Integrally-formed composite sleeper and preparation device

Abstract

The utility model provides an integrally-formed synthetic sleeper and a preparation device, the integrally-formed synthetic sleeper comprises a polyurethane resin matrix, continuous glass fibers are longitudinally arranged in the polyurethane resin matrix and used for longitudinal reinforcement of the synthetic sleeper, and a reinforcement layer composed of glass fiber fabric and polyurethane resin is arranged on the surface of the polyurethane resin matrix. The thickness of the reinforcing layer is 1 to 10 mm; the overall strength of the composite sleeper can be remarkably improved, and transverse cracking is avoided.

Description

Technical Field

[0001] The utility model relates to the technical field of rail transportation, and in particular to an integrally formed synthetic sleeper and a preparation device thereof. Background Art

[0002] Sleepers are important parts in the field of rail transit. They can evenly transfer the load transmitted by the train to the roadbed, and play an important role in the stable and safe operation of rail transit. At present, the most widely used sleepers in the world are wooden sleepers and reinforced concrete sleepers. However, wooden sleepers are prone to decay and aging, uneven strength, and high water absorption. Reinforced concrete sleepers have high maintenance costs, short life, poor toughness, heavy weight, difficult installation, and difficult on-site drilling. Therefore, in recent years, new synthetic sleepers have been widely studied by countries around the world.

[0003] Polyurethane foam synthetic sleepers are composite material synthetic sleepers formed by glass fiber reinforced polyurethane foam, also known as synthetic sleepers. They are widely used due to their advantages such as light weight, high strength, corrosion resistance, insulation, good weather resistance, and high production and installation efficiency. However, synthetic sleepers in the prior art also use unidirectional continuous glass fiber reinforcement and no lateral fiber reinforcement. There is a risk of lateral cracking during use. During the production of synthetic sleepers, a release agent needs to be sprayed on the surface of the mold sleeper to allow the sleeper to be demolded smoothly. After demolding, the product surface needs to be polished and painted. The production process is complicated and generates more VOC and dust pollution. Utility Model Content

[0004] In view of this, the utility model aims to propose an one-piece synthetic sleeper and a preparation device. One of the problems to be solved is that the synthetic sleepers in the prior art use unidirectional continuous glass fiber reinforcement and no lateral fiber reinforcement, which poses a risk of lateral cracking during use; the second problem to be solved is that during production, a release agent needs to be sprayed on the sleeper surface to allow the sleeper to be demolded smoothly. After demolding, the product surface needs to be polished and painted, which complicates the production process and generates more VOC and dust pollution.

[0005] In order to achieve the above object, the technical solution of the utility model is implemented as follows:

[0006] An integrally formed synthetic sleeper comprises a polyurethane resin matrix, in which continuous glass fibers are longitudinally arranged for longitudinal reinforcement of the synthetic sleeper, and a reinforcement layer composed of glass fiber fabric and polyurethane resin is arranged on the surface of the polyurethane resin matrix, wherein the thickness of the reinforcement layer is 1 to 10 mm.

[0007] Setting a reinforcement layer on the surface of the synthetic sleeper can significantly increase the overall strength of the synthetic sleeper and avoid lateral cracking; the glass fiber fabric uses composite felt of a set color to produce synthetic sleepers of the required color, which reduces the painting process and reduces pollution to the environment. The color of the synthetic sleeper can be customized according to demand to meet the personalized needs of different customers. It can ensure that the color of the synthetic sleeper remains consistent throughout the entire production process, which helps to improve the appearance quality of the product and increase the beauty and consistency of the product. Composite felt, as a material for glass fiber fabric, has good durability and anti-aging properties, which can ensure that the color of the synthetic sleeper remains bright and stable after long-term use.

[0008] Furthermore, the surface density of the glass fiber fabric is 300 to 1500 g / m 2 .

[0009] This arrangement makes it easy to adjust the surface density of the glass fiber fabric according to actual application conditions, and can produce synthetic sleepers with different surface reinforcement layer thicknesses, thereby expanding the application range of the synthetic sleepers.

[0010] Furthermore, the glass fiber fabric uses composite felt of a set color to produce synthetic sleepers of the desired color. The painting process is reduced, the pollution to the environment is reduced, the color of the synthetic sleeper 100 can be customized according to the needs, and the personalized needs of different customers can be met. The color of the synthetic sleeper 100 can be ensured to be consistent throughout the production process, which helps to improve the appearance quality of the product and increase the beauty and consistency of the product. The composite felt, as the material of the glass fiber fabric 511, has good durability and anti-aging performance, and can ensure that the color of the synthetic sleeper 100 remains bright and stable after long-term use.

[0011] The present application also provides a preparation device for an integrally formed synthetic sleeper, which is used to prepare the integrally formed synthetic sleeper described above, and includes a yarn frame, a closed glue dipping box, a glue injection machine, a felt guide, a felt frame, a crawler machine and a sawing machine arranged in sequence, the felt guide including a first felt guide and a second felt guide, the felt frame including a first felt frame and a second felt frame, the yarn frame is used to place continuous glass fibers, the closed glue dipping box is used to uniformly impregnate the continuous glass fibers with polyurethane resin, the glue injection machine is used to transport the polyurethane resin into the closed glue dipping box, the first felt frame is used to place glass fiber fabrics, the first felt guide is used to guide the glass fiber fabrics to be coated on the surface of the continuous glass fibers, the second felt frame is used to place release paper, the second felt guide is used to guide the release paper to be coated on the surface of the glass fiber fabric, the crawler machine is provided with a mold, the mold is used to heat and pressurize the continuous glass fibers coated with polyurethane resin, so that the polyurethane resin is cured to form a fiber-reinforced polyurethane synthetic sleeper, and the sawing machine is used to cut the fiber-reinforced polyurethane synthetic sleeper.

[0012] This setup can significantly improve production efficiency and ensure the quality and consistency of the composite sleepers.

[0013] Furthermore, the crawler machine includes a lower crawler machine and an upper crawler machine, and baffles are arranged on the left and right sides of the crawler machine. The baffles cooperate with the upper crawler machine and the lower crawler machine to form a mold cavity. The synthetic sleeper is solidified and formed in the mold cavity, and automatically separated from the mold cavity as the crawler machine rotates.

[0014] This setting can not only accurately control the shape and size of the composite sleepers, ensure the consistency and quality of the products, but also improve production efficiency and operational convenience.

[0015] Furthermore, the glue injection machine includes a component A tank, a component B tank, a mixing gun head and a diverter. The component A tank and the component B tank are connected to the mixing gun head through pipelines, respectively. The mixing gun head is connected to the diverter through the pipeline. The diverter is connected to the closed dipping box through the diversion glue injection tube. The component A tank is used to store polyurethane resin A, the component B tank is used to store polyurethane resin B, the mixing gun head is used to mix polyurethane resin A and polyurethane resin B, and the diverter is used to evenly divide the mixed polyurethane resin output by the mixing gun head and input it into the closed dipping box.

[0016] This arrangement can ensure that the polyurethane resin A and the polyurethane resin B are fully mixed to form a uniform mixed polyurethane resin, which is evenly distributed on the surface of the continuous glass fiber, thereby improving the quality and strength of the synthetic sleeper.

[0017] Furthermore, the creel is provided with a yarn separation plate, and the yarn separation plate is used to layer the continuous glass fibers.

[0018] This setting can ensure the quantity and uniform distribution of fibers in each layer, improve the fiber reinforcement uniformity of the synthetic sleeper, and enhance the strength and stability of the product.

[0019] Furthermore, the closed glue dipping box is provided with a plurality of glue injection holes, the mixing gun head is connected to a flow diverter, and the flow diverter is connected to the glue injection holes through a plurality of flow diversion glue injection tubes.

[0020] This arrangement facilitates the control of the flow of the polyurethane resin, ensures uniform impregnation of the continuous glass fibers, and improves the quality and performance of the synthetic sleeper.

[0021] Furthermore, the second felt frame is used for placing the release cloth.

[0022] Release sheets have greater strength and durability, can better protect the synthetic sleeper surface from damage, and can be reused after proper cleaning and maintenance, saving costs and reducing waste generation.

[0023] Compared with the prior art, the one-piece synthetic sleeper and the preparation device described in the utility model have the following advantages:

[0024] 1) It can significantly increase the overall strength of the synthetic sleeper and avoid lateral cracking;

[0025] 2) It reduces the steps of spraying release agent, surface painting and polishing, reduces VOC and dust pollution in the production process, and reduces pollution to the environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of the overall structure of the device for preparing an integrally formed synthetic sleeper according to an embodiment of the utility model;

[0027] Figure 2 for Figure 1 Schematic diagram of the structure of the middle felt guide;

[0028] Figure 3 It is a schematic structural diagram of the synthetic sleeper described in the embodiment of the utility model.

[0029] Description of reference numerals:

[0030] 1. Yarn frame; 11. Continuous glass fiber; 2. Closed dipping box; 3. Glue injection machine; 31. Component A material tank; 32. Component B material tank; 33. Mixing gun head; 34. Diverter; 35. Diverter injection hose; 4. Felt guide; 41. First felt guide; 42. Second felt guide; 5. Felt frame; 51. First felt frame; 511. Glass fiber fabric; 52. Second felt frame; 521. Release paper; 6. Track machine; 61. Lower track machine; 62. Upper track machine; 7. Sawing machine; 100. Synthetic sleeper; 101. Polyurethane resin matrix; 102. Reinforcement layer. DETAILED DESCRIPTION

[0031] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and understandable, the specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0032] The specific implementation is as follows:

[0033] like Figure 1-3 As shown, an integrally formed synthetic sleeper comprises a polyurethane resin matrix 101, continuous glass fibers 11 are longitudinally arranged in the polyurethane resin matrix 101, and are used for longitudinal reinforcement of the synthetic sleeper 100. The surface of the polyurethane resin matrix 101 is provided with a reinforcing layer 102 composed of glass fiber fabric 511 and polyurethane resin, and the thickness of the reinforcing layer 102 is 1 to 10 mm; the overall density is 0.64 to 1.4 g / cm 3, wherein the polyurethane resin accounts for 35-50% of the total weight of the synthetic sleeper 100; the continuous glass fiber 11 accounts for 35-60% of the total weight of the synthetic sleeper 100, and the glass fiber fabric 511 accounts for 3-10% of the total weight of the synthetic sleeper 100.

[0034] Specifically, the continuous glass fibers 11 are longitudinally arranged in the polyurethane resin matrix 101, which can increase the overall strength and stability of the synthetic sleeper 100. The reinforcing layer 102 is arranged on the surface of the polyurethane resin matrix 101, which can significantly increase the overall strength of the synthetic sleeper 100 and avoid transverse cracking. The thickness of the reinforcing layer 102 ranges from 1 to 10 mm, and the appropriate thickness can be flexibly selected according to the specific application scenario, thereby expanding the scope of application. The material ratio in the present application can further improve the performance and quality of the synthetic sleeper 100.

[0035] Preferably, the continuous glass fiber 11 is configured as alkali-free glass fiber direct yarn or twisted yarn, and the linear density is 4800-19200 tex.

[0036] Preferably, the glass fiber fabric 511 is made of composite felt of a set color, which is used to produce synthetic sleepers 100 of the required color, thereby reducing the painting process and alleviating pollution to the environment. The color of the synthetic sleeper 100 can be customized according to demand to meet the personalized needs of different customers, and the color of the synthetic sleeper 100 can be ensured to remain consistent throughout the entire production process, which helps to improve the appearance quality of the product and increase the beauty and consistency of the product. The composite felt used as the material of the glass fiber fabric 511 has good durability and anti-aging properties, and can ensure that the color of the synthetic sleeper 100 remains bright and stable after long-term use.

[0037] Preferably, the glass fiber fabric 511 is one or more combinations of continuous mat, stitched mat, chopped mat, mesh cloth, biaxial cloth made of glass fiber, carbon fiber, basalt fiber, nylon fiber, polyester fiber.

[0038] As a preferred example of the present invention, the polyurethane resin is compounded by component A and component B in a weight ratio of 100:100-150; wherein component A is a polyol combination material, and component B is isocyanate.

[0039] Specifically, polyol has good elasticity and flexibility, can increase the durability and impact resistance of the synthetic sleeper 100, and can also provide suitable viscosity and fluidity, which is beneficial to the processing and molding of polyurethane resin. Isocyanate can control the hardness, strength and durability of polyurethane resin, so that the synthetic sleeper 100 has appropriate rigidity and strength. This setting can ensure the performance and quality of polyurethane resin and improve the overall strength and stability of synthetic sleeper 100.

[0040] As a preferred example of the present invention, the average hydroxyl value of component A is 300-500 mgKOH / g, the viscosity at 25°C is 500-2000 mPa·s, and the functionality is 3-6; the isocyanate content of component B is 30-32%, the viscosity at 25°C is 200-600 mPa·s, and the functionality is 2-3.

[0041] Specifically, the average hydroxyl value ranges from 300 to 500 mgKOH / g, which can provide sufficient reactivity and is conducive to the reaction with the isocyanate of component B to form a polyurethane resin. The moderate viscosity makes component A easy to process and mix, which is conducive to the preparation of polyurethane resin. The higher the functionality, the higher the degree of cross-linking of the polyurethane resin, and the hardness and strength will also increase, which helps to improve the hardness and strength of the synthetic sleeper. This setting can provide sufficient reactivity and viscosity, which is conducive to the reaction of component A with component B to form a polyurethane resin, and can improve the hardness and strength of the synthetic sleeper.

[0042] As a preferred example of the present invention, the surface density of the glass fiber fabric 511 is 300 to 1500 g / m 2 , which can be one or more layers

[0043] Specifically, the greater the surface density of the glass fiber fabric, the more layers, the thicker the reinforcement layer, the higher the lateral strength of the synthetic sleeper, but the longitudinal strength will be slightly reduced. The surface density of the glass fiber fabric 511 can be adjusted according to actual application conditions, and synthetic sleepers with different surface reinforcement layer thicknesses can be produced.

[0044] The present application also provides a process for preparing an integrally formed synthetic sleeper, which is used to prepare the above-mentioned integrally formed synthetic sleeper, comprising the steps of:

[0045] Step S1: Calculating the number of continuous glass fibers 11 according to the density and glass fiber content of the synthetic sleeper 100;

[0046] Step S2: layering the continuous glass fiber 11 according to the calculation results;

[0047] Step S3: uniformly impregnating the layered continuous glass fibers 11 with polyurethane resin;

[0048] Step S4: sequentially wrapping the glass fiber fabric 511 and the release paper 521 on the outside of the continuous glass fiber 11 impregnated with the polyurethane resin;

[0049] Step S5: heating the continuous glass fiber 11 coated with the glass fiber fabric 511 and the release paper 521 and the polyurethane resin, and curing the polyurethane resin to form a fiber-reinforced polyurethane synthetic sleeper 100;

[0050] Step S6: cutting and segmenting the cured fiber-reinforced polyurethane synthetic sleeper 100 according to size requirements to obtain a finished synthetic sleeper 100.

[0051] Specifically, by calculating the number of layers of continuous glass fibers 11, the appropriate number of fiber layers can be determined according to the density and glass fiber content of the synthetic sleeper 100, thereby achieving control over the strength and stability of the synthetic sleeper 100. The layered continuous glass fibers 11 can be better combined with the polyurethane resin to improve the overall strength and stability of the synthetic sleeper 100. The coated glass fiber fabric 511 can increase the surface strength of the synthetic sleeper and avoid lateral cracking. Coating the release paper 521 on the outside of the glass fiber fabric 511 facilitates product demoulding, without the need for spraying a release agent and surface polishing, thereby reducing VOC and dust pollution in the production process.

[0052] The present application also provides a preparation device for an integrally formed synthetic sleeper, which is used to prepare the above-mentioned integrally formed synthetic sleeper, including a creel 1, a closed glue dipping box 2, a glue injection machine 3, a felt guide 4, a felt frame 5, a crawler machine 6 and a sawing machine 7 arranged in sequence, the felt guide 4 includes a first felt guide 41 and a second felt guide 42, the felt frame 5 includes a first felt frame 51 and a second felt frame 52, the creel 1 is used to place continuous glass fibers 11, the closed glue dipping box 2 is used to uniformly impregnate the continuous glass fibers 11 with polyurethane resin, the glue injection machine 3 is used to transport polyurethane resin into the closed glue dipping box 2, and the first .... The frame 51 is used to place the glass fiber fabric 511, the first felt guide 41 is used to guide the glass fiber fabric 511 to be coated on the surface of the continuous glass fiber 11, the second felt frame 52 is used to place the release paper 521, the second felt guide 42 is used to guide the release paper 521 to be coated on the surface of the glass fiber fabric 511, the crawler 6 is provided with a mold, the mold is used to heat and pressurize the continuous glass fiber 11 coated with polyurethane resin, so that the polyurethane resin is cured to form a fiber-reinforced polyurethane synthetic sleeper 100, and the sawing machine 7 is used to cut the fiber-reinforced polyurethane synthetic sleeper 100.

[0053] Specifically, the creel 1 is provided with a yarn dividing plate for stratifying the continuous glass fiber 11, ensuring the quantity and uniform distribution of fibers in each layer, improving the fiber reinforcement uniformity of the synthetic sleeper 100, and enhancing the strength and stability of the product. In actual production, the continuous glass fiber 11 is led out from the creel 1, passes through the yarn dividing plate, the closed dipping box 2, the first felt guide 41, and the second felt guide 42 from front to back, and then enters the crawler 6. The continuous glass fiber 11 moves backward under the extrusion and traction of the crawler 6. This arrangement can greatly improve production efficiency and ensure the quality and consistency of the synthetic sleeper 100.

[0054] Preferably, the second felt frame 52 is used to place a release cloth, and the release paper / cloth comprises at least 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.

[0055] As a preferred example of the present utility model, the crawler machine 6 includes a lower crawler machine 61 and an upper crawler machine 62, and baffles are arranged on the left and right sides of the crawler machine 6. The baffles cooperate with the upper crawler machine 62 and the lower crawler machine 61 to form a mold cavity. The synthetic sleeper 100 is cured and formed in the mold cavity, and automatically separated from the mold cavity as the crawler machine 6 rotates.

[0056] Specifically, this arrangement can not only accurately control the shape and size of the composite sleeper 100, ensuring the consistency and quality of the product, but also improve production efficiency and operational convenience.

[0057] As a preferred example of the present utility model, the glue injection machine 3 includes a component A tank 31, a component B tank 32, a mixing gun head 33 and a diverter 34. The component A tank 31 and the component B tank 32 are respectively connected to the mixing gun head 33 through pipelines, the mixing gun head 33 is connected to the diverter 34 through a pipeline, and the diverter 34 is connected to the closed dipping box 2 through a diversion glue injection tube 35. The component A tank 31 is used to store polyurethane resin A, the component B tank 32 is used to store polyurethane resin B, the mixing gun head 33 is used to mix polyurethane resin A and polyurethane resin B, and the diverter 34 is used to evenly divide the mixed polyurethane resin output by the mixing gun head 33 and input it into the closed dipping box 2.

[0058] Specifically, through the mixing of the mixing gun head 33, it can be ensured that the polyurethane resin A and the polyurethane resin B are fully mixed to form a uniform mixed polyurethane resin, which has better fluidity and wettability, thereby improving the consistency and quality of the synthetic sleeper 100. The mixed polyurethane resin output by the mixing gun head 33 is evenly divided and input into the closed dipping box 2 through the diverter 34, thereby ensuring that the mixed polyurethane resin is evenly distributed on the surface of the continuous glass fiber 11 during the injection process, thereby improving the quality and strength of the synthetic sleeper 100. This arrangement can ensure that the polyurethane resin A and the polyurethane resin B are fully mixed to form a uniform mixed polyurethane resin, which is evenly distributed on the surface of the continuous glass fiber 11, thereby improving the quality and strength of the synthetic sleeper 100.

[0059] Preferably, the closed dipping box 2 is provided with a plurality of injection holes, the mixing gun head 33 is connected to the diverter 34, and the diverter 34 is connected to the injection holes through a plurality of diverter injection tubes 35. This arrangement facilitates the control of the flow rate of the polyurethane resin, ensures the uniform impregnation of the continuous glass fiber 11, and improves the quality and performance of the synthetic sleeper 100.

[0060] As a preferred example of the present invention, the pulling speed of the mold is 0.3-1.0 m / min, the mold temperature is 40-90° C., and the curing time of the synthetic sleeper 100 in the mold is 40-60 min.

[0061] Specifically, by controlling the pulling speed, mold temperature and curing time, the synthetic sleeper 100 can be fully cured in the mold, thereby improving product quality and production efficiency.

[0062] Example 1

[0063] The hydroxyl value of component A of the polyurethane composite material is 320±20 mgKOH / g, the viscosity is 1200 mPas, and component B is polymerized MDI with an isocyanate index of 31.2%. The mass ratio of component A to component B is set to 100:100, and components A and B are pumped into the glue injection machine in advance for standby use;

[0064] By changing the position of the baffle plate and the distance between the lower crawler machine 61 and the upper crawler machine 62, the mold cavity size of the crawler machine 6 is adjusted to 200 mm (width) × 140 mm (height), and the product density is 0.70 ± 0.04 g / cm 3 , calculated based on a glass fiber content of 50%, the reinforcement material uses 9600tex continuous glass fiber 11 direct yarn, the number of which is 1030 bundles. The continuous glass fiber 11 passes through the closed dipping box 2 into the mold and enters the crawler machine cavity under the extrusion and traction of the crawler machine 6. The glass fiber fabric 511 uses a width of 700mm and a surface density of 600g / m 2 The continuous felt has two layers, and the felt guide 4 uses a layer of PET release paper as the release paper 521, with a width of 720 mm and a surface density of 90 g / m 2 , the glass fiber fabric 511 and the release paper 521 wrap the continuous glass fiber in sequence and enter the mold together.

[0065] When the mold temperature of the crawler machine 6 is preheated to 50°C, the glue injection machine 3 is turned on for glue injection. The glass fiber fabric 511 and the demoulding paper 521 are sequentially coated on the outside of the continuous glass fiber 11 impregnated with the polyurethane resin. The resin flow of the glue injection machine 3 is adjusted in time to ensure that the polyurethane resin evenly impregnates the continuous glass fiber 11 and the fiber fabric 511. The production speed is controlled at 0.75m / min. The product is demoulded after being cured in the mold for 40 minutes. After the product is demoulded, it is sawed according to the set length. After sawing, the demoulding paper 521 is cleaned to obtain the finished synthetic sleeper 100. The thickness of the glass fiber fabric reinforcement layer 102 on the surface of the finished synthetic sleeper 100 is 1.5mm.

[0066] Example 2

[0067] The hydroxyl value of component A of the polyurethane composite material is 400±20 mgKOH / g, the viscosity is 800 mPas, and component B is polymerized MDI with an isocyanate index of 31.2%. The mass ratio of component A to component B is set to 100:120, and components A and B are pumped into the glue injection machine in advance for standby use;

[0068] By changing the position of the baffle plate and the distance between the lower crawler machine 61 and the upper crawler machine 62, the mold cavity size of the crawler machine 6 is adjusted to 230 mm (width) × 140 mm (height), and the product density is 0.80 ± 0.04 g / cm 3 , calculated based on a glass fiber content of 50%, the reinforcement material uses 13800tex continuous glass fiber plied yarn, the number of which is 840 bundles, the continuous glass fiber 11 passes through the closed dipping box 2 into the mold, and enters the crawler machine mold cavity under the extrusion and traction of the crawler machine 6, the glass fiber fabric 511 is 750mm wide, and the density of the 3-layer layer is 600g / m 2 The density of fiberglass mesh + 1 layer is 450g / m 2 The polyester stitched composite felt is black, and the felt guide 4 uses a layer of PE release film as the release paper 521, with a width of 770 mm and a surface density of 120 g / m 2 , the glass fiber fabric 511 and the release paper 521 wrap the continuous glass fiber in sequence and enter the mold together.

[0069] When the mold temperature of the crawler machine 6 is preheated to 60°C, the glue injection machine 3 is turned on for glue injection. The glass fiber fabric 511 and the demoulding paper 521 are sequentially coated on the outside of the continuous glass fiber 11 impregnated with the polyurethane resin. The resin flow of the glue injection machine 3 is adjusted in time to ensure that the polyurethane resin evenly impregnates the continuous glass fiber 11 and the fiber fabric 511. The production speed is controlled at 0.6m / min. The product is demoulded after being cured in the mold for 50 minutes. After the product is demoulded, it is sawed according to the set length. After sawing, the demoulding paper 521 is cleaned to obtain a finished black synthetic sleeper 100. The thickness of the glass fiber fabric reinforcement layer 102 on the surface of the finished synthetic sleeper 100 is 3mm.

[0070] Example 3

[0071] The hydroxyl value of component A of the polyurethane composite material is 480±20 mgKOH / g, the viscosity is 700 mPas, and component B uses polymeric MDI with an isocyanate index of 31.2%. The mass ratio of component A to component B is set to 100:140, and components A and B are pumped into the glue injection machine in advance for standby use;

[0072] By changing the position of the baffle plate and the distance between the lower crawler machine 61 and the upper crawler machine 62, the mold cavity size of the crawler machine 6 is adjusted to 240 mm (width) × 240 mm (height), and the product density is 1.20 ± 0.06 g / cm 3 , calculated with a glass fiber content of 55%, the reinforcement material uses 19200tex continuous glass fiber plied yarn, the number is 1990 bundles, the continuous glass fiber 11 passes through the closed dipping box 2 into the mold, and enters the crawler machine mold cavity under the extrusion and traction of the crawler machine 6. The glass fiber fabric 511 uses a width of 980mm and a 6-layer density of 600g / m 2 0° / 90° glass fiber biaxial fabric + 1 layer density 450g / m 2 The continuous felt, the felt guide 4 uses a layer of PET release paper as the release paper 521, the width is 1000mm, the surface density is 120g / m 2 , the glass fiber fabric 511 and the release paper 521 wrap the continuous glass fiber in sequence and enter the mold together.

[0073] When the mold temperature of the crawler machine 6 is preheated to 60°C, the glue injection machine 3 is turned on for glue injection. The glass fiber fabric 511 and the demoulding paper 521 are sequentially coated on the outside of the continuous glass fiber 11 impregnated with the polyurethane resin. The resin flow of the glue injection machine 3 is adjusted in time to ensure that the polyurethane resin is evenly impregnated into the continuous glass fiber 11 fiber fabric 511. The production speed is controlled at 0.55m / min. The product is demoulded after being cured in the mold for 50 minutes. After the product is demoulded, it is sawed according to the set length. After sawing, the demoulding paper 521 is cleaned to obtain the finished synthetic sleeper 100. The thickness of the glass fiber fabric reinforcement layer 102 on the surface of the finished synthetic sleeper 100 is 6mm.

[0074] Comparative Example 1

[0075] All reinforcement materials are 9600tex continuous glass fiber direct yarn, with 1120 bundles arranged, and no glass fiber fabric reinforcement on the surface;

[0076] Other molding process parameters are the same as those in “Example 1”.

[0077] Comparative Example 2

[0078] All reinforcement materials are made of 13800tex continuous glass fiber yarn, with 900 bundles arranged, and no glass fiber fabric reinforcement on the surface;

[0079] Other molding process parameters are the same as those in “Example 2”.

[0080] Comparative Example 3

[0081] All reinforcement materials are 9600tex continuous glass fiber direct yarn, with 2180 bundles arranged, and no glass fiber fabric reinforcement on the surface;

[0082] Other molding process parameters are the same as those in “Example 3”.

[0083] Performance measurement

[0084] In the above embodiments and comparative examples, the density is determined in accordance with GB / T1463-2005 "Test method for density and relative density of fiber reinforced plastics"; the mechanical properties of Examples 1, 2 and Comparative Examples 1, 2 are tested with reference to CJ / T3992012 "Polyurethane foam synthetic sleepers" standard; the mechanical properties of Example 3 and Comparative Example 3 are tested with reference to TJ / GW161-2018 "HFFP composite material sleepers for railway steel beams" interim technical conditions.

[0085] The fiber-reinforced polyurethane composite synthetic sleepers obtained in Examples 1 to 3 and Comparative Examples 1 to 3 were tested, and the specific results are shown in Table 1.

[0086] Table 1. Comparison of performance of synthetic sleeper products in the examples and comparative examples

[0087]

[0088]

[0089] Note: 1. The compression strength is sampled from the product surface;

[0090] 2. The direction along the fibers is vertical; the direction perpendicular to the fibers is horizontal.

[0091] It can be seen from the test results in Table 1 that for the example and comparative example products with similar density, except for the vertical compression strength, the lateral compression strength, the pull-out strength of the threaded spikes and the bending zone load of the finished product of the example products are all greater than those of the comparative example, which proves that the surface reinforcement layer of the utility model can significantly increase the overall strength of the synthetic sleeper, and has obvious advantages in performance compared with the existing unidirectional fiber reinforced synthetic sleepers.

[0092] In summary, the one-piece molded synthetic sleeper and preparation device described in the present application have the following advantages: 1. It can significantly increase the overall strength of the synthetic sleeper 100 and avoid lateral cracking; 2. It reduces the painting process and reduces pollution to the environment. The color of the synthetic sleeper 100 can be customized according to demand to meet the personalized needs of different customers. It can ensure that the color of the synthetic sleeper 100 remains consistent throughout the production process, which helps to improve the appearance quality of the product. It has good durability and anti-aging properties, and can ensure that the color of the synthetic sleeper 100 remains bright and stable after long-term use; 3. It is easy to demold the product without spraying release agent and surface polishing, which reduces VOC and dust pollution in the production process.

[0093] Although the utility model is disclosed as above, the utility model is not limited thereto. Any person skilled in the art can make various changes and modifications without departing from the spirit and scope of the utility model. Therefore, the protection scope of the utility model shall be subject to the scope defined by the claims.

Claims

1. An integrally formed synthetic sleeper, characterized in that: The invention comprises a polyurethane resin matrix (101), continuous glass fibers (11) are longitudinally arranged in the polyurethane resin matrix (101) and are used for longitudinal reinforcement of a synthetic sleeper (100). A reinforcing layer (102) composed of glass fiber fabric (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 to 10 mm.

2. The one-piece synthetic sleeper according to claim 1, characterized in that: The surface density of the glass fiber fabric (511) is 300 to 1500 g / m 2 .

3. The one-piece synthetic sleeper according to claim 1, characterized in that: The glass fiber fabric (511) is a composite felt of a set color, and is used to produce a synthetic sleeper (100) of a desired color.

4. A device for preparing an integrally formed synthetic sleeper, used for preparing the integrally formed synthetic sleeper according to any one of claims 1 to 3, characterized in that: The invention comprises a yarn frame (1), a closed glue dipping box (2), a glue injection machine (3), a felt guide (4), a felt frame (5), a crawler machine (6) and a sawing machine (7) which are arranged in sequence, 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 yarn frame (1) is used for placing continuous glass fibers (11), the closed glue dipping box (2) is used for uniformly impregnating the continuous glass fibers (11) with polyurethane resin, the glue injection machine (3) is used for conveying polyurethane resin into the closed glue dipping box (2), the first felt frame (51) is used for placing glass fiber fabrics ( 511), a first felt guide (41) is used to guide the glass fiber fabric (511) to be wrapped around the surface of the continuous glass fiber (11), a second felt frame (52) is used to place a release paper (521), the second felt guide (42) is used to guide the release paper (521) to be wrapped around the surface of the glass fiber fabric (511), the crawler (6) is provided with a mold, the mold is used to heat and pressurize the continuous glass fiber (11) impregnated with polyurethane resin, so that the polyurethane resin is cured to form a fiber-reinforced polyurethane synthetic sleeper (100), and the sawing machine (7) is used to cut the fiber-reinforced polyurethane synthetic sleeper (100).

5. The manufacturing device of the integrally formed synthetic sleeper according to claim 4, characterized in that: The crawler machine (6) comprises a lower crawler machine (61) and an upper crawler machine (62). Baffles are arranged on the left and right sides of the crawler machine (6). The baffles cooperate with the upper crawler machine (62) and the lower crawler machine (61) to form a mold cavity. The synthetic sleeper (100) is solidified and formed in the mold cavity and is automatically separated from the mold cavity as the crawler machine (6) rotates.

6. The manufacturing device of the integrally formed synthetic sleeper according to claim 4, characterized in that: The glue injection machine (3) comprises a component A material tank (31), a component B material tank (32), a mixing gun head (33) and a flow divider (34); the component A material tank (31) and the component B material tank (32) are respectively connected to the mixing gun head (33) through pipelines; the mixing gun head (33) is connected to the flow divider (34) through a pipeline; the flow divider (34) is connected to the closed glue dipping box (2) through a flow diversion glue injection pipe (35); the component A material tank (31) is used to store polyurethane resin A; the component B material tank (32) is used to store polyurethane resin B; the mixing gun head (33) is used to mix polyurethane resin A and polyurethane resin B; the flow divider (34) is used to evenly divide the mixed polyurethane resin output by the mixing gun head (33) and input it into the closed glue dipping box (2).

7. The manufacturing device of the integrally formed synthetic sleeper according to claim 4, characterized in that: The yarn frame (1) is provided with a yarn separation plate, and the yarn separation plate is used to separate the continuous glass fibers (11).

8. The manufacturing device of the integrally formed synthetic sleeper according to claim 6, characterized in that: The closed glue dipping box (2) is provided with a plurality of glue injection holes, the mixing gun head (33) is connected to a flow divider (34), and the flow divider (34) is connected to the glue injection holes through a plurality of flow diversion glue injection tubes (35).

9. The manufacturing device of the integrally formed synthetic sleeper according to claim 4, characterized in that: The second felt frame (52) is used for placing the stripping cloth.

Images