Thermoset composite material and structural component and method of making the same from engineered recycled rubber powder
A thermoset composite material that my used in the fabrication of structural components including railroad ties comprise a substantially homogeneous blend of an amount of vulcanized rubber particles including a predetermined ratio of different particles sizes, and a thermoset elastomeric binding agent added to the vulcanized rubber particles. The blend may comprise about 30% to about 97% by weight of the vulcanized rubber particles, and the blend is subjected to compression molding at a predetermined temperature and pressure for a resident time period forming the composite material. The ratio of different rubber particle sizes is selected so that the composite material has a desired density or is within a range of desired densities.
1. A thermoset composite material, comprising:
a substantially homogeneous blend of an amount of vulcanized recycled rubber particles including a predetermined ratio of different particles sizes, and a thermoset elastomeric polyurea binding agent added to the vulcanized rubber particles; and,
a fibrous filler material and a granulated silica filler material;
the blend comprises about 30% to about 97% by weight of the vulcanized recycled rubber particles, and the blend is subjected to compression molding at a predetermined temperature and pressure for a resident time period forming the composite material; and,
wherein the ratio of different rubber particle sizes is selected so that the composite material has a desired density or is within a range of desired densities.
2. The composite material of claim 1 , wherein the blend comprises about 30% to 70% by weight of the vulcanized rubber particles.
3. The composite material of claim 2 , wherein the blend comprises about 40% to 50% by weight of the vulcanized rubber particles.
4. The composite material of claim 1 , wherein the blend further comprises a depolymerized vulcanized rubber material and/or an amorphous carbon material.
5. The composite material of claim 1 , wherein the blend comprises about 3% to about 15% by weight of the binding agent and the remainder being the vulcanized rubber particles.
6. The composition material of claim 5 , wherein the blend comprises about 5% to about 10% by weight of the thermoplastic elastomer and the remainder being the vulcanized rubber particles.
7. The composite material of claim 1 , wherein the blend is subjected to compression molding at about 1,000 psi to about 5,000 psi, at a temperature ranging from about 200° F. to about 350° F. for a resident time of about 3 to 10 minutes.
8. The composite material of claim 7 , wherein the blend is subjected to compression molding at about 4,500 psi, at a temperature of about 350° F. for a resident time of about 7 to 10 minutes.
9. The composite material of claim 1 , wherein a particle size of the vulcanized rubber particles is about 20 mesh to about 60 mesh.
10. The composite material of claim 9 , wherein the particle size of the vulcanized rubber powder is about 30 mesh to about 40 mesh.
11. The composite material of claim 1 , wherein the composite material as a density from about 45 lb/ft 3 to about 80 lb/ft 3 .
12. The composite material of claim 11 , wherein the composite material has a density from about 60 lb/ft 3 to about 70 lb/ft 3 .
13. The composite material of claim 1 , wherein the compression molding of the blend is performed to fabricate a railroad tie.
14. The composite material of claim 1 , wherein the ratio of different vulcanized rubber particles includes about 25% of −20 mesh, about 25% of −40 to +60 mesh and about 50% of −80 mesh.
15. A thermoset composite material, comprising:
a substantially homogeneous blend of an amount of vulcanized recycled rubber particles produced from comminuting a rubber article at temperatures that do not exceed a glass transition temperature of the rubber article, and a thermoset elastomeric polyurea binding agent added to the vulcanized rubber particles; and
a fibrous filler material and a granulated silica filler material;
wherein the blend comprises about 30% to about 97% by weight of the vulcanized recycled rubber particles and a particle size of the rubber particles does not exceed 20 mesh; and,
the blend is subjected to compression molding at a pressure of at least 1,000 psi and at a temperature of at least 200° F. for a resident time period forming the composite material.
16. The composite material of claim 14 , wherein the blend is subjected to compression molding at a pressure of about 4,500 psi at a temperature of about 350° F.
17. A method of making a thermoset composite material according to claim 1 , comprising:
mixing an amount of vulcanized recycled rubber particles, including a predetermined ratio of different particle sizes, with a thermoset elastomeric polyurea binding agent to generate a substantially, homogeneous blend;
providing to the blend a fibrous filler material and a granulated silica filler material; and,
applying a compressive molding force to the blend at a predetermined temperature and pressure for a resident time.
18. The method of claim 17 wherein the ratio of different particle sizes includes about 25% of −20 mesh, about 25% of −40 to +60 mesh and about 50% of −80 mesh.
19. A railroad tie fabricated from a thermoset composite material according to claim 1 , comprising:
a substantially homogeneous blend of an amount of vulcanized recycled rubber particles including a predetermined ratio of different particle sizes, and a thermoset elastomeric polyurea binding agent added to the vulcanized rubber particles; and,
a fibrous filler material and a granulated silica filler material;
the blend comprises about 30% to about 97% by weight of the vulcanized recycled rubber particles, and the blend is subjected to compression molding at a predetermined temperature of about 350° F. and pressure of about 4,5000 psi for a resident time period forming the composite material; and,
wherein the ratio of different rubber particle sizes is selected so that the composite material has a desired density of about 60 lbs/ft 3 to about 70 lbs/ft 3 .
20. The railroad tie of claim 19 , further comprising an elongated configuration including a top and bottom parallel surface and two parallel side surfaces wherein grooves are formed in the one or both of the side surfaces and the bottom surface.
21. A thermoset composite material, comprising:
a substantially homogeneous blend of an amount of vulcanized recycled rubber particles including a predetermined ratio of different particles sizes, and a thermoset elastomeric polyurea binding agent added to the vulcanized rubber particles; and,
a fibrous filler material and a granulated silica filler material;
the blend comprises about 30% to about 97% by weight of the vulcanized recycled rubber particles, and the blend is subjected to compression molding at a predetermined temperature and pressure for a resident time period forming the composite material.