JP3283296B2 - Method for producing plate-like molded body - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a plate-like molded product such as a sleeper suitable for being laid on a ballast ballast of a railway.

[0002]

2. Description of the Related Art Conventionally, in a concrete sleeper often used for a sleeper, in order to prevent a lateral slippage, a rubber plate is stuck on a laying surface on a bottom surface thereof to increase frictional resistance with a ballast track. Had been done. Further, in the case of a synthetic sleeper which has recently been used as a railway sleeper (see Japanese Utility Model Publication No. Sho 61-23042). Lateral pressure was applied to the rails at the branch and curve when passing through the train, and especially in the case of ballast tracks, lateral displacement of the axial path was likely to occur. Therefore, in this sleeper, a device such as attaching a rubber plate has been devised as in the case of the PC concrete sleeper.

[0003]

By the way, in the case of the above-mentioned synthetic sleeper to which the rubber plate is not attached, the synthetic sleeper itself has a certain degree of elasticity. In the density range, this was extremely insufficient to prevent lateral displacement. Therefore, it is naturally conceivable to use a low-density member by polymerizing and bonding the same material as the above-mentioned synthetic sleeper. However, even with the same material, there remains a problem in the reliability of the bonding.

[0004] The present invention has been developed in view of the above points, and its object is to facilitate ballast penetration while maintaining the required rigidity as a whole, and to provide lateral displacement of the ballast orbit. Plate-shaped molded body that can be used as a sleeper that can prevent
It is to provide a manufacturing method of.

[0005]

In order to achieve the above object effectively, the present invention has the following arrangement. That is, the first layer which is a thermosetting resin foam in which long fibers are embedded in the longitudinal direction, and the second layer which is made of the same material as the first layer and has a lower density than the first layer A method for producing a formed plate-like molded body, wherein a plurality of long fibers are bundled and arrayed in a continuous manner on an impregnating table arranged vertically at predetermined intervals, During the progress, the foaming-curable resin liquid is adhered to the fiber bundle on the impregnating table, and each fiber bundle to which the resin liquid is adhered is impregnated with the impregnating table and the impregnating table. Each of the impregnated plates is reciprocated in the width direction of the fiber bundle while being sandwiched by the respective plates, so that each of the fiber bundles is impregnated with the resin liquid, and the respective fiber bundles impregnated with the resin liquid are converged. The resin liquid impregnated fiber bundle forming the second layer is Liquid resin impregnated fiber bundles forming the can lead to molding passage so that the upper side in the molding passage, the lower
The resin liquid for forming the second layer is foamed first, so that the expansion ratio of the resin liquid for forming the lower second layer is larger than the expansion ratio of the resin liquid for forming the upper first layer. And a method for producing a plate-shaped molded product having a configuration in which the resin liquids are foamed and cured.

[0006]

[Action] The configuration of the manufacturing method, it is possible to integrally formed continuously from the first layer and the second layer having different densities plate-shaped molded product of the same material.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. FIG. 1 is obtained by an embodiment according to the present invention.
That an example perspective view of the plate shaped body, the plate-like molded body 1 is used in particular sleeper, it is constituted by a first layer 2 having different densities and the second layer 3. That is, the first layer 2
Is formed of a thermosetting resin foam 5 in which reinforcing long fibers 4 are buried in the longitudinal direction in a plate shape having a rectangular cross section, and has a density of 0.6 to 1.0 g / cm ³ . Also, the second layer 3
Is basically the same material as the first layer 2 and has a density of 0.4 to
0.7 g / cm ³ , always lower density than the first layer. The thickness ratio between the first layer 2 and the second layer 3 is 3: 1 to 1
Preferably it is 10: 1. Furthermore, the above-mentioned reinforcing filament 4
Any of inorganic and organic long fibers may be used, but glass long fibers are most preferable in view of strength and economy.

The thermosetting resin foam 5 is not particularly limited as long as it is thermosetting and is a hard resin foam. Particularly, a hard urethane resin or a hard polyester resin to which foamability is imparted is used. Is preferred. In this sleeper (plate-like molded product), the lower low-density second layer 3 is laid as a laying surface of a ballast ballast, and after laying, the ballast 20 is partially laid down with a low-density second layer as shown in FIG. It is in a state of being bitten into the layer 3. Therefore, the frictional resistance with the ballast roadbed increases, and the lateral displacement of the rail is suppressed. Further, by cutting and removing the outer skin of the second layer 3 (the high-density low-foam skin is formed at the time of foaming), the ballast 20 is more likely to bite into the sleeper .

[0009] Next will be described a manufacturing method of the plate-shaped molded body (sleepers). FIG. 2 is an explanatory view showing a manufacturing process of the plate-shaped molded body , in which a plurality of long glass fibers 8 are bundled and arranged on impregnating tables 6 and 7 which are arranged vertically at predetermined intervals. While the bundles 9 and 10 are continuously advanced, the urethane resin mixing and discharging machines 11 and 11 apply urethane resin liquids (foam curable resin liquids) 11 a to the fiber bundles 9 and 10 on the impregnating tables 6 and 7 during the progress. , 11b are caused to adhere downward. In this case, the upper side where the urethane resin liquid 11a is adhered to the fiber bundle 9 becomes the first layer 2, the density of the first layer 2 is 0.6 g / cm ³ or more, and the urethane resin liquid 1
The lower side to which 1b is attached becomes the second layer 3, and this second layer 3
The supply amount of the urethane resin liquid 11 is set according to the molding size so that the density of the urethane resin liquid 11 is less than 0.6 g / cm ³ .

The urethane resin liquids 11a, 11a
b is attached to each of the impregnating tables 6, 7
And the impregnating plates 12 and 13 disposed above the impregnating tables respectively. Next, the impregnating plates 12 and 13 are reciprocated in the width direction of the fiber bundles 9 and 10 to impregnate the fiber bundles 9 and 10 with the resin liquids 11a and 11b, respectively. Further, each fiber bundle 9 impregnated with the resin liquid 11,
The plate 10 is converged in a state of being kept in a layered state and is guided to the forming passage 14, and is foamed and hardened while moving in the forming passage to form the plate-like formed body 1. In order to foam the fiber bundles 9 and 10 impregnated with the urethane resin, the thickness of the first layer 2 and the second layer 3
In order to make the thickness of the first layer 2 uniform, the urethane resin liquid 11b of the second layer 3 having a low density is foamed first, and the second layer 3 is foamed to a predetermined thickness. The foaming and curing of the urethane resin liquid 11a are performed.

As means for foaming the urethane resin liquid 11b of the second layer 3 first, the urethane resin liquid 11b of the second layer 3 is used.
The catalyst amount of b is increased or the resin temperature setting is increased. Alternatively, the distance from the urethane resin mixing and discharging machine 11 of the second layer 3 to the inlet of the molding passage is increased. In addition, each layer 2,
As means for controlling the expansion ratio of the urethane resin liquids 11a and 11b of No. 3, a mold 15 at the time of expansion (formed by four endless steel belts).
If the set temperature is high, the urethane resin will react faster,
In addition, high foaming is likely to occur. Therefore, by changing the temperature setting conditions above and below the mold foaming zone 16, it becomes easy to control the foaming start timing and the foaming ratio of the first and second layers. The optimal temperature condition is that the upper mold 15a
0 to 40 ° C, and the lower mold 15b is preferably 30 to 50 ° C.

Further, the expansion ratio of the second layer 3 of the urethane resin in a plate-shaped molded body is larger than the first layer 2, in the formulation of the urethane resin is less than the first layer 2 the amount blowing agent ing. This is because the mold does not fill up when the urethane resin of the second layer 3 is foamed and the foaming is free, so that a predetermined foaming ratio can be sufficiently secured with the amount of the foaming agent set as described above. When the urethane resin liquid of the first layer 2 is foamed, the foaming proceeds in the direction of shrinking the previously foamed second layer 3, and the first layer 2 is formed to ensure that the foamed resin is filled in the mold. The amount of the foaming agent of the urethane resin liquid of No. 2 is set to be large. Incidentally it is free foaming the first layer urethane resin solution of the plate-shaped formed
It is about 2.5 to 4 times the expansion ratio of the form .

The fiber bundle 10 impregnated with the urethane resin 11b for forming the second layer 3 having a low density in the above embodiment.
The reason why the lower side of the fiber bundle is led to the molding passage 14 and foamed first is because the lower surface side of the fiber bundle comes into contact with the mold 15 and is heated first, so that the foaming start timing and the foaming ratio can be easily controlled. . Table 1 shows examples of weight ratio ranges, composition ratios, and urethane resin compounding ratios of the first layer and the second layer on the next page.

[0014]

[Table 1]

[0015]

The method for producing a plate-like molded product according to the present invention is described above.
In the molding passage, the lower second layer
The expansion ratio of the resin liquid used to form the upper first layer
Each of the above resins so as to be larger than the expansion ratio of the resin liquid.
Allow the liquid to foam and harden, and
Layer which is a thermosetting resin foam with embedded long fibers
And lower density than the first layer, made of the same material as the first layer
Manufactures a plate-like molded body formed by the second layer
can do.

When the plate-like molded product obtained by the present invention is used as a sleeper, the first high-density layer and the second low-density layer having the required rigidity are integrally formed. As a result, while maintaining the required rigidity as a whole, it is possible to easily bite in the ballast and increase the resistance of the ballast to the ballast track. Therefore, lateral displacement of the ballast track can be prevented more reliably.

Further , this plate-shaped molded article can be used for other purposes such as building members without limiting the use of the sleeper. Further, as described above, since the first high-density layer and the second thin low-density layer are integrally formed, there is no fear of peeling of the joint surface and poor adhesion.

[Brief description of the drawings]

FIG. 1 is a perspective view of an example of a plate-like molded product obtained according to the present invention.

FIG. 2 is an explanatory view showing a production process of a method for producing a plate-shaped molded product according to the present invention .

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Plate-shaped molded object, 2 ... 1st layer, 3 ... 2nd layer, 4 ... Reinforcing long fiber, 5 ... Thermosetting resin foam,
6, 7: impregnated table, 8: glass filament, 9, 10
... Fiber bundle, 11 ... Urethane resin mixing and discharging machine, 1
1a, 11b: foam-curable resin liquid (urethane resin liquid), 12, 13, ... impregnated plate, 14: molding passage,

Claims (1)

(57) [Claims] 1. A first layer which is a thermosetting resin foam in which long fibers are embedded in a longitudinal direction, and a second layer made of the same material as the first layer and having a lower density than the first layer. A method for producing a plate-like molded body formed by layers, wherein a plurality of long fibers are bundled and arranged in a continuous manner on an impregnating table arranged vertically at predetermined intervals. While the foaming-curable resin liquid is adhered to the fiber bundle on the impregnating table during the progress, and each fiber bundle to which the resin liquid is adhered is distributed above the impregnating table and above the impregnating table. Each of the fiber bundles is impregnated with the resin liquid while being sandwiched by the provided impregnation plates, and each of the impregnation plates is reciprocated in the width direction of the fiber bundle to impregnate each of the fiber bundles with the resin liquid. And the resin liquid impregnated fiber bundle forming the second layer is The resin liquid impregnated fiber bundle for forming one layer is guided to the molding passage so that it is on the upper side.
The resin liquid for forming the second layer is foamed first, so that the expansion ratio of the resin liquid for forming the lower second layer is larger than the expansion ratio of the resin liquid for forming the upper first layer. Wherein the foaming and curing of the respective resin liquids are performed.