeper of a composite material and a preparation method thereof, which optimizes the structure and materials of the sleeper body, adopts a sleeper body made of a glass fiber reinforced plastic material filled with an internal filler in two internal cavities, and an elastic bottom layer formed integrally with the sleeper body and the lower end surface of the internal filler to form an elastic sleeper, thereby solving the drawbacks of high replacement cost and heavy weight of traditional sleepers, significantly reducing the weight of the sleeper, ensuring the structural strength of the sleeper, and pre-embedding a nylon sleeve on the upper end surface of the sleeper body to effectively ensure various functions of the sleeper in actual use, providing solid support for the safety and stability of railway transportation, and effectively reducing maintenance and replacement costs. The sleeper has good elasticity, a short one-piece molding processing cycle, low cost, high efficiency, meets the high quality and high performance requirements of the sleeper, and has extremely high use value.

[0004] The technical solution adopted by the present invention is: an elastic sleeper of a composite material, comprising an elastic bottom layer and a sleeper body arranged on the upper end surface of the elastic bottom layer, the upper end surface of the sleeper body is pre-embedded with a nylon sleeve for connecting and fixing the rail with a mounting fastener, and two symmetrically arranged cavities on the lower end surface of the sleeper body are provided with internal fillers, and the integrally formed sleeper body, the internal filler and the elastic bottom layer on its lower end surface form a conical structure with an upper end size smaller than a lower end size.

[0005] The elastic bottom layer comprises an elastic layer and a bottom plate, the bottom plate is fixed to the upper end surface of the elastic layer, and the sleeper body and the lower end surface of the inner filler are in contact with and fixedly connected to the upper end surface of the bottom plate.

[0006] Furthermore, the bottom plate is molded by glass fiber reinforced plastics.

[0007] Furthermore, the elastic layer is made of rubber material and is vulcanized into one with the bottom plate.

[0008] Furthermore, the inner filler is formed by vulcanization of rubber particles.

[0009] Furthermore, the sleeper body is formed integrally with a glass fiber reinforced plastic material, an inner filler and an elastic bottom layer.

[0010] The preparation method of the elastic sleeper of composite material comprises the following steps:

[0011] 1) Lay the mold flat with the opening facing upwards, and pass the small ends of the two nylon positioning bolts through the two through holes on the bottom surface of the mold respectively and connect them with the nylon sleeves at the corresponding positions in the mold through threads. The nylon sleeves are tightened and fixed in the mold by the nylon positioning bolts to complete the positioning of the nylon sleeves in the mold;

[0012] 2) Cut the FRP material piece by piece according to the size of the laying position in the mold cavity, then lay the FRP along the inner wall around the mold, then lay it to the bottom of the mold cavity, then lay it around the nylon sleeve and on the top of the nylon sleeve, so that the FRP material completely wraps the nylon sleeve inside, and finally lay the middle support filling of the FRP in the middle of the long side of the mold cavity;

[0013] 3) Using a core mold with two U-shaped structures to mold the glass fiber reinforced plastic material laid in the mold, so that a semi-finished sleeper body is formed after molding;

[0014] 4) placing the semi-finished sleeper body in the mold, filling the two cavities on the semi-finished sleeper body with rubber particles, then laying a fiberglass reinforced plastic material of a required thickness on the top surface, and finally laying rubber on the fiberglass reinforced plastic material;

[0015] 5) Use a flat plate to heat, vulcanize and mold the material in the mold as a whole, so that the rubber and fiberglass material inside the mold are molded and vulcanized into one, forming an elastic sleeper.

[0016] In the above step 1), the mold is a hollow box-shaped structure with an open top, and the inner walls around the mold are all inclined surfaces to form a conical inner cavity as a whole.

[0017] In the above step 2), the fiberglass reinforced plastics filled and laid around the inner wall, bottom surface, nylon sleeve circumference and middle support of the mold are used to form the main body of the sleeper made of fiberglass reinforced plastics.

[0018] In the above step 4), the rubber particles filled in the cavity are used to form the inner filler of the rubber material, and the fiberglass material laid on the upper end surface of the rubber particles is used to form the bottom plate, and the rubber laid on the fiberglass material is used to form the elastic layer.

[0019] The advantages of the present invention compared with the prior art are:

[0020] 1. This technical solution optimizes the structure and materials of the sleeper body, adopts a sleeper body made of glass fiber reinforced plastic material filled with internal fillers in two internal cavities, and an elastic bottom layer formed integrally with the sleeper body and the lower end surface of the internal filler to form an elastic sleeper, which solves the disadvantages of high replacement cost and heavy weight of traditional sleepers, significantly reduces the weight of sleepers, and ensures the structural strength of sleepers.

[0021] 2. This technical solution adopts a structure in which a sleeper body made of glass fiber reinforced plastics and an inner filler with rubber inside are combined with a glass fiber reinforced plastics bottom plate and an elastic layer of rubber material and formed in one piece, which greatly improves the elastic performance of the sleeper, has a good buffering and vibration reduction effect, and simplifies the sleeper processing procedure;

[0022] 3. This technical solution effectively ensures the various functions of the sleeper in actual use by pre-embedding the nylon sleeve on the upper end surface of the sleeper body, provides solid support for the safety and stability of railway transportation, and can effectively reduce maintenance and replacement costs;

[0023] 4. This technical solution has a simple structure and novel design. The integrated compression molding and vulcanization molding process greatly shortens the processing cycle of the sleeper. It has low cost and high efficiency, meets the high quality and high performance requirements of the sleeper, and has extremely high use value. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the structure of the present invention;

[0025] Figure 2 It is a schematic diagram of the structure of the nylon sleeve of the present invention being detachably positioned and fixed in a mold;

[0026] Figure 3 It is a schematic diagram of the initial pressing forming of the sleeper body of the present invention in the mold;

[0027] Figure 4 This is a three-dimensional diagram of the sleeper body formed into a semi-finished product by the first molding of the present invention;

[0028] Figure 5 It is a schematic diagram of the structure after the two cavities in the mold of the present invention are filled with rubber particles;

[0029] Figure 6 It is a schematic diagram of the structure after the elastic bottom layer material in the mold of the present invention is laid. DETAILED DESCRIPTION

[0030] The following will be combined with the embodiments of the present invention Figure 1-6, the technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0031] It should be noted that, in this document, unless otherwise stated, it should be understood that the terms "center", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", "third", etc., are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0032] In this document, the terms "comprises", "comprising" or any other variation thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further limitations. The elements defined by the sentence "comprising a ..." do not exclude the presence of other identical elements in the process, method, article or device comprising the elements.

[0033] Composite elastic sleepers, such as Figure 1As shown, it comprises an elastic bottom layer 1 and a sleeper body 2 arranged on the upper end surface of the elastic bottom layer 1. The upper end surface of the sleeper body 2 is pre-embedded with a nylon sleeve 3 for connecting and fixing the rail with the mounting fastener. By pre-embedding the nylon sleeve 3 on the upper end surface of the sleeper body 2, various functions of the sleeper in actual use are effectively guaranteed, providing solid support for the safety and stability of railway transportation, and effectively reducing maintenance and replacement costs; two symmetrically arranged cavities 7 on the lower end surface of the sleeper body 2 are provided with inner fillers 4, and the integrally formed sleeper body 2, the inner filler 4 and the elastic bottom layer 1 on the lower end surface thereof form A conical structure with an upper end dimension smaller than a lower end dimension; in the above structure, an elastic sleeper is formed by a sleeper body 2 made of a fiberglass material with an inner filler 4 filled in two internal cavities 7 and an elastic bottom layer 1 integrally formed with the sleeper body 2 and the lower end surface of the inner filler 4, which solves the drawbacks of high replacement cost and heavy weight of traditional sleepers, significantly reduces the weight of the sleeper, and ensures the structural strength of the sleeper. The inner filler 4 formed by vulcanization molding of rubber particles is used to absorb and consume energy. The vibration energy is absorbed by the inner filler 4 and converted into heat energy for consumption, thereby further improving the vibration reduction performance of the composite sleeper.

[0034] The specific structure of the elastic bottom layer 1 is as follows: the elastic bottom layer 1 includes an elastic layer 1-1 and a bottom plate 1-2, the bottom plate 1-2 is fixed to the upper end surface of the elastic layer 1-1, and the lower end surfaces of the sleeper body 2 and the inner filler 4 are in contact with and fixedly connected to the upper end surface of the bottom plate 1-2; in the above structure, the elastic layer 1-1 plays a role in providing vibration reduction and buffering, and the bottom plate 1-2 and the sleeper body 2 are both made of fiberglass, which has the advantages of reducing the weight of the sleeper and maintaining sufficient strength, meeting the requirements of high strength and low weight of the sleeper, and has strong corrosion resistance, which greatly extends the service life of the sleeper, has good node performance, will not reflect or block the propagation of microwaves, and is of great significance to signal transmission and safety in the track system, and good thermal insulation performance enables the sleeper to maintain stable performance under different temperature conditions.

[0035] Specifically, the bottom plate 1-2 is molded by glass fiber reinforced plastics; specifically, the elastic layer 1-1 is vulcanized with the bottom plate 1-2 by rubber material; specifically, the inner filler 4 is vulcanized with rubber particles; specifically, the sleeper body 2 is molded with glass fiber reinforced plastics material, the inner filler 4 and the elastic bottom layer 1; in the above structure, the sleeper body 2 made of glass fiber reinforced plastics and the inner filler 4 with rubber inside are combined with the glass fiber reinforced plastic bottom plate 1-1 and the elastic layer 1-2 of rubber material and are integrally molded, which greatly improves the elastic performance of the sleeper, has a good buffering and vibration reduction effect, and simplifies the sleeper processing process.

[0036] The preparation method of the elastic sleeper of composite material comprises the following steps:

[0037] 1) If Figure 2As shown, the mold 5 is laid flat with its opening facing upward, so that the small ends of the two nylon positioning bolts 6 pass through the two through holes on the bottom surface of the mold 5 respectively and are threadedly connected with the nylon sleeve 3 at the corresponding position in the mold 5, and the nylon sleeve 3 is tightened and fixed in the mold 5 by the nylon positioning bolts 6, so that the nylon sleeve 3 is positioned in the mold 5; specifically, the mold 5 is a hollow box-shaped structure with an opening at the upper end, and the inner walls around the mold 5 are all inclined surfaces to form a cone-shaped inner cavity as a whole;

[0038] 2) Cut the FRP material piece by piece according to the size of the laying position of the inner cavity of the mold 5, then lay the FRP along the inner wall around the mold 5, and then lay it toward the bottom surface of the inner cavity of the mold 5, and then lay it around the nylon sleeve 3 and on the top surface of the nylon sleeve 3, so that the FRP material completely wraps the nylon sleeve 3 inside, and finally lays the middle support filling of the FRP in the middle position of the long side of the inner cavity of the mold 5; specifically, the FRP laid on the inner wall around the mold 5, the bottom surface, the nylon sleeve 3 and the middle support filling is used to form the sleeper body 2 made of FRP;

[0039] 3) Using a core mold with two U-shaped structures to mold the glass fiber reinforced plastic material laid in the mold 5, so that a semi-finished sleeper body 2 is formed after molding, such as Figure 3 and Figure 4 As shown;

[0040] 4) If Figure 5 As shown, the semi-finished sleeper body 2 is placed in the mold 5, the two cavities 7 on the semi-finished sleeper body 2 are filled with rubber particles, and then the fiberglass material of the required thickness is laid on the top surface, and finally the rubber is laid on the fiberglass material; wherein the rubber particles filled in the cavities 7 are used to form the inner filler 4 of the rubber material, and the fiberglass material laid on the upper end surface of the rubber particles is used to form the bottom plate 1-2, and the rubber laid on the fiberglass material is used to form the elastic layer 1-1, as shown in FIG. Figure 6 As shown; the inner filler 4 and the elastic layer 1-1 are both for improving the vibration reduction and seismic resistance of the sleeper, reducing foundation vibration, rolling noise and wave deformation of the track;

[0041] 5) The material in the mold 5 is heated, vulcanized and molded as a whole using a flat plate, so that the rubber and the fiberglass reinforced plastic material inside the mold 5 are molded and vulcanized into one, forming an elastic sleeper.

[0042] In the present technical scheme, the mold 5 used for the first molding and the overall heating vulcanization and molding is the same. During molding, only the core mold and the flat plate need to be replaced. The structure is simple and the design is novel. The one-piece molding and vulcanization molding process greatly shortens the processing cycle of the sleeper. It has low cost and high efficiency. It is corrosion-resistant, fatigue-resistant, lightweight, high-strength and has good insulation. It meets the high quality and high performance requirements of the sleeper and has extremely high use value.

[0043] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

[0044] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. Composite elastic sleeper, characterized by: The invention comprises an elastic bottom layer (1) and a sleeper body (2) arranged on the upper end surface of the elastic bottom layer (1); a nylon sleeve (3) for connecting and fixing a rail with a mounting fastener is pre-embedded in the upper end surface of the sleeper body (2); and the inner hole wall and the outer wall of the nylon sleeve (3) are both provided with threads; an inner filler (4) is arranged in two symmetrically arranged cavities (7) on the lower end surface of the sleeper body (2); and the sleeper body (2), the inner filler (4) and the elastic bottom layer (1) on the lower end surface thereof are integrally formed to form a conical structure with an upper end dimension smaller than a lower end dimension, and the elastic bottom layer (1) and the sleeper body (2) wrap the inner filler (4) inside.

2. The elastic sleeper made of composite material according to claim 1, characterized in that: The elastic bottom layer (1) comprises an elastic layer (1-1) and a bottom plate (1-2), wherein the bottom plate (1-2) is fixed to the upper end surface of the elastic layer (1-1), and the lower end surfaces of the sleeper body (2) and the inner filler (4) are in contact with and fixedly connected to the upper end surface of the bottom plate (1-2).

3. The elastic sleeper made of composite material according to claim 2, characterized in that: The bottom plate (1-2) is molded using glass fiber reinforced plastic material.

4. The elastic sleeper made of composite material according to claim 3, characterized in that: The elastic layer (1-1) is made of rubber material and is vulcanized into one with the bottom plate (1-2).

5. The elastic sleeper made of composite material according to claim 1, characterized in that: The inner filler (4) is formed by vulcanization of rubber particles.

6. The elastic sleeper made of composite material according to any one of claims 1 to 5, characterized in that: The sleeper body (2) is made of glass fiber reinforced plastic material and is integrally formed with an inner filler (4) and an elastic bottom layer (1).

7. A method for preparing a composite elastic sleeper, characterized in that The following steps are involved: 1) The mold (5) is laid flat with the opening facing upward, so that the small ends of the two nylon positioning bolts (6) pass through the two through holes on the bottom surface of the mold (5) respectively and are threadedly connected with the nylon sleeves (3) at the corresponding positions in the mold (5), and the nylon positioning bolts (6) tighten and fix the nylon sleeves (3) in the mold (5), thereby completing the positioning of the nylon sleeves (3) in the mold (5); 2) cutting the glass fiber reinforced plastic material piece by piece according to the size of the laying position of the inner cavity of the mold (5), then laying the glass fiber reinforced plastic material along the inner walls around the mold (5), and then laying it towards the bottom surface of the inner cavity of the mold (5), and then winding and laying it around the circumference of the nylon sleeve (3) and laying it on the top surface of the nylon sleeve (3), so that the glass fiber reinforced plastic material completely wraps the nylon sleeve (3) inside, and finally laying the middle support filling of the glass fiber reinforced plastic material in the middle position of the long side of the inner cavity of the mold (5); 3) using a core mold with two U-shaped structures to mold the glass fiber reinforced plastic material laid in the mold (5), so that a semi-finished sleeper body (2) is formed after molding; 4) placing the semi-finished sleeper body (2) in the mold (5), filling the two cavities (7) on the semi-finished sleeper body (2) with rubber particles, then laying a fiberglass reinforced plastic material of a required thickness on the top surface, and finally laying rubber on the fiberglass reinforced plastic material; 5) Using a flat plate to heat and vulcanize the material in the mold (5) as a whole and perform molding, so that the rubber and the glass fiber reinforced plastic material in the mold (5) are molded and vulcanized into one, thereby forming an elastic sleeper.

8. The method for preparing the composite elastic sleeper according to claim 7, characterized in that: In the above step 1), the mold (5) is a hollow box-shaped structure with an open top, and the inner walls of the mold (5) are all inclined surfaces to form a conical inner cavity.

9. The method for preparing the composite elastic sleeper according to claim 7, characterized in that: In the above step 2), the inner wall around the mold (5), the bottom surface, the circumference of the nylon sleeve (3) and the glass fiber reinforced plastics filled and laid in the middle support are used to form the sleeper body (2) made of glass fiber reinforced plastics.

10. The method for preparing the composite elastic sleeper according to claim 7, characterized in that: In the above step 4), the rubber particles filled in the cavity (7) are used to form an inner filler (4) of rubber material, and the fiberglass material laid on the upper end surface of the rubber particles is used to form a bottom plate (1-2), and the rubber laid on the fiberglass material is used to form an elastic layer (1-1).

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