JP4583647B2 - Method for manufacturing synthetic sleepers using recovered materials as raw materials - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a new synthetic sleeper by reusing recovered materials.
[0002]
[Prior art]
Conventionally, sleepers made of wood or PC have been widely used. However, wooden sleepers have a short service life and are refrained from use due to problems such as depletion of wood resources. Moreover, the sleepers made of PC are heavy, and it takes time and labor for laying work. Therefore, the applicant of the present application has conventionally dealt with synthetic sleepers that are excellent in strength and durability, light in weight and easy to handle, as an alternative to the wooden and PC sleepers. A synthetic sleeper is made of a hard foamed resin molded body reinforced with long fibers.
[0003]
Even a synthetic sleeper with excellent durability does not have an infinite useful life, and cracks and dents are produced over the years. If these defects are minor, they are treated with sanding, etc., or filled and repaired with an adhesive. In recent years, however, these processes cannot be sufficiently repaired, and it is necessary to replace synthetic sleepers. Has arisen.
[0004]
[Problems to be solved by the invention]
In the case of wooden sleepers, defective sleepers that have been removed by replacement work have been disposed of as waste materials because rainwater, etc., has entered the interior from cracks and the center of the sleepers may be corroded. .
[0005]
On the other hand, in the case of a defective synthetic sleeper removed by replacement work, since it is made of resin, the center part of the sleeper has excellent physical properties at the beginning of molding even if there are defective parts such as cracks and dents in the surface layer part. Often maintained. In addition, there is a current situation that the manufacturing cost of synthetic wood is higher than that of normal wood, and it is required to reduce the cost of synthetic sleepers made of this synthetic wood.
[0006]
Therefore, the present invention collects defective synthetic sleepers and manufactures a new synthetic sleeper using the recovered material as a raw material, thereby reducing the cost of the synthetic sleeper and sufficient bending while using the recovered material. An object is to obtain strength and tensile strength.
[0007]
[Problems to be solved by the invention]
In order to achieve the above object, the present invention takes the following technical means.
[0008]
That is, the synthetic sleeper manufacturing method using the recovered material of the present invention as a raw material is formed on the surface by grinding or cutting the surface of a defective synthetic sleeper made of fiber-reinforced resin that has been removed from the railway track and recovered. A process for producing a regenerated synthetic wood with a smooth plate-like or prismatic shape by removing dents and / or cracks, and embedding a plug into a hole formed in a defective synthetic sleeper and fixing it. When,
A step of fingering a longitudinal end of the recycled synthetic wood;
A step of abutting and adhering the end portions in the longitudinal direction of a pair of regenerated synthetic wood.
[0009]
In the present invention, by the above-mentioned finger processing, a plurality of angle teeth having a predetermined length in the longitudinal direction from the end portion and extending in the width direction or thickness direction of the sleeper are formed at the longitudinal end portion of the recycled synthetic wood. Unevenness is formed. Furthermore, the chevron-like irregularities of the pair of regenerated synthetic timbers are joined to each other in a fitted state by abutting the ends, and the cross-sectional shape of the joint becomes a square shape.
[0010]
According to the present invention, an existing synthetic sleeper whose cross-sectional shape has deteriorated due to long-term use is recovered, and defective portions such as cracks and dents are removed by processing such as cutting and grinding, and rail fastening such as dog nails and screw nails is performed. By plugging the holes in the traces from which the members have been pulled out to make the surface smooth, it is possible to produce regenerated synthetic wood with a good degree of plate or prismatic shape from the collected existing synthetic sleepers. . And by fingering the ends of this regenerated synthetic wood, by finger joining the ends of the pair of regenerated synthetic wood, even if each regenerated synthetic wood does not have a predetermined longitudinal dimension as a sleeper, The said joining member can ensure sufficient longitudinal direction dimension as a sleeper. Furthermore, because finger joints are used, the bonding area is secured large while shortening the longitudinal dimension of the joints as much as possible, and sufficient tensile strength and bending strength are obtained as sleepers at the joints. Is possible. And the said joining member single-piece | unit can also be used as a new synthetic sleeper, and when the thickness or width | variety of a joining member is less than the required dimension as a sleeper, two or more said joining members are piled up, or By attaching the same material to the surface of the joining member, the necessary dimensions as sleepers can be ensured. Thus, according to the manufacturing method of the present invention, it is possible to effectively use the recovered material, and it is possible to manufacture a long synthetic sleeper with sufficient strength while keeping the length of the joint portion short.
[0011]
In the production method of the present invention described above, by bonding a plurality stacked state joining member formed by adhesive bonding with an adhesive the ends of the playing synthetic wood pair of fiber-reinforced resin in the thickness direction or the width direction Therefore, a predetermined dimension as a sleeper can be secured. In this case, it is preferable to shift the positions of the finger connecting portions of the adjacent joining members in the longitudinal direction. According to this, since the weak finger connection portions are dispersed in the longitudinal direction, the breaking strength can be made uniform over the entire length of the sleeper in the longitudinal direction. The synthetic sleeper having such a structure can be suitably used as a long branch sleeper where the fastening position of the rail is not constant.
[0012]
In addition, a new synthetic sleeper can be produced using only the above-mentioned recycled synthetic wood. However, a newly formed fiber reinforced resin plate (preferably a long fiber reinforced foamed resin plate, more preferably synthetic wood) is used in combination. Synthetic sleepers may be made. That is, in addition to the above steps, the production method of the present invention bonds the fiber reinforced resin plate constituting the uppermost layer and the lowermost layer of the sleeper and continuing over the entire length of the sleeper to the recycled synthetic wood. Can have steps. According to this, even when the recovered material is extremely poor and the appearance of the recycled synthetic wood is not good even by surface processing (for example, when there are many traces of plugging processing), the fiber-reinforced resin plate with a newly formed surface The synthetic wood having a good appearance can be manufactured, and the core material is made of the recovered material, so that the material cost can be reduced. Further, it is preferable that the plug is made of a fiber reinforced resin.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 (a) shows an example of a defective synthetic sleeper 1 (collected material) recovered after being removed from a railway track. A dent 2 is formed on the bottom surface of the collected material 1 over its entire length. A crack 3 is formed at one end in the direction, and holes 4 are formed at a plurality of locations on the upper surface. This hole 4 is formed by a trace of a dog nail or a screw nail for fixing the tie plate to the sleeper. These recesses 2, cracks 3 and holes 4 become defective portions when the recovered material is reused.
[0014]
In this embodiment, first, the defective portion of the recovered material 1 is removed by grinding, cutting, or embedding a plug. That is, by grinding the lower surface of the recovery material 1, the dent 2 is removed, and the lower surface is made smooth. Further, the end where the crack 3 is generated is removed by cutting or grinding to obtain a columnar body as shown in FIG. Further, the plug 4 is embedded and fixed to the hole 4. Through these repair operations, a recycled synthetic wood 10 having a smooth plate-like or prismatic shape is produced from the recovered material 1.
[0015]
The shape of the embedding plug 5 and the embedding method can be various. For example, when a cylindrical resin molded product as shown in FIG. 1 (b) is used as the plug 5, the hole 4 is formed with an appropriate drilling tool (such as a gimmune) as shown in FIG. 2 (a). A hole 4 'having a smooth inner peripheral surface by drilling, and filling the adhesive 6 inside the hole 4' as shown in FIG. 2 (b), and just filling the hole 4 ' 5 can be driven in as shown in FIG. The plug 5 may be a rectangular columnar body as well as a cylindrical shape. In this case, the inner surface of the hole 4 is cut so that the square columnar plug 5 is just fitted. .
The molding material for the plug 5 may be a long fiber reinforced hard resin foam of the same material as the synthetic sleeper, FRP, or other hard resin such as nylon or polypropylene. It is.
[0016]
The end portions in the longitudinal direction of the regenerated synthetic wood 10 obtained by the above processing are subjected to finger processing by a finger processing machine, and the regenerated synthetic wood 10 is regenerated as a synthetic sleeper by finger-connecting the regenerated synthetic woods 10 to each other. Used.
[0017]
FIG. 3 shows an overall perspective view of the synthetic sleeper according to the first embodiment of the present invention. This synthetic sleeper is manufactured by finger-connecting two regenerated synthetic woods 10. The ends of the pair of recycled synthetic wood 10 connected to each other in the longitudinal direction are finger connection portions 11 and 12 having complementary shapes, respectively. Both the connecting portions 11 and 12 have a plurality of mountain-shaped convex portions 13 having a predetermined length in the longitudinal direction of the sleepers and extending in the width direction of the sleepers, and the plurality of convex portions 13 are in the thickness direction of the sleepers. Are arranged side by side. In this embodiment, the connection part 11 of one synthetic wood 10 has four convex parts 13, the connection part 12 of the other synthetic wood 10 has three convex parts 13, and these connection parts 11 and 12 are mutually Are joined to each other by fingers to form a columnar body having a square cross section. The upper and lower surfaces of each convex portion 13 are used as adhesive bonding surfaces, and these bonding surfaces are processed into tapered surfaces. Further, a vertical surface may or may not be provided on the distal end surface and the proximal end portion of the convex portion 13. The taper angle of the joint surface is preferably in the range of 5 ° to 15 °, but can be any other desired angle, and no taper need be provided at all. In addition, the tension transmission between the long fibers facing the cut ends with the taper surface as a boundary, the tension of one fiber is transmitted as a matrix to the other fibers that bridge in phase between the cut ends, The path that is transmitted from the other fiber to the other fiber is a main component, and the efficiency of the tension transmission increases as the other fiber wraps deeply between the fiber ends. Therefore, the smaller the taper angle, the more advantageous in terms of tension transmission efficiency.
[0018]
And an adhesive agent is apply | coated to the joint surface (namely, the said taper surface and substantially perpendicular surface) of both the connection parts 11 and 12 of a pair of synthetic wood 10, and these joint surfaces are faced | matched and adhere | attached. Note that the adhesive is not particularly limited as long as it can bond the joint surfaces of the synthetic woods 10 to each other. The adhesive may be a material such as a long fiber or a thermosetting resin foam constituting the synthetic sleeper. It can be selected as appropriate. For example, when the synthetic sleeper is composed of long glass fibers and hard urethane resin foam, urethane resin or epoxy resin can be suitably used as the adhesive.
[0019]
By finishing the joining member formed by finger-connecting the two recycled synthetic woods 10 to a predetermined size, the joining member alone can be used as a synthetic sleeper, and as shown in FIG. 5 and FIG. The joining member is a core material layer, and the upper and lower surfaces of the joining member constitute the uppermost layer and the lowermost layer of the sleeper and are continuous over the entire length of the sleeper in the longitudinal direction (that is, without a joining part). What is bonded to a joining member made of two recycled synthetic woods can also be used as a synthetic sleeper. In this case, as the fiber reinforced resin plate 14, it is preferable to use a plate material made of a long glass fiber reinforced hard resin foam, but FRP may be used. Further, it is preferable that the resin plate 14 and the synthetic wood 10 are firmly bonded by applying an adhesive over the entire joint surface.
[0020]
Moreover, as shown in FIG. 7, the core material layer sandwiched between the upper and lower resin plates 14 has a joining member formed by finger-connecting at least two recycled synthetic woods 10 and 10 in the thickness direction (vertical direction). ) May be bonded in a stacked state. According to the present embodiment, a predetermined dimension as a sleeper can be secured by bonding a plurality of joining members in the thickness direction in a stacked state. In this case, the positions of the finger connecting portions of the adjacent joining members can be shifted from each other in the longitudinal direction.
[0021]
In addition, as shown in FIG. 8, a relatively thin-walled recycled material is obtained by using, as a core material, a plurality of thick-walled joining members obtained by finger-connecting relatively thick-walled recycled synthetic wood. A thin sleeper obtained by finger-connecting synthetic wood is used as a surface layer, and a plurality of joining members are laminated and bonded together in the upper and lower directions, thereby producing one synthetic sleeper.
[0022]
In the embodiment shown in FIG. 7 and FIG. 8, the stacking direction of the plurality of joining members is the vertical direction (thickness direction), but this stacking direction is the width direction (front and back) as shown in FIG. 9 and FIG. Direction). Also in this case, the longitudinal positions of the finger connecting portions in the respective joining members are shifted, and the laminated body of these joining members is used as a core material layer of sleepers, and the fiber reinforced resin plates 14 constituting the uppermost layer and the lowermost layer are vertically arranged. It is preferable to adhere to the recycled synthetic wood 10. This bonding may be performed after the plurality of bonding members are bonded to each other in a laminated form, or the plurality of bonding members may be bonded to the surface of the resin plate 14 one by one. Further, in this embodiment, the finger processing of the end portion in the longitudinal direction of the regenerated synthetic wood has a predetermined length in the longitudinal direction from the end portion and forms chevron-like irregularities so as to extend in the thickness direction of the sleeper. Is done.
[0023]
In addition, it is preferable to employ | adopt a glass long fiber reinforced plastic foam as a synthetic wood which comprises a synthetic sleeper and a plug. As the type of foamed resin in the foam, for example, a hard thermosetting resin such as a urethane resin, an epoxy resin, a vinyl ester resin, an unsaturated polyester resin, or a phenol resin is preferably used. In order to improve compressive strength and reduce costs in the foamed resin, inorganic fillers such as calcium carbonate, gypsum, talc, aluminum hydroxide, clay, and lightweight bones such as shirasu balloon, perlite, glass balloon, etc. A material may be added.
[0024]
The fiber for reinforcing the foam may be any of inorganic fibers such as glass fibers, carbon fibers and metal fibers, and organic fibers such as natural fibers and synthetic fibers. Glass fiber is suitable. Examples of the glass fiber include glass roving, glass roving cloth, glass mat, and continuous strand mat. These fibers may be used alone, or two or more layers may be laminated, or long fibers and short fibers may be mixed and used.
It should be noted that a long glass fiber reinforced rigid urethane foam (for example, manufactured by Sekisui Chemical Co., Ltd., trade name “Eslon Neo Lumber FFU”, etc.) that uses long glass fibers in the longitudinal direction as reinforcing fibers is adopted. It is most preferable for reducing the weight, durability and processability.
[0025]
Moreover, the adhesive agent for adhere | attaching synthetic timbers can be suitably selected according to materials, such as the long fiber which comprises a synthetic sleeper, and a thermosetting resin foam. For example, when the synthetic sleeper is composed of long glass fibers and a hard urethane resin foam, an epoxy resin can be suitably used as the adhesive.
【The invention's effect】
According to the present invention, defective synthetic sleepers are collected and a new synthetic sleeper is produced using the collected material as a raw material, thereby reducing the cost of the synthetic sleeper and sufficient bending while using the collected material. Strength and tensile strength can be obtained. Furthermore, by adopting the finger connection structure, the length in the longitudinal direction of the connection part for obtaining sufficient adhesive strength can be made as small as possible, and the weak range of sleepers can be kept to a small range. When the rail is laid through the tie plate at an arbitrary position in the longitudinal direction of the sleeper, the possibility that an excessive concentrated load acts on the connecting portion is laid directly above the connecting portion. be able to.
[Brief description of the drawings]
FIG. 1 (a) is a simplified perspective view showing an example of a defective synthetic sleeper that has been removed from a railroad track and collected, and FIG. 1 (b) is a diagram illustrating removing a defective portion of a defective synthetic sleeper and filling it in a hole portion. It is a simplified perspective view which shows the process of driving in a stopper.
FIG. 2 is an explanatory view showing an example of a repairing process for a hole portion of recycled synthetic wood, where (a) is a longitudinal sectional view of the hole before repairing, and (b) is a hole portion drilling the inner peripheral surface. FIG. 5C is a longitudinal sectional view before smoothing and embedding the plug, and FIG. 5C is a longitudinal sectional view of the state where the embedding plug is driven into the hole portion.
FIG. 3 is an overall perspective view of a synthetic sleeper obtained by the manufacturing method according to the first embodiment of the present invention.
FIG. 4 is an exploded perspective view of the synthetic sleeper.
FIG. 5 is an overall perspective view of a synthetic sleeper obtained by the manufacturing method according to the second embodiment of the present invention.
FIG. 6 is an exploded perspective view of the synthetic sleeper.
FIG. 7 is an overall perspective view of a synthetic sleeper obtained by the manufacturing method according to the third embodiment of the present invention.
FIG. 8 is an overall perspective view of a synthetic sleeper obtained by the manufacturing method according to the fourth embodiment of the present invention.
FIG. 9 is an overall perspective view of a synthetic sleeper obtained by the manufacturing method according to the fifth embodiment of the present invention.
FIG. 10 is an overall perspective view of the synthetic sleeper.
[Explanation of symbols]
1 Existing synthetic sleepers (collected materials)
2 Recess 3 Crack 4 Hole 5 Plug 10 Recycled synthetic wood 11, 12 Finger processing part 13 Angle-like unevenness 14 Fiber reinforced resin plate

Claims (4)

The surface of the defective synthetic sleeper made of fiber reinforced resin removed from the railroad track is ground or cut to remove dents and / or cracks formed on the surface, and the defective synthetic sleeper is formed on the defective synthetic sleeper. A process of producing a plate-shaped or prism-shaped recycled synthetic wood with a smooth surface by embedding a plug in the hole and fixing it;
A step of fingering a longitudinal end of the recycled synthetic wood;
A process of abutting and adhering the longitudinal ends of a pair of regenerated synthetic wood,
By the finger processing, a plurality of chevron-like irregularities having a predetermined length in the longitudinal direction from the end portion and extending in the width direction or thickness direction of the sleeper are formed at the longitudinal end portion of the recycled synthetic wood,
A predetermined dimension as a sleeper is secured by bonding a plurality of laminated members in the thickness direction or width direction by bonding the ends of a pair of recycled synthetic wood made of fiber reinforced resin with an adhesive. ,
By using the recovered material as a raw material, the chevron-like irregularities of a pair of recycled synthetic wood are joined together in a fitted state by abutting the ends, and the cross-sectional shape of the joint becomes a square shape. Of manufacturing synthetic sleepers. The method of manufacturing a synthetic sleeper using the recovered material as a raw material according to claim 1 , wherein the positions of finger connecting portions of adjacent joining members are shifted from each other in the longitudinal direction. The recovered material according to claim 1 or 2, comprising a step of adhering a fiber reinforced resin plate constituting the uppermost layer and the lowermost layer of the sleeper and continuous over the entire length of the sleeper to the recycled synthetic wood. A method of manufacturing synthetic sleepers. The manufacturing method of the synthetic sleeper using the collection | recovery material of Claims 1-3 which the said plug consists of fiber reinforced resin as a raw material.

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