Earthwork prevention process for anti-seismic and waterproof earthwork of railway track

Abstract

The application relates to the technical field of railway engineering materials, in particular to an anti-seismic and waterproof earthwork cloth manufacturing process for a railway track.S1: material pretreatment, selecting nano-modified polyester filaments, elastic rubber, HDPE resin, self-healing adhesive and nano-silicon dioxide powder as core raw materials;S2: completing preparation of each layer;S3: composite process, closely combining the anti-aging surface layer, the anti-seismic and damping middle layer and the anti-corrosion bottom layer through an intelligent temperature control composite process in an embedding structure to form a gradient composite structure;S4: factory prefabrication;S5: on-site paving and sealing;S6: finished product detection and repair, and completing the manufacturing.The layered preparation, precise embedding and intelligent temperature control composite process are adopted, the layers are closely adhered, molecular-level fusion is realized, the problems of layering and degumming between the layers are effectively avoided, and the overall structural stability of the earthwork cloth is favorably ensured.

Description

Technical Field

[0001] This invention relates to the field of railway engineering materials technology, and in particular to a manufacturing process for earthquake-resistant and waterproof earthwork fabric for railway tracks. Background Technology

[0002] Earthquake-resistant and waterproof earthwork fabric for railway tracks is a core functional material that ensures the stability of the track subgrade and extends the service life of the track. It is mainly laid on the surface of the track subgrade and plays a key role in earthquake resistance and vibration reduction, waterproofing and seepage prevention, corrosion resistance and aging resistance. The scientific and rational nature of its preparation process directly determines the comprehensive performance of the product and the reliability of its engineering applications.

[0003] Currently, the existing manufacturing process for earthwork fabric for railway tracks has many shortcomings: First, the interlocking structure design and molding method are not perfect during the preparation of each layer, resulting in loose bonding between layers. This makes the fabric susceptible to delamination and debonding due to vibrations from railway operation, which seriously affects the combined effect of earthquake resistance and waterproofing. Second, the design of the earthquake-resistant and damping middle layer structure is unreasonable, lacking effective earthquake-resistant energy-absorbing components. This makes it difficult to buffer the continuous vibration loads generated during track operation and fails to meet the earthquake resistance requirements under complex working conditions. Summary of the Invention

[0004] The technical problem to be solved by this invention is to address the aforementioned technical deficiencies by providing a manufacturing process for earthquake-resistant and waterproof earthwork fabric for railway tracks, comprising the following steps: S1: Material pretreatment. Nano-modified polyester filaments, elastic rubber, HDPE resin, self-healing adhesive, and nano-silica powder are selected as core raw materials. Each raw material undergoes appropriate pretreatment, specifically: the nano-modified polyester filaments are dried, combed, and dispersed; the elastic rubber is pulverized; the HDPE resin and nano-silica powder undergo melt modification; and the self-healing adhesive is mixed with a curing agent and stirred evenly to ensure that each raw material meets the compatibility requirements of subsequent processes. S2: Complete the preparation of each layer, use needle punching process to prepare anti-aging surface layer, mix pretreated elastic rubber particles with modified HDPE melt at a mass ratio of 3:1, inject into customized molding mold, and integrally form shock-absorbing middle layer through molding process, and use spunbond process to form anti-corrosion bottom layer. S3: Composite process, which tightly combines the anti-aging surface layer, the shock-absorbing middle layer and the anti-corrosion bottom layer through an interlocking structure and intelligent temperature-controlled composite process to form a gradient composite structure; S4: Factory prefabrication, the gradient composite structure is prefabricated into segmented substrates, and a honeycomb waterproof membrane is integrally formed on the anti-aging surface layer, completing trimming, calibration and packaging; S5: On-site laying and sealing. Precast substrates are transported to the site for precise laying. Overlapping joints are sealed with a double seal of hot melt and self-healing coating. S6: Finished product inspection and repair. The performance of the formed earthwork fabric is tested, and any unqualified items are repaired in a targeted manner until all test items are qualified and the production is completed.

[0005] The manufacturing process of the anti-aging surface layer is as follows: pretreated nano-modified polyester filaments are formed by needle punching, with the needle punching density controlled at 200-250 needles / cm² and the surface layer thickness at 1.5-2.0mm; after forming, a nano-silica coating is applied to its outer surface. The nano-silica coating is made by mixing nano-silica powder and water-based adhesive at a mass ratio of 2:1, with a coating thickness of 0.1-0.2mm. After coating, it is dried and cured at 120-150℃; at the same time, a lower protruding interlocking structure adapted to the shock-absorbing middle layer is formed at the bottom of the anti-aging surface layer by molding, which is ready for use.

[0006] To further optimize this technical solution, the anti-corrosion base layer manufacturing process is as follows: the pretreated nano-modified polyester filaments are spunbonded, and the thickness of the base layer is controlled to be 1.0-1.5mm; during the spunbonding process, 2% to 3% of corrosion inhibitor is added simultaneously and mixed evenly; at the same time, a raised interlocking structure that matches the bottom of the shock-absorbing intermediate layer is formed on the top of the anti-corrosion base layer by molding; after molding, it is naturally cooled to room temperature for use.

[0007] Further optimizing this technical solution, the manufacturing process of the seismic damping intermediate layer is as follows: Pretreated elastic rubber granules and modified HDPE melt are mixed uniformly at a mass ratio of 3:1, injected into a customized molding die, and integrally formed into a hexagonal honeycomb mesh structure through molding. The molding temperature is controlled at 150-170℃, the molding pressure at 5-8MPa, and the heat and pressure holding time at 1-2 hours. The upper and lower surfaces of the seismic damping intermediate layer are molded into a wavy structure. The wavy structure of the upper and lower surfaces is respectively integrated with the lower protruding interlocking structure of the anti-aging surface layer and the upper protruding interlocking structure of the top of the anti-corrosion bottom layer. After molding, it is naturally cooled to room temperature for later use. Hollow rubber spheres are prepared using the pretreated elastic rubber through melt injection molding. These hollow rubber spheres are used to fill the honeycomb mesh structure. Each honeycomb mesh structure contains at least one hollow rubber sphere. The diameter of the hollow rubber sphere matches the inscribed circle diameter of the hexagonal honeycomb mesh structure, ensuring that the filling does not compress the mesh structure or affect the interlayer interlocking.

[0008] To further optimize this technical solution, the composite process is as follows: First, a nano-level bonding transition layer is filled into the interlocking gap at the top of the seismic damping intermediate layer. The nano-level bonding transition layer is made of the same material as the nano-silica coating of the anti-aging surface layer. The seismic damping intermediate layer is precisely aligned with the lower protruding interlocking structure of the anti-aging surface layer and the upper protruding interlocking structure at the top of the anti-corrosion bottom layer through the wavy structure on the upper and lower surfaces, respectively. The layers are then placed in an intelligent temperature-controlled composite machine, with the composite temperature controlled at 130-160℃, the composite pressure at 3-5MPa, and the composite speed at 0.3-0.5m / min. This allows the three-layer structure to achieve molecular-level fusion, forming a gradient composite structure without delamination or debonding risks.

[0009] To further optimize this technical solution, the prefabrication process of the segmented substrate is as follows: the gradient composite structure is prefabricated into segmented substrates using CNC die-cutting equipment, with the length of the segmented substrates controlled to be 5-10m and the width to be 2-3m, and an overlap allowance of 10-12cm reserved; after prefabrication, the segmented substrates are calibrated for flatness, trimmed, and marked with positioning marks, and then pre-packaged for use, in preparation for the subsequent integrated molding of the honeycomb waterproof membrane.

[0010] To further optimize this technical solution, the honeycomb waterproof membrane molding process is as follows: it is extruded synchronously with the segmented substrate prefabricated in step S4, using modified HDPE melt as raw material; the bottom of the honeycomb waterproof membrane has downward-extending waterproof protrusions with a diameter of 2-3mm and a height of 0.5-1mm, which are precisely fitted into the hexagonal honeycomb mesh structure of the seismic damping middle layer; the surface of the waterproof protrusions is coated with an ultra-thin self-healing adhesive with a coating thickness of 0.03-0.05mm, and after the waterproof membrane is formed, it is finally trimmed, aligned and packaged together with the segmented substrate.

[0011] To further optimize this technical solution, the overlap sealing process is as follows: Precast substrates are transported to the construction site using soft-sided transport vehicles; the roadbed is cleaned and leveled before laying, and precise positioning is achieved using positioning guides and a leveling instrument. The laying angle is adjusted according to the curves and slopes of the track to ensure a tight fit between the precast substrates and the roadbed, without wrinkles or voids; the overlap allowances of adjacent precast substrate sections are aligned, and the overlap is heated using an intelligent temperature-controlled hot melt gun, controlling the heating temperature at 180-200℃ and the heating time at 10-15 seconds, so that the honeycomb waterproof membrane and the gradient composite structure at the overlap achieve molecular-level fusion; after heating, a 0.2-0.3mm thick self-healing adhesive is applied to the overlap, followed by a 0.1mm thick nano-protective coating, and the sealing is completed after natural cooling to 25±5℃.

[0012] Compared with existing technologies, this invention has the following advantages: 1. It adopts a layered preparation, precise embedding, and intelligent temperature-controlled composite process, ensuring that each layer is tightly bonded and achieves molecular-level fusion, effectively avoiding interlayer delamination and debonding problems. This structure effectively guarantees the overall structural stability of the earthwork fabric; 2. The seismic-resistant and damping middle layer adopts a hexagonal honeycomb mesh structure filled with hollow rubber balls, achieving dual seismic resistance and energy absorption, effectively buffering track vibrations. This structure effectively guarantees the seismic resistance and damping performance of the earthwork fabric; 3. The honeycomb waterproof membrane and the segmented substrate are synchronously integrally molded, with the waterproof protrusions precisely embedded in the honeycomb mesh structure, and the overlapping joints are double-layered. 4. The heavy-sealing process provides excellent waterproof protection, effectively ensuring the waterproof and seepage-proof performance of the earthwork fabric; 5. The process is highly replicable, effectively improving the consistency of product performance, ensuring the feasibility of the process and the stability of product quality; 6. The anti-aging surface is coated with a nano-silica coating, and the anti-corrosion bottom layer is mixed with anti-corrosion agents, resulting in excellent anti-aging and anti-corrosion performance, effectively ensuring the service life of the earthwork fabric; 7. The segmented prefabrication and precise on-site laying method is suitable for complex working conditions such as track curves and slopes, making construction convenient and efficient, effectively ensuring the convenience and adaptability of engineering construction. Attached Figure Description

[0013] Figure 1 A schematic diagram of an explosion of a type of earthquake-resistant and waterproof earthwork fabric for railway tracks; Figure 2 This is a cross-sectional view of a type of earthquake-resistant and waterproof earthwork fabric for railway tracks. Figure 3 This is a top view of the seismic-resistant and vibration-damping middle floor in Example 1; Figure 4 This is a top view of the seismic-resistant and vibration-damping middle floor in Example 2; Figure 5 This is a cross-sectional view of the ellipsoidal rubber ball in Example 2.

[0014] In the diagram: 1. Anti-aging surface layer; 11. Honeycomb waterproof membrane; 2. Earthquake-resistant and shock-absorbing intermediate layer; 21. Spherical rubber ball; 22. Elliptical rubber ball; 3. Corrosion-resistant bottom layer. Detailed Implementation

[0015] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0016] Example 1 A type of earthquake-resistant and waterproof earthwork fabric for railway tracks, combined with Figures 1 to 3As shown, it consists of an anti-aging surface layer 1, an anti-vibration and shock-absorbing middle layer 2, and an anti-corrosion bottom layer 3. The specific steps of its manufacturing process are as follows: S1: Material pretreatment. Nano-modified polyester filaments, elastic rubber, HDPE resin, self-healing adhesive, and nano-silica powder are selected as core raw materials. Each raw material undergoes appropriate pretreatment, specifically: the nano-modified polyester filaments are dried at 80℃ for 3 hours, then combed and dispersed to ensure uniform fiber distribution without clumping. The nano-modified polyester filaments serve as the main fiber component for fabricating the anti-aging surface layer 1 and the anti-corrosion bottom layer 3; the elastic rubber is pulverized to 5mm particles; HDPE resin and nano-silica powder are mixed at a mass ratio of 95:5 and melt-modified at 180℃ for 30 minutes to prepare modified HDPE melt; the self-healing adhesive is mixed with 2% curing agent and stirred for 20 minutes until homogeneous, ensuring that each raw material meets the requirements for subsequent processes. S2: Complete the preparation of each layer. Use needle punching process to form the anti-aging surface layer 1, controlling the needle punching density to be 200 needles / cm² and the surface layer thickness to be 1.5mm. After forming, coat its outer surface with a nano-silica coating. The nano-silica coating is made by mixing nano-silica powder and water-based adhesive at a mass ratio of 2:1, with a coating thickness of 0.1mm. After coating, dry and cure at 120℃ for 30min. At the same time, at the bottom of the anti-aging surface layer 1, a lower protrusion interlocking structure adapted to the shock-absorbing middle layer 2 is formed by molding. The height of the lower protrusion interlocking structure is 0.3mm and the spacing is 2mm, for later use. The anti-corrosion base layer 3 was prepared by spunbonding process, and the thickness of the base layer was controlled to be 1.0 mm. During the spunbonding process, 2% corrosion inhibitor was added and mixed evenly. At the same time, an upper protrusion fitting structure adapted to the bottom of the shock-absorbing middle layer 2 was formed on the top of the anti-corrosion base layer 3 by molding. After molding, it was naturally cooled to 25°C for use. The height of the upper protrusion fitting structure was 0.4 mm. Pretreated elastic rubber granules and modified HDPE melt are mixed evenly at a mass ratio of 3:1 and injected into a customized molding die. The shock-absorbing middle layer 2, composed of a hexagonal (top view) honeycomb mesh structure, is integrally formed through the molding process. The molding temperature is controlled at 150℃, the molding pressure at 5MPa, and the heat and pressure holding time at 2h. The upper and lower surfaces of the shock-absorbing middle layer 2 are molded into a wave-shaped structure. The wave-shaped structure of the upper and lower surfaces is respectively integrated with the lower protrusion of the anti-aging surface layer 1 and the upper protrusion of the top of the anti-corrosion bottom layer 3. After molding, it is naturally cooled to 25℃ for later use. Hollow rubber balls are prepared using pretreated elastic rubber via melt injection molding. In this embodiment, the hollow rubber balls are spherical rubber balls 21. The injection temperature is 160℃ and the injection pressure is 4MPa. The prepared spherical rubber balls 21 are used to fill the honeycomb mesh basket structure. Figure 4As shown, each honeycomb basket structure is filled with a spherical rubber ball 21 with a diameter of 2mm, which matches the diameter of the inscribed circle of the hexagonal honeycomb basket structure, ensuring that the basket structure is not squeezed or the interlayer interlocking is not affected after filling; S3: Composite process. First, a nano-level bonding transition layer is filled into the interlocking gap at the top of the seismic damping middle layer 2. The nano-level bonding transition layer is made of the same material as the nano-silica coating of the anti-aging surface layer 1. The seismic damping middle layer 2 is precisely aligned with the lower protruding interlocking structure of the anti-aging surface layer 1 and the upper protruding interlocking structure at the top of the anti-corrosion bottom layer 3 through the wave-shaped structure on the upper and lower surfaces, respectively. It is then placed in an intelligent temperature-controlled composite machine, which controls the composite temperature at 130℃, the composite pressure at 3MPa, and the composite speed at 0.3m / min, so that the three-layer structure can achieve molecular-level fusion and form a gradient composite structure without delamination or debonding risk. S4: Factory prefabrication. The gradient composite structure is prefabricated into segmented substrates using CNC die-cutting equipment. The length of each segmented substrate is controlled to be 5m and the width to be 2m, with a 10cm overlap allowance. After prefabrication, the segmented substrates are calibrated for flatness (calibration accuracy ≤0.1mm / m), trimmed (trimming error ≤0.5mm), marked with positioning marks, and initially packaged with waterproof non-woven fabric for later use. A honeycomb waterproof membrane 11 is integrally formed on the anti-aging surface layer 1 and extruded synchronously with the segmented substrate prefabricated in step S4. Modified HDPE melt is used as raw material, and the extrusion temperature is 180℃. Waterproof protrusions extend downward from the bottom of the honeycomb waterproof membrane 11. The outer contour of the waterproof protrusions is adapted to the honeycomb mesh structure in the seismic damping middle layer 2, with a height of 0.5mm, and precisely fits into the hexagonal honeycomb mesh structure of the seismic damping middle layer 2. A layer of ultra-thin self-healing adhesive is coated on the surface of the waterproof protrusions with a coating thickness of 0.03mm. After the waterproof membrane 11 is formed, it is finally trimmed, aligned, and packaged together with the segmented substrate. S5: On-site laying and sealing. The precast substrate is transported to the construction site using a soft transport vehicle. Before laying, the roadbed is cleaned and leveled. The positioning guide rail and level calibrator are used for precise positioning. The laying angle is adjusted by 15° at the curve of the rail to ensure that the precast substrate is tightly attached to the roadbed without wrinkles or voids. The overlap allowance of the two adjacent precast substrate sections is aligned. The overlap is heated with an intelligent temperature-controlled hot melt gun. The heating temperature is controlled at 180℃ and the heating time is 15s to achieve molecular-level fusion of the honeycomb waterproof membrane 11 and the gradient composite structure at the overlap. After heating, a 0.2mm thick self-healing adhesive is applied to the overlap, and then a 0.1mm thick nano protective coating is applied. After natural cooling to 20℃, the sealing is completed. S6: Finished product inspection and repair. The anti-aging performance, seismic performance, waterproof and seepage prevention performance, puncture resistance performance and overlap sealing performance of the formed earthwork fabric are tested. The test found that the waterproof performance of one overlap sealing point was not up to standard. Self-healing adhesive was used to locally repair the area and then the test was repeated until all test items were up to standard, and the production was completed.

[0017] Example 2 The core difference between this embodiment and Embodiment 1 is that the hollow rubber spheres filled in the seismic damping intermediate layer 2 are ellipsoidal rubber spheres 22, and the specific parameters of each process step are adapted and adjusted. Other process details not mentioned are the same as in Embodiment 1. The specific differences in the steps are as follows: S1: Material pretreatment, with the following differential parameters: Nano-modified polyester filaments are dried at 100℃ for 2 hours; elastic rubber is crushed into 8mm particles; HDPE resin and nano silica powder are mixed at a mass ratio of 92:8 and melt-modified at 200℃ for 20 minutes; self-healing adhesive is mixed with 3% curing agent and stirred for 15 minutes until uniform.

[0018] S2: Complete the preparation of each layer. The difference parameters are as follows: the needle density of the anti-aging surface layer 1 is 250 needles / cm², the surface thickness is 2.0mm, the thickness of the nano silica coating is 0.2mm, and after coating, it is dried and cured at 150℃ for 20min; the height of the lower protrusion interlocking structure is 0.5mm. The thickness of the anti-corrosion base layer 3 is 1.5mm, and 3% corrosion inhibitor is added simultaneously during the spunbond molding process. The height of the upper raised interlocking structure is 0.5mm. The molding temperature of the seismic-resistant and damping intermediate layer 2 is 170℃, the molding pressure is 8MPa, and the heat preservation and pressure holding time is 1h. In this embodiment, the hollow rubber spheres are prepared into ellipsoidal rubber spheres 22 using melt injection molding. The injection temperature is 170℃ and the injection pressure is 5MPa. Figure 5 As shown, the minor axis diameter of the ellipsoidal rubber sphere 22 is 3mm, which matches the diameter of the inscribed circle of the hexagonal honeycomb mesh structure. The thickness of the major axis end of the ellipsoidal rubber sphere 22 is greater than the thickness of the minor axis end.

[0019] S3: Composite process, with the following parameters: composite temperature 160℃, composite pressure 5MPa, composite speed 0.5m / min.

[0020] S4: Factory prefabricated, with the following differences in parameters: the segmented substrate is 10m long and 3m wide, with a 12cm overlap allowance; the extrusion temperature of the honeycomb waterproof membrane 11 is 190℃.

[0021] S5: On-site laying and sealing, with the following differences in parameters: the laying angle is adjusted by 5° at the track ramp; the hot melt heating temperature is 200℃ and the heating time is 10s; the thickness of the self-healing adhesive coating at the overlap is 0.3mm, and the sealing is completed after natural cooling to 30℃.

[0022] S6: Finished product inspection and repair, the differences are as follows: Various performance tests are carried out on the formed earthwork cloth. All test items are qualified and the production is completed directly.

[0023] S6: Finished product inspection and repair. The formed earthwork fabric is tested for anti-aging performance, seismic performance, waterproof and seepage-proof performance, puncture resistance and overlap sealing performance. If all test items are qualified, the production is completed directly.

[0024] The above description is merely an optional embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A manufacturing process for earthquake-resistant and waterproof earthwork fabric for railway tracks, characterized in that, Includes the following steps: S1: Material pretreatment. Nano-modified polyester filaments, elastic rubber, HDPE resin, self-healing adhesive, and nano-silica powder are selected as core raw materials. Each raw material undergoes appropriate pretreatment, specifically: the nano-modified polyester filaments are dried, combed, and dispersed; the elastic rubber is pulverized; the HDPE resin and nano-silica powder undergo melt modification; and the self-healing adhesive is mixed with a curing agent and stirred evenly to ensure that each raw material meets the compatibility requirements of subsequent processes. S2: Complete the preparation of each layer, use needle punching process to prepare anti-aging surface layer (1), mix pretreated elastic rubber particles with modified HDPE melt at a mass ratio of 3:1, inject into customized molding mold, and use molding process to integrally form shock-absorbing middle layer (2), and use spunbond process to form anti-corrosion bottom layer (3). S3: Composite process, the anti-aging surface layer (1), the shock-absorbing middle layer (2), and the anti-corrosion bottom layer (3) are tightly bonded together by an intelligent temperature-controlled composite process through an interlocking structure to form a gradient composite structure; S4: Factory prefabrication, the gradient composite structure is prefabricated into segmented substrate, and honeycomb waterproof membrane (11) is integrally formed on the anti-aging surface layer (1) to complete trimming, calibration and packaging; S5: On-site laying and sealing, transporting prefabricated substrates to the site for precise laying, and using hot-melt and self-healing coatings for double sealing of overlapping joints; S6: Finished product inspection and repair. The performance of the formed earthwork fabric is tested, and any unqualified items are repaired in a targeted manner until all test items are qualified and the production is completed.

2. The manufacturing process of a seismic-resistant and waterproof earthwork fabric for railway tracks according to claim 1, characterized in that, The manufacturing process of the anti-aging surface layer (1) in step S2 is as follows: the pretreated nano-modified polyester filament is formed by needle punching, and the needle punching density is controlled to be 200-250 needles / cm² and the surface layer thickness is 1.5-2.0mm. After molding, a nano-silica coating is applied to its outer surface. The nano-silica coating is made by mixing nano-silica powder and water-based adhesive at a mass ratio of 2:

1. The coating thickness is 0.1-0.2 mm. After coating, it is dried and cured at 120-150℃. At the same time, a lower protrusion interlocking structure that is compatible with the anti-vibration and shock-absorbing middle layer (2) is formed at the bottom of the anti-aging surface layer (1) by molding, and is ready for use.

3. The manufacturing process of a seismic-resistant and waterproof earthwork fabric for railway tracks according to claim 1, characterized in that, The manufacturing process of the anti-corrosion bottom layer (3) in step S2 is as follows: the pretreated nano-modified polyester filament is spunbonded and the thickness of the bottom layer is controlled to be 1.0-1.5mm; during the spunbonding process, 2% to 3% of anti-corrosion agent is added and mixed evenly, and at the same time, a raised interlocking structure that is compatible with the bottom of the anti-vibration and damping middle layer (2) is formed on the top of the anti-corrosion bottom layer (3) by molding. After molding, it is naturally cooled to room temperature for use.

4. The manufacturing process of a seismic-resistant and waterproof earthwork fabric for railway tracks according to claim 1, characterized in that, The manufacturing process of the anti-vibration and damping intermediate layer (2) in step S2 is as follows: the pretreated elastic rubber particles and modified HDPE melt are mixed evenly at a mass ratio of 3:1, injected into a customized molding mold, and integrally formed into a honeycomb basket structure with a hexagonal top view through the molding process. The molding temperature is controlled at 150-170℃, the molding pressure is 5-8MPa, and the heat preservation and pressure holding time is 1-2h. The upper and lower surfaces of the anti-vibration and damping intermediate layer (2) are molded into a wave-shaped structure. The wave-shaped structure of the upper and lower surfaces is respectively integrated with the lower protrusion of the anti-aging surface layer (1) and the upper protrusion of the top of the anti-corrosion bottom layer (3). After molding, it is naturally cooled to room temperature for later use. Hollow rubber balls are prepared using pretreated elastic rubber and melt injection molding process. The prepared hollow rubber balls are used to fill honeycomb mesh basket structures. Each honeycomb mesh basket structure is filled with at least one hollow rubber ball. The diameter of the hollow rubber ball is adapted to the diameter of the inscribed circle of the hexagonal honeycomb mesh basket structure to ensure that the mesh basket structure is not squeezed or the interlayer interlocking is not affected after filling.

5. The manufacturing process of a seismic-resistant and waterproof earthwork fabric for railway tracks according to claim 1, characterized in that, The composite process described in step S3 is as follows: First, a nano-level bonding transition layer is filled at the interlocking gap at the top of the anti-vibration and damping intermediate layer (2). The nano-level bonding transition layer is made of the same material as the nano-silica coating of the anti-aging surface layer (1). The anti-vibration and damping intermediate layer (2) is precisely connected to the lower protruding interlocking structure of the anti-aging surface layer (1) and the upper protruding interlocking structure at the top of the anti-corrosion bottom layer (3) through the wave-shaped structure of the upper and lower surfaces. The layers are then placed in an intelligent temperature-controlled composite machine, and the composite temperature is controlled at 130-160℃, the composite pressure at 3-5MPa, and the composite speed at 0.3-0.5m / min. This allows the three-layer structure to achieve molecular-level fusion and form a gradient composite structure without delamination or debonding risks.

6. The manufacturing process of a seismic-resistant and waterproof earthwork fabric for railway tracks according to claim 1, characterized in that, The prefabrication process of the segmented substrate in step S4 is as follows: the gradient composite structure is prefabricated into segmented substrates using CNC die-cutting equipment, the length of the segmented substrate is controlled to be 5-10m and the width to be 2-3m, and an overlap allowance of 10-12cm is reserved; after the prefabrication is completed, the segmented substrate is calibrated for flatness, trimmed, marked with positioning marks, and pre-packaged for later use, in preparation for the subsequent integrated molding of the honeycomb waterproof membrane (11).

7. The manufacturing process of a seismic-resistant and waterproof earthwork fabric for railway tracks according to claim 1, characterized in that, The forming process of the honeycomb waterproof membrane (11) in step S4 is as follows: it is extruded and formed synchronously with the segmented substrate prefabricated in step S4, using modified HDPE melt as raw material; the bottom of the honeycomb waterproof membrane (11) has waterproof protrusions extending downward, with a diameter of 2-3mm and a height of 0.5-1mm, which are precisely fitted with the hexagonal honeycomb mesh structure of the earthquake-resistant and damping middle layer (2); the surface of the waterproof protrusions is coated with an ultra-thin self-healing adhesive with a coating thickness of 0.03-0.05mm. After the honeycomb waterproof membrane (11) is formed, it is finally trimmed, calibrated and packaged together with the segmented substrate.

8. The manufacturing process of a seismic-resistant and waterproof earthwork fabric for railway tracks according to claim 1, characterized in that, The overlapping sealing process described in step S5 is as follows: the precast substrate is transported to the construction site using a soft transport vehicle; the roadbed is cleaned and leveled before laying, and the positioning guide rail and level calibrator are used for precise positioning. The laying angle is adjusted according to the curves and slopes of the track to ensure that the precast substrate and the roadbed are tightly attached without wrinkles or hollows; the overlap allowance of the two adjacent precast substrate sections is aligned, and the overlap is heated using an intelligent temperature-controlled hot melt gun. The heating temperature is controlled at 180-200℃ and the heating time is 10-15s, so that the honeycomb waterproof membrane (11) and the gradient composite structure at the overlap can achieve molecular-level fusion; after heating, a layer of self-healing adhesive with a thickness of 0.2-0.3mm is applied to the overlap, and then a layer of nano-protective coating with a thickness of 0.1mm is covered. After natural cooling to 25±5℃, the sealing is completed.

Images