Polymer composite, article including polymer composite, process for producing dry polymer composite, process for producing sleeper

Abstract

The present invention relates to a polymer composite, a polymer composite article, a method for producing a dry polymer composite, and a method for producing a railroad tie, the polymer composite comprising: sand; at least one filler; a thermosetting resin selected from at least one of dicyclopentadiene, neopentyl glycol, or a combination thereof; at least two additives, one of which is a compatibilizing additive and the other of which is a flexibilizing additive; and fibers selected from at least one of carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, or a combination thereof.

Description

[Technical Field]

[0001] The present invention relates to a polymer composite, an article comprising a polymer composite, a process for producing a dry polymer composite, and a process for producing a sleeper. [Background technology]

[0002] Materials called polymer composites are used when it is necessary to obtain a more resistant material than pure polymers, or for applications requiring specific properties. Generally, these materials contain a polymer matrix, fillers, additives, and / or drugs, with the amounts of these components varying depending on the application.

[0003] An example of the use of polymer composites is their application in sleepers. Known sleepers use concrete and structural reinforcement, which limit their mechanical strength, durability, and applications, and have the disadvantage of being heavy, in addition to the disadvantages of the manufacturing process. Advances in this field have attempted to provide new advantages to sleepers, such as the case of Brazilian Supplementary Registration Document BRC10403092-3, which describes a plastic concrete sleeper that uses sand and resin as its components. However, the mechanical properties achieved by the sleeper described in this document are limited; for example, the tensile strength is approximately the same as that of concrete.

[0004] Another example of a known sleeper is described in document BR102014007171-7, which describes a sleeper formed by overlapping layers of wooden sheets that are bonded together using a structural synthetic polymer resin. However, the use of wood for sleepers, and in particular the use of eucalyptus wood described in this document, has many drawbacks, such as low durability, risk of fungal attack and insect infestation, water / moisture absorption and therefore changes in mechanical properties.

[0005] It is known that known polymer composites have mechanical limitations that limit their use. This gap can be observed, for example, in the field of railroad ties, where the results obtained with known commercially available materials are still insufficient.

[0006] Furthermore, the processes for making polymer composites and articles using such materials require the use of water and / or do not take into account the hygroscopic nature of plaster.

[0007] The materials commonly used for sleepers have drawbacks that can be summarized as follows: hardwood is currently banned for the manufacture of wooden sleepers; eucalyptus wood is less durable than other sleepers; concrete deteriorates rapidly in reinforced structures due to corrosion. Summary of the Invention [Problem to be solved by the invention]

[0008] In light of the problems described in the prior art, the present invention aims to provide a polymer composite that has high mechanical durability (durability to axial compression and four-point bending, and high abrasive wear resistance), excellent dielectric properties, low porosity and water absorption; chemical and corrosion resistance, and a lower density than typically found in other structural composites.

[0009] Another object of the present invention is to provide a polymer composite that may exhibit several uses, among them metric gauge sleepers, wide gauge sleepers, cross members, purlins, beams, precast tiles, preformed channels, molded floors, interlocking floors, precast civil engineering panels, artificial stone for countertops and floors, paving slabs for bridges, road covers for bridges and highways, precast slabs, cladding, and Kobogo hollow bricks.

[0010] Another object of the present invention is to provide a polymer composite that, compared to wood, is not subject to fungal attack and therefore insect infestation and does not deteriorate over time; is resistant to decay, insect attack, and solar radiation; and ultimately absorbs moisture without causing a loss of hardness or other mechanical properties, without chemical reactions with water, acids, bases, and organic compounds in the eventual runoff, as occurs with eventual porosity.

[0011] Another object of the present invention is to provide a polymer composite that is: relatively light and waterproof compared to reinforced concrete, since it does not require steel frames in its structure as in reinforced concrete; and does not contain toxic components after hardening.

[0012] Another object of the present invention is to provide a polymer composite that is: void-free or shrink-free; has heat-blocking properties; tolerates any size; is inert and impermeable; and is highly homogeneous, yielding reliability.

[0013] It is also an object of the present invention to provide articles comprising the polymer composite of the present invention, such as sleepers, that perform satisfactorily when subjected to vehicle or traction loads of up to 40 tonnes per axle on broad gauge, or relatively lesser loads on metric and standard gauge.

[0014] Another object of the present invention is to provide articles, such as sleepers, comprising the polymer composites of the present invention that exhibit performance that matches that exhibited by pure heartwood wood sleepers for the same spacing employed with wood.

[0015] Another object of the present invention is to provide articles, such as railroad ties, comprising the polymer composites of the present invention that do not show signs of crushing or deformation in the area of ​​the fasteners when subjected to the traffic conditions cited herein.

[0016] Another object of the present invention is to provide articles, such as railroad ties, having a unitary cross section without voids or wicking, comprising the polymer composite of the present invention.

[0017] Another object of the present invention is to provide articles, such as sleepers, comprising the polymer composite of the present invention, which have insulating properties and do not pose a risk to track circuit occupation.

[0018] The present invention also aims to provide a process for producing dry polymer composites and / or sleepers for the above purposes.

[0019] Another object of the present invention is to provide a process for producing dry polymer composites and / or railroad ties that does not use water in its production and does not generate liquid waste. [Means for solving the problem]

[0020] The present invention relates to a polymer composite comprising: sand; at least one filler; a thermosetting resin selected from at least one of dicyclopentadiene, neopentyl glycol, or a combination thereof; at least two additives, one of the additives being a compatibilizing additive and the other additive being a flexibilizing additive; and fibers selected from at least one of the following: carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, or a combination thereof.

[0021] Optionally, the filler is selected from at least one of the following: granular silica or microspheres, high and low purity quartz alumina, foundry sand, fine sand, or extra-fine sand, limestone, talc, gravel powder, plaster, lime, dolomite, calcite, barite, natural or organophilic bentonite, natural or organophilic kaolinite, natural or organophilic metakaolinite, natural or organophilic attapulgite, natural or organophilic montmorillonite, natural or organophilic illite, natural or organophilic antigorite, natural or organophilic anita, natural or organophilic sepiolite, natural or organophilic vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, gilsonite, or combinations thereof.

[0022] Optionally, the compatibilizing additive is selected from at least one of the following: vinyltrimethoxysilane, vinyltriethoxysilane, methacryltrimethoxysilane, methacryloxypropyltrimethoxysilane, calcium diacrylate, zinc diacrylate, or a combination thereof.

[0023] Optionally, the softening additive is selected from at least one of the following: butyl acrylate, butyl methyl acrylate, methyl methacrylate, acrylic acid, methacrylic acid, phthalic anhydride, maleic anhydride, diallyl phthalate, triethylene glycol methacrylate, ethylhexyl methacrylate, or a combination thereof.

[0024] Optionally, the polymer composite may further comprise: ground rubber in an amount of 0% to 30% by weight; a layered fiber blanket, wherein the fibers are selected from at least one of the following: metal fibers, glass fibers, carbon fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, or combinations thereof; a screen and / or frame made of layered and / or structural metallic and / or polymeric materials; and a reaction accelerator system, wherein the reaction accelerator system is cobalt naphthenate and is present in an amount of 0.25% to 2.5% by weight of the composite. The reaction accelerator system is incorporated with dimethylaniline (DMA) in an amount of 0.025% to 0.10% by weight. Optionally, the polymer composite may further comprise an initiator in an amount ranging from 0.05% to 6.00% by weight.

[0025] Optionally, the polymer composite may include: 38% to 96% by weight of mid-sand; 3% to 33% by weight of filler; 3% to 33% by weight of dicyclopentadiene, and / or 5% to 30% by weight of neopentyl glycol; 0.1% to 1.5% by weight of a compatibilizing additive; 0.1% to 1.5% by weight of a softening additive; and 0.1% to 5% by weight of carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, and / or combinations thereof.

[0026] The present invention relates to a polymer composite article comprising a polymer composite, wherein fibers contained in the composite have a fiber length that is 70% to 99% of the length of the part.

[0027] The present invention relates to a process for producing a dry polymer composite, comprising the steps of: mixing sand and filler for 10 to 40 minutes to form a mixture of dry ingredients; mixing at least one compatibilizing additive and at least one softening additive with a thermosetting resin for 10 to 30 seconds to form a syrup; mixing the syrup with the mixture of dry ingredients for up to 5 minutes; inserting into the resulting material at least one anchoring element comprising a bundle of fibers, wherein the fibers are selected from at least one of the following: carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, or combinations thereof; pre-curing the resulting material in an atmospheric oven with air circulation at a temperature of 50 to 80°C for 60 to 180 minutes; and curing the resulting material at atmospheric pressure and room temperature for at least 7 days.

[0028] Optionally, the dry polymer composite production process includes the following steps: drying the sand and filler before mixing these components; mixing an initiator into the syrup for 10 to 30 seconds before mixing the syrup with the dry component mixture; and pressing the resulting material for 20 to 60 seconds before pre-curing. Optionally, the pressing step can be replaced by vibrating the material mixture at different points on the object using a concrete vibrator until there is no visible air in the material mixture. Typical vibration times for the pre-curing stage are 20 to 60 seconds. Optionally, the oven used in the process includes an exhaust fan to remove moisture. Optionally, the oven can be replaced with a thermal heating blanket that respects the same parameters of time, temperature, and opening for moisture removal.

[0029] The present invention refers to a process for producing a sleeper, comprising the steps of producing a polymer composite according to the production process already described and molding the material in a sleeper mould before the step of inserting the anchoring elements. Optionally, the pressing step is carried out with a load of 10 to 30 tonnes for 20 to 60 seconds. Optionally, the pressing step can be replaced by a vibration step for 20 to 60 seconds.

[0030] Optionally, the anchoring element has an intermediate layer of bundles or blankets of at least one of the following: carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, or combinations thereof, where the fibers are longitudinal to the sleeper and distributed in layers or organized in bundles.

[0031] Optionally, the oven used in this step has at least two side exhaust fans for moisture removal. Optionally, the oven can be replaced with a thermal heating blanket that respects the same parameters of time, temperature, and openings for moisture removal.

[0032] The figures show the results of tests carried out on the examples of the invention described below. [Brief explanation of the drawings]

[0033] [Figure 1] FIG. 1 - Photograph showing a sleeper having an embodiment of the material of the present invention subjected to modulus of rupture (MOR) testing. [Figure 2] FIG. 2 - A series of photographs showing sleepers having embodiments of the material of the present invention subjected to drop testing. DETAILED DESCRIPTION OF THE INVENTION

[0034] First, it should be noted that the polymer composites of the present invention may be applied or used in many different types of articles, products, or contexts, such as railway sleepers, cross members, purlins, beams, precast tiles, precast channels, interlocking floors, precast civil engineering panels, artificial stone for benches and floors, paving in slab form or applied by cast-in-place construction in bridges, precast slabs, cladding boards, hollow bricks, etc. Although specific reference is made herein to sleepers, this specific example of the application of the material of the present invention should not be used to unduly limit the scope of protection, but rather this example is meant to facilitate understanding of the material according to the present invention.

[0035] In one embodiment, the present invention relates to a polymer composite comprising: fine aggregate, such as sand, preferably medium sand; at least one resin for thermosetting resins, selected from at least one of dicyclopentadiene (DCPD), neopentyl glycol (NPG), and / or combinations thereof; and at least one additive.

[0036] In one embodiment, the additive is selected from at least one of a compatibilizing additive and / or a softening additive. The compatibilizing additive, also known as a coupling agent, is selected from at least one of the following: vinyltrimethoxysilane, vinyltriethoxysilane, methacryltrimethoxysilane, methacryloxypropyltrimethoxysilane, calcium diacrylate, zinc diacrylate, and / or combinations thereof. The polymeric softening additive, or softener, is selected from at least one of the following: butyl acrylate, butylmethyl acrylate, methyl methacrylate, acrylic acid, methacrylic acid, phthalic anhydride, maleic anhydride, diallyl phthalate, triethylene glycol methacrylate, ethylhexyl methacrylate, and / or combinations thereof.

[0037] In embodiments that include two additives, one of the additives is a compatibilizing additive and the other additive is a softening additive.

[0038] In one embodiment, the polymer composite of the present invention comprises at least one filler selected from at least one of the following: granular silica or microspheres, high and low purity quartz alumina, foundry sand, fine or extra-fine sand, limestone, talc, gravel powder, gypsum, lime, dolomite, calcite, barite, natural or organophilic bentonite, natural or organophilic kaolinite, natural or organophilic metakaolinite, natural or organophilic attapulgite, natural or organophilic montmorillonite, natural or organophilic illite, natural or organophilic antigorite, natural or organophilic anita, natural or organophilic sepiolite, natural or organophilic vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, and gilsonite, and / or combinations thereof, wherein the mixture is suitable for meeting the packing and distribution requirements of ballast.

[0039] In one embodiment, the polymer composite of the present invention comprises fibers selected from at least one of the following: carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, and / or combinations thereof. The fibers used may be short and uniformly distributed in the matrix or long and unidirectionally aligned, and may be arranged in layers or fibrous cores.

[0040] In one embodiment, the polymer composite of the present invention comprises ground rubber, which may be derived from tires.

[0041] In one embodiment, the polymer composite of the present invention comprises layered or structured metallic or polymeric fibers and a frame.

[0042] The components described above for different embodiments of the present invention may be combined in different ways, with at least two components being combined to produce different versions of the present invention. Details of each component and possible concentrations are provided below.

[0043] resin:

[0044] The resin present in the polymer composite of the present invention is a thermosetting resin selected from at least one of dicyclopentadiene (DCPD), neopentyl glycol (NPG), and / or combinations thereof.

[0045] DCPD:

[0046] Dicyclopentadiene (DCPD) has the formula C 10 H 12 At room temperature, it is a pale yellow liquid with a dry odor. Its main use is in resins, especially unsaturated polyester resins. It is also used in paints and adhesives.

[0047] In the present invention, DCPD is added in an amount ranging from 5% by mass to 30% by mass, preferably from 8% by mass to 25% by mass, and more preferably from 10% by mass to 20% by mass, based on the total mass of the composite composition.

[0048] NPG:

[0049] Pure neopentyl glycol (NPG) is a crystalline, white, odorless, hygroscopic solid organic compound used in the synthesis of polyesters, coatings, lubricants, and plasticizers. In polyester resins, NPG improves resistance to heat, light, especially UV light, and water. Esterification with fatty acids or carboxylic acids can yield lubricating esters with reduced susceptibility to oxidation and hydrolysis. NPG is also used in the production of monomers for alkyd resins, polyurethane resins, and UV-resistant coatings.

[0050] NPG is commercially synthesized by the aldol reaction of formaldehyde with isobutyraldehyde. This forms hydroxypivalaldehyde, which can be converted to neopentyl glycol with excess formaldehyde or by catalytic hydrogenation of the aldehyde group to an alcohol. This procedure can be carried out using strong alkaline catalysts such as sodium hydroxide, potassium hydroxide, or calcium hydroxide. A drawback is the production of large amounts of sodium formate as a by-product, making it commercially unviable. One way to circumvent this problem is to carry out the aldol condensation catalyzed by a tertiary amine and proceed with the hydrogenation using magnesium oxide-supported copper chromite, or catalysts containing platinum, ruthenium, and tungsten, or even copper, zinc, and zirconium. Hydrogenation of hydroxypivalaldehyde can be carried out using a nickel catalyst and a mixture of aliphatic alcohols and ethers as solvents at temperatures below 100°C under humidity control. Another method for obtaining 2-disubstituted propane-1,3-diols is by the reaction of ethanal, also 2-disubstituted, with formaldehyde. Thus, the reaction of 1-4-dioxino with isobutaraldehyde in the presence of an acidic ion exchanger allows for the production of neopentyl glycol in 87% yield. Photolysis of 2-(2-hydroxy-5-methoxyphenyl)-5,5-dimethyl-1,3-dioxane with light at 300 nm produces neopentyl glycol and 2-hydroxy-5-methoxybenzaldehyde in 98% yield.

[0051] In the present invention, the NPG resin is added in an amount ranging from 3% by mass to 33% by mass, preferably from 7% by mass to 27% by mass, and more preferably from 9% by mass to 18% by mass, based on the total mass of the composite composition.

[0052] sand:

[0053] In one embodiment of the present invention, the sand composition is formed primarily from silica particles but may contain other minerals such as feldspar, mica, zircon, magnetite, ilmenite, monazite, and cassiterite. Also, commercially available sand has moisture content, given that it is a medium-sized sand (0.1 mm to 2.0 mm, or preferably 0.2 mm to 0.6 mm) that has been washed to remove most of the organic impurities.

[0054] In the present invention, the sand is added in an amount ranging from 38% to 96% by mass, preferably from 42% to 90% by mass, more preferably from 53% to 82% by mass, based on the total mass of the composite composition.

[0055] Filling material:

[0056] Among the filler options, gypsum is a naturally occurring mineral extracted from mineral deposits around the world. The polymer composites of the present invention are preferably produced with gypsum extracted from mineral deposits, although gypsum from industrial processes can also be used. Its chemical formula corresponds to calcium sulfate dihydrate (CaSO4·2H2O), and after calcination or dehydration processes, calcium sulfate hemihydrate (CaSO4·1 / 2H2O), also known as gypsum, is produced. This material is made up of spherical particles ranging in size from 53 μm to 150 μm. This material has a high tendency to rehydrate and is very hygroscopic, which significantly improves its mechanical strength.

[0057] Gypsum, also known as plasterstone, is composed of calcium sulfate dihydrate, i.e., it is a calcium ore with the chemical composition (CaSO₄·2H₂O). It is an inorganic substance that generally ranges in color from white to translucent, has a microcrystalline, lamellar appearance, a pearlescent luster, an oily (or fibrous) feel, and a low hardness of about 2.0. It is the most abundant sulfate in the Earth's crust and occurs in evaporites or in the form of alternating layers of shale, limestone, and clay, and can also be found in meteorites. Upon firing, gypsum loses its water of crystallization and can be transformed into plaster, if it retains its water of crystallization (CaSO₄·1 / 2H₂O), or into calcium sulfate (anhydrous gypsum), if it has completely lost its water of crystallization (CaSO₄).

[0058] The main use of gypsum is in the production of cement, but it is also used in the production of sulfuric acid, chalk, glass, enamel, plaster, and in the production of beer. In addition, plaster or calcium sulfate is also used as a material for foundry moulds, a dehydrating agent, a binder, and a soil conditioner (a source of calcium or sulphur), and in metallurgy (to form slag).

[0059] Another very important source is agricultural plaster, which is produced as a by-product of phosphoric acid production. Agricultural plaster results from the reaction of sulfuric acid with phosphate rock to produce phosphoric acid, which means that plaster is a by-product of H3PO4 production: [ka]

[0060] For every tonne of phosphoric acid produced, approximately 4.5 tonnes of plaster is produced.

[0061] In addition to plaster and / or gypsum, other fillers may be used, such as granular silica or microspheres, high and low purity quartz alumina, foundry sand, fine or ultrafine sand, residual sand from mining processes, limestone, talc, gravel powder, plaster, lime, dolomite, calcite, barite, natural or organophilic bentonite, natural or organophilic kaolinite, natural or organophilic metakaolinite, natural or organophilic attapulgite, natural or organophilic montmorillonite, natural or organophilic illite, natural or organophilic antigorite, natural or organophilic anita, natural or organophilic sepiolite, natural or organophilic vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, and gilsonite, and / or combinations thereof, the mixture of which is suitable to meet the mechanical requirements.

[0062] The use of these fillers is primarily due to the particle-encapsulation effect in the material. The use of large particle size fillers, such as sand, creates voids between the particles, which can be occupied by smaller particles, reducing the pore volume and voids, which improves the compression resistance of the material. The technical effects achieved by the fillers are physical and can be achieved by the fillers mentioned above.

[0063] However, the application of plaster, in this case, demonstrates that in addition to the physical aspect of encapsulation, it also involves related chemical components. Because plaster is a highly hygroscopic material, the water generated during the polymerization reaction is captured by the plaster particles present in the material, removing water from the reaction medium and enabling relatively efficient hardening, which produces a final material with improved mechanical properties compared to fillers that do not have this effect. However, for this phenomenon to occur, the dehydration of the plaster must be ensured by subjecting it to a heat drying process, which reduces the humidity by more than 90%. Using plaster as is without a drying process has a negative impact on the final material, as the moisture present in the plaster is released during the heating used to initiate the polymerization reaction, hindering the material's hardening and often preventing the final material from solidifying, resulting in a lack of mechanical resistance or even crumbling.

[0064] Some of the fillers mentioned are not hygroscopic and may even be considered inert, providing only the encapsulation effect mentioned above. Other fillers mentioned, such as clay minerals, are hygroscopic and, like plaster, may promote a similar encapsulation and sequestration effect for water produced as a by-product of the polymerization reaction. However, some clay minerals contain transition metals in their structure, which may catalyze undesirable side reactions during polymerization, altering the mechanical properties of the resulting material.

[0065] In the present invention, the filler is added in an amount ranging from 3% to 33% by mass, preferably from 5% to 26% by mass, more preferably from 7% to 18% by mass, based on the total mass of the composite composition.

[0066] Accelerator Systems:

[0067] Accelerator systems are composed of chemicals that do not interfere with the polymerization reaction when used alone, but strongly accelerate the reaction when combined. In some embodiments, their use is optional, depending on the reaction time. In one embodiment, the polymer composite of the present invention includes an accelerator system mixed with the resin in an amount ranging from 0.05% to 13% by weight, preferably from 0.10% to 6.50% by weight, and more preferably from 0.25% to 2.50% by weight, based on the total weight of the composite. Preferably, 0.25% to 2.50% of cobalt naphthenate or cobalt octoate is used, either alone or in combination with dimethylaniline (DMA) in an amount ranging from 0.025% to 0.10%.

[0068] Initiator:

[0069] An initiator is a chemical compound that undergoes self-fission under the influence of heat or radiation, or simply chemical reactivity, to form free radicals or either anions or cations that can initiate a polymerization reaction. In the present invention, the initiator undergoes self-fission under heat to form free radicals that initiate bulk polymerization via radicals. In one embodiment, the polymer composite of the present invention contains an initiator in an amount ranging from 0.01% to 6.00% by weight, preferably 0.05% to 3.00% by weight, and more preferably 0.10% to 2.00% by weight, based on the total weight of the composite. Preferably, 0.08% to 2.00%, or preferably 0.10% to 1.50%, of a medium-reactivity methyl ethyl ketone peroxide compound desensitized with dimethyl phthalate is used.

[0070] Compatibilizers:

[0071] The compatibilizer has a chemical chain with one side chemically compatible with the organic phase and the other side chemically compatible with the inorganic phase, where each side reacts with the respective phase, thus creating a kind of chemical bridge between the phases. This substantially improves the adhesion between the materials, as chemical adhesion occurs through the interaction of porosity and recesses instead of simple physical adhesion, thereby improving the tensile strength of the material. In one embodiment, the polymer composite of the present invention includes a compatibilizing additive, also called a coupling agent, which is used in an amount of 0.05% to 2.0% by weight, preferably 0.1% to 1.5% by weight, more preferably 0.15% to 1.0% by weight of the compound, preferably vinyltrimethoxysilane or vinyltriethoxysilane, which may be replaced by at least one of methacryltrimethoxysilane, methacryloxypropyltrimethoxysilane, calcium diacrylate, zinc diacrylate, and / or combinations thereof.

[0072] Softening Additives:

[0073] Flexibilizers can be chemically bonded to the polymer chain or can form interspersed structures with the polymer chain. In the case of flexibilizers that are chemically bonded to the polymer, the flexibilizing groups act as a kind of spring in the chain, increasing flexibility and therefore tensile strength. These groups are small energy absorbers that allow the material to undergo minimal deformation on the scale of the polymer chain, but are imperceptible to the naked eye, dissipating energy and increasing flexibility and tensile strength.

[0074] On the other hand, softeners that form interspersed structures with the polymer create slightly larger energy absorbing structures that also induce slightly larger deformations, but are not visually detectable, and act in a similar manner, absorbing energy, promoting smaller deformations, and releasing energy to adjacent structures, dissipating the energy.

[0075] In one embodiment, the polymer composite of the present invention comprises a polymeric softening additive, which is used in an amount ranging from 0.05% to 2.0% by weight, preferably from 0.1% to 1.5% by weight, more preferably from 0.15% to 1.0% by weight of the compound, and is selected from at least one of butyl acrylate, butyl methyl acrylate, methyl methacrylate, triethylene glycol methacrylate, ethylhexyl methacrylate, acrylic acid, methacrylic acid, phthalic anhydride, maleic anhydride, diallyl phthalate, triethylene glycol methacrylate, ethylhexyl methacrylate, and / or combinations thereof.

[0076] Crushed rubber:

[0077] The ground rubber functions as a physical shock absorber within the composite, potentially increasing impact resistance and flex resistance properties, and is optionally used depending on the application. In one embodiment, the polymer composite of the present invention includes ground rubber. The ground rubber may be obtained from tires in an amount ranging from 0.1% to 30% by weight, or preferably from 1% to 18% by weight, or more preferably from 5% to 10% by weight, based on the total weight of the composite.

[0078] fiber:

[0079] Fibers are applied in the present invention as a safety feature, particularly for application in sleepers, beams, and structural parts subjected to bending stress. Regardless of the article referred to, other applications not foreseen herein may use the composites of the present invention with fibers to achieve desired properties. Considering that the material has brittle fracture characteristics despite having a very high breaking load, which makes fracture and failure less likely, and that even with the use of compatibilizers and softeners, the material does not have a yield limit and suddenly breaks once it reaches this limit, it does not have enough ductility to send a signal when the breaking load is approached. Therefore, the use of fibers, primarily long fibers, applied in the longitudinal direction of the part and supported only by the material itself during molding without applying any traction force, provides anchoring within the part upon fracture, ensuring that the sleeper does not separate into separate parts and only generates cracks within the structure, thereby allowing, for example, the sleeper to maintain its gauge and prevent accidents within the line.

[0080] Figure 1 shows a sleeper that underwent a modulus of rupture (MOR) test. It can be seen that although the sleeper reached complete structural failure, the components did not separate. This is because the anchoring effect of the components was enhanced by the presence of fibers inside the sleeper.

[0081] Only synthetic fibers were considered for this application because a certain tensile strength is required. Plant fibers have mechanical properties that are highly dependent on the conditions of the plant from which they were extracted. An excess or deficiency of water, sunlight, nutrients, etc. dramatically alters the mechanical properties of plant fibers, making it very difficult to achieve reproducibility and repeatability in the process. Therefore, plant fibers should not be used in some embodiments. Synthetic fibers, on the other hand, exhibit mechanical properties that are controlled only by their manufacturing process, and once the process is controlled, they exhibit reproducibility and repeatability in their properties.

[0082] In some embodiments of the present invention, fibers may also function as structural reinforcement to increase the traction of the material, and are used as short fibers uniformly dispersed in the matrix for other applications of the composites of the present invention. The present invention includes fibers selected from at least one of the following: carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, and / or combinations thereof. Depending on the application of the composite of the present invention, the fibers used may be short and uniformly distributed in the matrix, or long and aligned in one direction. In the specific case of sleepers, structural applications, or applications requiring tensile reinforcement, the fibers should preferably be long and aligned along the length of the part, occupying the entire length of the object. In the case of a sleeper, for example, this may occupy the entire length between the outer shoulders, which is the area where the sleeper experiences the greatest mechanical stress.

[0083] The fibers are contained in an amount of 0.05 to 10% by mass, preferably 0.1 to 5% by mass, and more preferably 0.2 to 1% by mass, based on the total mass of the composite. Preferably, glass fibers, metal fibers, or carbon fibers are used.

[0084] The fibres contained in the composite have a fibre length required to prevent catastrophic failure at the point of greatest weakness and / or greatest load on the part. In the case of a sleeper, its function is to prevent catastrophic failure such as opening the gauge, i.e. the entire length between the shoulders. Sleepers are subject to relatively high stresses in the support area (where the rails are) and in the centre (where the traction forces are applied) of the part. As these are the critical points where failure can occur, the fibres must be long enough to cover the entire length between the joints at both ends of the sleeper. Other similar examples can be understood by analogy to the situation described in the case of the sleeper.

[0085] In one embodiment, the length of the fibers comprises 70% to 99%, preferably 85% to 95%, or more preferably 88% to 92% of the length of the part or article.

[0086] In one embodiment, the polymer composite of the present invention includes carbon fiber. Tests performed with carbon fiber have shown materials with relatively good tensile strength, reduced cracking, and improved resistance to drops in preliminary impact tests, and / or the possibility of reducing the number of fibers to achieve similar technical effects, resulting in reduced manufacturing costs. Figure 2 shows a series of photographs taken from a drop test video of a carbon fiber reinforced sleeper. It can be seen that the first drop from a height of 2 m onto a concrete floor showed no obvious damage to the sleeper. In the second drop, the sleeper cracked in the shoulder area, but the integrity of the piece and the sleeper gauge was maintained.

[0087] Structure:

[0088] Not only fibers, but also metal structures or fiber composites, such as fiber rebars (glass, aramid, carbon, basalt, graphite, metal or polymer), can be used in the form of wire, rebar or mesh to help improve the mechanical strength of the material for specific applications. In the specific case of sleeper applications, structures such as rebars, braids or profiles can be used instead of fiber bundles as a safety system against catastrophic failure with final loss of the sleeper gauge.

[0089] In one embodiment, the polymer composite of the present invention comprises a metal or polymer wire or mesh structure in an amount ranging from 0.05% to 10% by weight, preferably from 0.1% to 5% by weight, more preferably from 0.2% to 1% by weight, based on the total weight of the composite. Preferably, a metal or polymer structure is used.

[0090] In one embodiment, the length of the rebar and metal or polymer wire or mesh structure comprises 70% to 99%, preferably 85% to 95%, more preferably 88% to 92% of the length of the part.

[0091] Finishing:

[0092] In one embodiment, the polymer composite of the present invention includes a finish, such as staining or polishing, etc. Such finishes can be optionally applied depending on the intended use of the resulting product.

[0093] In a preferred embodiment, the polymer composites of the present invention are used to produce a variety of articles such as railway sleepers, crosspieces, purlins, beams, precast tiles, precast channels, interlocking paving blocks, precast building panels, artificial stone for worktops and floors, paving in slab form or applied by cast-in-place for use in bridges, precast slabs, cladding slabs, Kobogo hollow bricks, etc.

[0094] In this case, taking sleepers as an example of realization among the possible articles of the invention, various characteristics can be observed, including: perfect adaptation to the required load, preferably in the range of 20 tons / axle to 40 tons / axle; a longer service life than concrete sleepers, and a lower component price than steel components. It should be noted that this composite, when used to produce sleepers, exhibits the following advantages and technical effects: - Its composition does not contain water; - Does not have a dense reinforcing skeleton; - Waterproof; - Lighter than concrete with metal fittings; - Fully compatible with concrete sleepers and partially compatible with wooden sleepers, allowing any shape and size; - It is a homogeneous material in composition and may contain anchoring structures, which creates a relatively high reliability of accident prevention; - High resistance to stresses, high mechanical strength in both compression and tension, in bending and radial compression as well as in fatigue processes; - It has long durability, which provides the best long-term cost-effectiveness.

[0095] It should also be noted that the polymer composite of the present invention is a polymer concrete obtained by replacing part or all of the binder in conventional concrete with a polymer.

[0096] Process for Producing the Dry Polymer Composite of the Present Invention

[0097] The process of producing precast parts

[0098] The polymer conjugates of the present invention are preferably produced from a process comprising the following steps: A. Drying sand and plaster / or cast; B. Weighing out each component consisting of at least one resin, sand, fine filler, preferably plaster; C. Mixing the dry ingredients, including sand and at least one filler, until very homogeneous, for approximately 5 to 40 minutes, using a conventional mechanical mixer (concrete mixer or industrial mixer) or hand mixing, at ambient pressure and temperature, depending on the amount of composite to be produced; D. Adding at least one additive, which is at least one coupling agent or softening agent, or a combination thereof, to at least one resin to form an organic mixture, also called a syrup. Mixing for about 10 to 30 seconds. E. Add the initiator to the organic mixture or syrup and mix for approximately 10 to 30 seconds until a homogeneous appearance is achieved. F. Add the organic mixture or syrup to the mixer containing the dry aggregate mixture and mix for a maximum of 5 minutes until a homogeneous appearance is achieved. G. Molding the article to produce in a mold, which is preferably pre-coated with a release agent, which may be paraffin, mineral oil, a polymer solution of a linear polymer (polyethylene, polypropylene, polyvinyl alcohol, polyvinyl chloride, polytetrafluoroethylene), vegetable wax, or a combination thereof, or even made of a non-stick material. H. Inserting anchoring elements, preferably bundles of long glass fibers or long carbon fibers, longitudinally into the mold. The anchoring elements can be replaced with a layer of glass fiber blanket or carbon fiber blanket. This step is optional depending on the application. I. Pressing with a load appropriate for the prosthesis to be molded for approximately 20 to 60 seconds depending on the thickness of the prosthesis. Optionally, instead of pressing, an internal vibrator in the mass may be used to vibrate for 20 to 60 seconds. J. Pre-cure in an atmospheric oven at a temperature of 50-80°C for about 60-180 minutes with air circulation, followed by curing at atmospheric pressure and temperature for at least 7 days. Optionally, the oven may be replaced by a thermal blanket, respecting the temperature and time parameters.

[0099] Due to the hygroscopic properties of the plaster, it was necessary to install an exhaust fan in the oven to remove the moisture formed during the polymerization reaction (a reaction that forms water as a by-product). The presence of a water-saturated atmosphere inside the oven causes a reaction equilibrium as the polymerization reaction proceeds, slowing or even preventing the hardening of the material. This effect is not seen with non-hygroscopic fillers. If the oven is replaced with a thermal blanket and a hygroscopic filler is used, openings must be provided to allow moisture to escape, due to the same effect as above.

[0100] Process for producing the sleeper (or article in general) of the present invention

[0101] The sleepers of the present invention are preferably produced from a process comprising the following steps: A. Producing the complex according to the process described above; B. Molding into a sleeper mold at the appropriate gauge to be produced. During molding, anchoring materials, such as intermediate layers of fiberglass blanket and / or long fibers longitudinal to the sleeper, may be introduced into the sleeper, either distributed in layers or bundled together. C. Pressing with a load of about 10 to 30 tons for about 10 to 60 seconds. Optionally, pressing can be replaced by vibration using an internal vibrator in the mass for 20 to 60 seconds, while avoiding reaching the fibers. D. Pre-cure in a normal pressure oven at a temperature of 50-80°C with circulating air for approximately 1-2 hours, followed by curing at normal pressure and temperature for at least 7 days. Due to the relatively large volume of the sleepers in relation to the hygroscopic properties of the plaster, it was necessary to adapt the oven with two side exhaust fans to remove the moisture formed during the polymerization reaction (a reaction that forms water as a by-product). As the polymerization reaction progresses, the constant water-saturated atmosphere inside the oven causes a reaction equilibrium, slowing or even preventing the hardening of the material. This effect is not observed with fillers that do not have hygroscopic properties. Optionally, the oven can be replaced with a thermal blanket, respecting the temperature and time parameters. If the oven is replaced with a thermal blanket and a hygroscopic filler is used, openings must be provided to allow moisture to escape, due to the same effect as above.

[0102] Cast-in-place composite production process:

[0103] The polymer conjugates of the present invention are preferably produced from a process comprising the following steps: A. Drying sand and plaster / or cast; B. Weighing each component consisting of at least one of resin, sand, fine filler, preferably plaster; C. Mixing the dry ingredients, including sand and at least one filler, until very homogeneous, for approximately 5 to 40 minutes, using a conventional mechanical mixer (concrete mixer or industrial mixer) or hand mixing, at ambient pressure and temperature, depending on the amount of composite to be produced; D. Transporting dry, mixed materials to the molding area. Materials must be stored in a way that prevents them from absorbing moisture from the environment and must remain dry until molding. E. Simultaneously, at a separate location or at the same location, forming a syrup by adding at least one additive, which is at least one coupling agent, softening agent, or a combination thereof, to at least one resin to form an organic mixture, also called a syrup, for about 10 to 30 seconds. F. Transporting the syrup to the molding area. The syrup has a minimum shelf life of 7 days and may be used in molding within this period without any change in its properties. G. At the molding location and time, add the initiator to the organic mixture or syrup and mix for approximately 10-30 seconds until a homogeneous appearance is achieved at the molding location. H. Add the organic mixture or syrup to the mixer containing the dry aggregate mixture and then mix in the molding area for up to 5 minutes until a homogeneous appearance is achieved. I. Pumping, dispersing and leveling the mixture at the molding station. J. Optionally, depending on the structure to be molded, anchoring elements, preferably bundles of long glass fibers, may be inserted longitudinally into the mold to accommodate the structure. The anchoring elements may be replaced by a layer of glass fiber blanket. This step is optional depending on the application. K. The material is compacted by passing it through a compaction roller, as in the case of roads. The number of passes depends on the thickness of the structure: for lanes up to 3 cm thick, one pass is sufficient. Optionally, if the thickness of the structure to be molded exceeds 12 cm, the passes through the compaction roller can be replaced by vibration. The vibration process is carried out using an internal vibrator in the mass, for 10 to 20 seconds at each vibration point. The number of vibration points depends on the size of the structure. L. Pre-cure using a thermal blanket at atmospheric pressure with air circulation at a temperature of 50-80°C for approximately 60-180 minutes.

[0104] Due to the hygroscopic properties of plaster, casting in place during periods of rain is not possible. For the same reason, casting in place in extremely humid environments is not possible. Casting must be done in a dry environment, and the solid material must be stored in a sealed container until casting to prevent it from absorbing moisture from the air. [Example]

[0105] First Example of Composition of the Complex of the Present Invention

[0106] The following are examples of embodiments of the polymer composites of the present invention:

[0107] [Table 1]

[0108] In this embodiment, the pre-accelerated resin may optionally already contain a reaction accelerator, preferably a reaction accelerator comprising 0.25% to 2.50% cobalt naphthenate.

[0109] In this embodiment, a 1% amount of initiator allows for a working time of about 15 minutes. Reducing this amount, for example to 0.5%, increases the working time to about 29 minutes. Optionally, initiator concentrations of 0.10% to 3.00% by weight, based on the total weight of the composite, can be used.

[0110] In this embodiment, the filler content refers to the total amount of aggregate when added to the sand content, selected from granular silica or microspheres, high and low purity alumina quartz, foundry sand, fine or extra-fine sand, limestone, talc, crushed stone powder, plaster, lime, dolomite, calcite, barite, natural or organophilic bentonite, natural or organophilic kaolinite, natural or organophilic metakaolinite, natural or organophilic attapulgite, natural or organophilic montmorillonite, natural or organophilic illite, natural or organophilic antigorite, natural or organophilic anita, natural or organophilic sepiolite, natural or organophilic vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, and gilsonite, and / or combinations thereof;

[0111] In this embodiment, the aggregate should not exceed 1% humidity. All fillers should be dried to ensure moisture control. Due to the highly hygroscopic nature of plaster, once dried, it should be stored in a sealed container and humidity control should be achieved to less than 0.6% humidity just prior to forming the composite.

[0112] Second Example of Composition of the Complex of the Present Invention

[0113] In an exemplary embodiment, the polymer composite of the present invention comprises: [Table 2]

[0114] In this embodiment, the pre-accelerated resin may optionally already contain a reaction accelerator, preferably a reaction accelerator comprising 0.25% to 2.50% cobalt naphthenate.

[0115] In this embodiment, an initiator amount of 0.10% to 3.00% allows for a working time of, for example, about 15 minutes. If this amount is reduced, for example to 0.5%, the working time becomes about 29 minutes. Optionally, initiator concentrations of 0.10% to 3.00% by weight, based on the total weight of the composite, can be used.

[0116] In this embodiment, the filler content selected from silica, alumina, foundry sand, fine or extra-fine sand, limestone, talc, crushed stone powder, gypsum, lime, dolomite, bentonite, barite, attapulgite, sepiolite, vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, and gilsonite, and / or combinations thereof, refers to the total amount of aggregate when added to the sand content.

[0117] In this embodiment, the aggregate must not exceed 1% moisture. All fillers must be dried to ensure moisture control. Due to the highly hygroscopic nature of plaster, once dried, it must be stored in a sealed container and humidity control must be achieved to less than 0.6% humidity just prior to forming the composite.

[0118] This embodiment also includes carbon fiber. The amount of carbon fiber is 0.05% to 10% by weight, or preferably 0.1% to 5% by weight, or more preferably 0.2% to 1% by weight, based on the total weight of the composite. Furthermore, the fibers included in the composite of this embodiment have a fiber length that is 70% to 99% of the length of the part, preferably 85% to 95%, or even more preferably 88% to 92%. Optionally, other types of fibers mentioned herein can be used in place of the carbon fiber.

[0119] Third Example of the Composition of the Complex of the Invention

[0120] In an exemplary embodiment, the polymer conjugate of the present invention comprises: - Sand in an amount of 38% by mass to 96% by mass. - fillers in an amount of 3% to 33% by weight, the fillers being selected from at least one of the following: plaster, gypsum, gilsonite, calcite, dolomite, or a combination of plaster and gypsum. Preferably, dicyclopentadiene in an amount of 3% to 33% by mass, or neopentyl glycol in an amount of 5% to 30% by mass, or alternatively, a combination of dicyclopentadiene and neopentyl glycol in an amount of 3% to 33%, wherein dicyclopentadiene accounts for 70 to 90% of the mixture and neopentyl glycol accounts for 30 to 10% of the mixture. - a coupling agent or compatibilizer additive in an amount of 0.1% to 1.5% by weight, the coupling agent being preferably vinyltrimethoxysilane, vinyltriethoxysilane, or methacryltrimethoxysilane; - a softener or softening additive in an amount of 0.1% to 1.5% by weight, the softener being preferably acrylic acid, methacrylic acid, butyl methacrylate, or triethylene glycol methacrylate. - optionally an initiator in an amount of 0.1% to 1.5% by weight, preferably consisting of the moderately reactive methyl ethyl ketone peroxide desensitized with dimethyl phthalate. optionally a reaction promoter in an amount of 0.25% to 2.5% by weight, the reaction promoter preferably being cobalt naphthenate or cobalt octoate.

[0121] This embodiment further includes carbon fiber. The amount of carbon fiber is 0.05% to 10% by mass, preferably 0.1% to 5% by mass, and more preferably 0.2% to 1% by mass, based on the total mass of the composite. Furthermore, the fibers contained in the composite of this embodiment have a fiber length that is 70% to 99%, preferably 85% to 95%, and more preferably 88% to 92% of the length of the component. The preferential use of carbon fiber is due to its high mechanical resistance compared to other fibers, which allows for the use of a relatively small amount of fiber, compensating for its relatively high cost. Another advantage is the relatively good mechanical properties observed in preliminary tests. The use of carbon fiber resulted in a material that achieved relatively excellent tensile strength, reduced cracking, and improved impact resistance.

[0122] The above example embodiments may be adjusted or supplemented with the general information regarding the present invention provided herein, taking into account ingredients, concentrations, amounts, and other technical details. Any adjustments of 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10% may be applied to adjust the concentration and amount ranges to obtain results that may be similar to those described for the present invention, or at least acceptable depending on the application. Additionally, the components described for the polymer conjugates of the present invention may be combined in ways other than those described in the above examples to achieve the desired end result.

[0123] test

[0124] Mechanical properties of materials

[0125] Measurements of resistance to axial and radial compression traction were performed on samples of the preferred embodiment obtained with dicyclopentadiene resin (DCPD) in Sileto's in-house laboratory according to ABNT NBR 7680-1 / 2015 (ASTM C39) and ABNT NBR 7222:2011 (ASTM C496 / C496M). The results showed axial compressive strength values ​​of (87.5±1.4) MPa after 14 days of curing and (95.5±0.2) MPa after 21 days of curing. The radial compressive tensile strength was found to be (9.88±0.34) MPa after 14 days of curing and (10.91±0.35) MPa after 21 days of curing. In conventional concrete, Portland cement exhibits axial compressive strength values ​​of approximately 10-45 MPa and radial compressive tensile strength values ​​of approximately 2-7 MPa, depending on the water-to-cement ratio used. Thus, preferred embodiments of the present invention are relatively more resistant to both axial and radial compression than conventional Portland cement embodiments.

[0126] Four-point bending strength was also evaluated internally at Sillet Laboratories on samples of the preferred embodiment obtained with dicyclopentadiene resin (DCPD) according to ABNT NBR 12142 standard "Concrete - Determination of Flexural Tensile Strength of Prismatic Specimens (ASTM C78)." The results obtained were a breaking strength of 152 kN (20.3 MPa) after 14 days of curing of the material and a breaking strength of 173 kN (23.1 MPa) after 21 days of curing.

[0127] Abrasive wear measurements were performed on samples of the preferred embodiment obtained with dicyclopentadiene resin (DCPD) in accordance with the ABNT NBR 9781-1 / 2013 standard (Concrete paving components - specifications and test methods (ASTM C936 / C936M-20)) in the accredited laboratory of Falcao Bauer (Quality Control Technology Center). The results showed an abrasive wear value of 19.0 mm, which classifies the material as highly resistant, according to the ABNT NBR 9781 standard (ASTM C936 / C936M-20), since the abrasive wear is less than 20.0 mm.

[0128] Measurements of compressive strength and water absorption capacity were also carried out on samples of the preferred embodiment obtained with dicyclopentadiene resin (DCPD) in the accredited laboratory of Falcao Bauer (Quality Control Technology Center) in accordance with ABNT standard NBR 9781-1 / 2013 (Concrete components for paving - specifications and test methods (ASTM C936 / C936M-20)). The compressive strength result of the interlocking floor of this preferred embodiment was (105±12) MPa, which indicates a compressive strength of more than 50 MPa and is therefore classified as a high-resistance floor. Regarding water absorption capacity, the interlocking floor obtained from the preferred embodiment showed an average result of 1.2% on average and 2.1% at maximum, which was accepted as the standard is an average water absorption capacity of 6.0% and a maximum of 7.0%.

[0129] An evaluation of the durability under pressure of materials obtained using dicyclopentadiene resin (DCPD) in preferred embodiments was conducted at Florida International University's School of Civil and Environmental Engineering. The evaluation was performed according to methods and equipment developed by the institution, in which test specimens were immersed in a liquid, subjected to hydrostatic pressure, and maintained for a specified period of time to determine their durability under high pressure, such as in offshore applications. A specimen of the preferred embodiment obtained using dicyclopentadiene resin (DCPD) withstood a pressure of approximately 225 psi for 1204 seconds without any structural damage. This result is comparable to that obtained with ultra-high-strength reinforced concrete (UHPC).

[0130] The Department of Civil and Environmental Engineering at Florida International University performed compressive strength tests on specimens from a preferred embodiment of dicyclopentadiene resin (DCPD) before and after evaluating their durability under pressure. The compressive strength of the material before testing was 11,742 ksi, and after testing it was 11,959 ksi, indicating that the material was not damaged by fluid pressure during testing.

[0131] CTL Group, Skokie, Illinois, performed the tests for abrasive wear resistance, freeze and thaw cycle resistance, compression resistance, and water absorption. The abrasive wear resistance was measured at 0.03 inches against a maximum allowable index of 0.118 inches, the abrasive index was measured at 0.01 against a maximum allowable index of 0.11, and the abrasive removal volume was measured at a maximum abrasive removal volume of 1.7 cm. 3 / cm 2 0.06cm 3 / cm 2 The mass loss measured over 28 freeze and thaw cycles was 225 g / m², the maximum allowable value. 2 2.7g / m 2 and at 49 freeze and thaw cycles, it reaches the maximum allowable value of 500 g / m 2 4.0g / m 2 The compressive strength of the 6 cm high test specimen was 16,790 psi, compared to the minimum allowable value of 8,000 psi in the standard, and the measured water absorption was 0.9% by weight, compared to the maximum allowable value of 5% by weight.

[0132] Tests on the sleepers themselves were carried out in the Acoustic, Dynamic and Static Testing Laboratory (LAEDE / IEME), which is authorized by INMETRO to carry out these tests in accordance with AREMA standards (American Railway Engineering and Maintenance Association) and ABNT NBR 11709:2015 - Concrete Sleepers - Projects, Materials and Compositions.

[0133] Compression at the rail support is achieved by applying a load of 445 kN at a constant rate of 120 kN / min to a rail supported on a 360 mm x 200 mm x 42 mm plate. According to AREMA Standard: 2019, the maximum allowable elastic vertical displacement is 6.3 mm, and the maximum residual vertical displacement after one minute of load release is 3.18 mm. A sleeper obtained using a preferred embodiment of the dicyclopentadiene (DCPD) resin of the present invention had an elastic vertical displacement of 1.13 mm and a residual vertical displacement of 0.38 mm.

[0134] Insert extraction was performed by applying an axial load of 53.4 kN to each insert separately and maintaining the load for 3 minutes. No inserts were extracted or damaged, and no damage, cracks, or fractures were observed anywhere in the sleepers obtained with the preferred embodiment obtained with the dicyclopentadiene resin (DCPD) of the present invention.

[0135] Torque testing on the inserts was carried out by applying a torque of 340 N.m to the vertical axis of each insert separately and maintaining it for 3 minutes, and visually inspecting the sleepers obtained with the preferred embodiment obtained with the dicyclopentadiene resin (DCPD) of the present invention to observe for any damage, cracks or breaks at any point.

[0136] Positive and negative moment tests at the supports and in the center were performed in accordance with ABNT NBR11709:2015 and AREMA:2019 using loads of 234.49 kN positive moment at the supports, 144.74 kN negative moment at the supports, 49.36 kN positive moment in the center, and 74.51 kN negative moment in the center, and no damage, cracks, or fractures were observed in any part of the sleeper obtained with the preferred embodiment using the dicyclopentadiene resin (DCPD) of the present invention.

[0137] Cyclic load tests on the support, also known as fatigue tests, were performed in accordance with ABNT NBR11709:2015 and AREMA:2019 standards using loads varying from 23.45 kN to 257.94 kN at a frequency of 4 Hz for a total of 3 million loading and unloading cycles, and no damage, cracks, or fractures were observed in any part of the sleeper obtained with the preferred embodiment using the dicyclopentadiene resin (DCPD) of the present invention.

[0138] An overload of 410.36 kN was applied to the sleeper support at a rate of 50 kN / min and held for 5 minutes, after which the load was removed, in accordance with standards NBR11709:2015 and AREMA:2019. No damage, cracks, or fractures were observed anywhere on the sleeper obtained with the preferred embodiment obtained using the dicyclopentadiene resin (DCPD) of the present invention. The sleeper support was then loaded again at the same rate until failure, which occurred at a load of 642.60 kN.

[0139] chemical properties

[0140] The material resulting from the preferred embodiment was evaluated in Qualy Lab's specialized waste classification laboratory according to the methodology and evaluation parameters contained in the ABNT NBR 10004 standard - Solid Waste - Classification. The material consisted of hardened material pieces, and the material itself, i.e., raw object, material leachate, and solubilized material, were also evaluated. All results were below the limit values ​​of the parameters allowed by the ABNT NBR 10004 standard, and no waste was classified as Class II B (inert non-hazardous waste).

[0141] Although example embodiments have been described, it should be understood that the scope of the invention is limited only by the content of the appended claims and covers other possible variations, including equivalents.

Claims

1. 1. A polymer composite comprising: sand: at least one filler; a thermosetting resin selected from at least one of dicyclopentadiene, neopentyl glycol, or a combination thereof; at least two additives, one of which is a compatibilizing additive and the other of which is a softening additive; and Fibers selected from at least one of the following: carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, or combinations thereof; A polymer composite comprising:

2. The filler is at least one of the following: Granular silica or microspheres, high and low purity aluminum oxide quartz, foundry sand, fine or ultrafine sand, limestone, talc, crushed stone, gypsum, lime, dolomite, calcite, barium, natural or organophilic bentonite, natural or organophilic kaolinite, natural or organophilic metakaolinite, natural or organophilic attapulgite, natural or organophilic montmorillonite, natural or organophilic illite, natural or organophilic antigorite, natural or organophilic anita, natural or organophilic sepiolite, natural or organophilic vermiculite, porous magnetite, calcium carbonate, magnesium carbonate, mica, graphite, gypsum, and gilsonite, and / or combinations thereof; 2. The polymer conjugate of claim 1, wherein the polymer conjugate is selected from:

3. The mutual compatibilizing additive is at least one of the following: vinyltrimethoxysilane, vinyltriethoxysilane, methacryltrimethoxysilane, methacryloxypropyltrimethoxysilane, calcium diacrylate, zinc diacrylate, or combinations thereof; The polymer conjugate of claim 1 or 2, wherein the polymer conjugate is selected from the group consisting of:

4. The softening additive is at least one of the following: Butyl acrylate, butyl methyl acrylate, methyl methacrylate, acrylic acid, methacrylic acid, phthalic anhydride, maleic anhydride, diallyl phthalate, triethylene glycol methacrylate, ethylhexyl methacrylate, The polymer conjugate of any one of claims 1 to 3, wherein the polymer conjugate is selected from

5. The polymer composite of any one of claims 1 to 4, further comprising ground rubber in an amount of 0 to 30% by weight.

6. Further, the present invention includes a layered fiber blanket, the fibers being at least one of the following: metal fibers, glass fibers, carbon fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers or combinations thereof; The polymer conjugate of any one of claims 1 to 5, wherein the polymer conjugate is selected from

7. The polymer composite of any one of claims 1 to 6, further comprising a screen and / or a frame made of layered and / or structured metallic and / or polymeric materials.

8. 7. The polymer composite of claim 1, further comprising a reaction accelerant system, wherein the reaction accelerant system is cobalt naphthenate and is included in an amount of 0.25% to 2.5% by weight of the composite.

9. 9. The polymer composite of claim 8, wherein the reaction accelerating system comprises dimethylaniline (DMA) in an amount of 0.025% to 0.10% by weight.

10. The polymer composite of any one of claims 1 to 9, further comprising an initiator in an amount ranging from 0.05% to 6.00% by weight.

11. The following: 38% to 96% by weight of medium sand; 3% to 33% by weight of a filler; 3% to 33% by weight of dicyclopentadiene and / or 5% to 30% by weight of neopentyl glycol; 0.1% to 1.5% by weight of a compatibilizing additive; 0.1% to 1.5% by weight of a softening additive; and 0.1% to 5% by weight of carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, and / or combinations thereof; The polymer conjugate of any one of claims 1 to 10, comprising:

12. 12. An article comprising a polymer composite, the article comprising the polymer composite of any one of claims 1 to 11, wherein the fibers comprised in the composite have a fiber length that is 70% to 99% of the part length.

13. 1. A method for producing a dry polymer composite, comprising: mixing the sand and filler for 5 to 40 minutes to form a dry ingredient mixture; mixing at least one compatibilizing additive and at least one softening additive with a thermosetting resin for 10 seconds to 30 seconds to form a syrup; transporting said dry mix and syrup to a molding location and ensuring said syrup has chemical stability for at least seven days; mixing the syrup with the dry ingredient mixture for up to 5 minutes; pouring the mixture into a mold or distributing and homogenizing the mixture within the molding area depending on the final product; inserting into the resulting material at least one anchoring element comprising a bundle of fibers, said fibers being selected from at least one of carbon fibers, metal fibers, glass fibers, aramid fibers, glass fiber basalt, graphite fibers, polymer fibers, or combinations thereof; Pre-curing the resulting material in an atmospheric oven at a temperature of 50-80°C for 60-180 minutes with air circulation or using a thermal blanket; and curing the resulting material at ambient pressure and temperature for at least 7 days; A method comprising:

14. 14. The method of claim 13, further comprising the step of drying the sand and filler prior to mixing the components.

15. 15. The method of claim 13 or 14, further comprising the step of mixing an initiator with the syrup for 10 to 30 seconds prior to the step of mixing the syrup with the mixture of dry ingredients.

16. 16. A method for producing a dried polymer composite according to any one of claims 13 to 15, comprising the step of pressing the resulting material using a press or compaction roller for a period of 20 seconds to 60 seconds, or alternatively vibrating the material, prior to the pre-curing step.

17. 17. The method for producing a dry polymer composite according to any one of claims 13 to 16, wherein the oven used in the method has an exhaust fan, which functions the same as a moisture outlet in the alternative use of a thermal blanket.

18. 1. A method of producing an article, comprising: Producing a polymer composite according to the production method of any one of claims 13 to 17, and forming the material in an article mold prior to the step of inserting the anchoring element; A method for producing an article, comprising:

19. 20. The method of claim 18, wherein the pressing step is carried out at at least five different positions on the article for at least 10 seconds at each position under a load of 10 to 30 tonnes of force, alternatively the pressing step can be replaced by vibration.

20. 20. The method of claim 18 or 19, wherein the anchoring elements have an intermediate layer of a blanket made of at least one of carbon fibers, metal fibers, glass fibers, aramid fibers, basalt fibers, graphite fibers, polymer fibers, or combinations thereof, the fibers being longitudinally elongated relative to the article and distributed in layers or bundles.

21. A method for producing an article according to any one of claims 18 to 20, wherein the oven used in said method has at least two side exhaust fans, which have the same function as the moisture outlets in the alternative use of a thermal blanket.

22. A method for producing an article according to any one of claims 18 to 21, wherein the article is a railroad tie.

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