Thermoset composite material and structural component and method of making the same from engineered recycled rubber powder
A thermoset composite material and composite railroad crosstie fabricated from the thermoset composite material that comprises a substantially homogeneous blend of an amount of vulcanized rubber particles, polyurea binding agent and urea melamine. The thermoset composite material may also contain a granulated silica material. The thermoset composite material may comprise about 30% to about 50% by weight of the vulcanized rubber particles, and it is subjected to compression molding at a predetermined temperature and pressure for a resident time period forming the composite railroad crosstie. The thermoset composite material and railroad crosstie may further comprise a fibrous glass material in the form of unbundled fibers and/or one more glass mats encapsulated within the thermoset composite material. In addition or alternatively, an elongated core insert may be encapsulated in the thermoset composite material.
1. A composite railroad crosstie, comprising:
a thermoset composite material comprising a blend of vulcanized recycled rubber particles, a polyurea binding agent, and a urea melamine filler in powder form; and,
wherein the blend comprises about 30% to about 50% by weight of the vulcanized recycled rubber particles, and the blend is subjected to a compressive molding force and heat for a resident time period forming the composite railroad crosstie.
2. The railroad crosstie of claim 1 wherein the thermoset composite material further comprises a granulated silica material.
3. The railroad crosstie of claim 1 wherein the urea melamine is a powdered recycled urea melamine.
4. The railroad crosstie of claim 2 wherein the thermoset composite material comprises:
about 15% to about 25% by weight of the urea melamine;
about 5% to about 15% by weight of the granulated silica material; and,
about 12% to about 20% by weight of the polyurea binding agent.
5. The railroad crosstie of claim 4 wherein the thermoset composite material further comprises about 0.3% to about 2.0% by weight of the water.
6. The railroad crosstie of claim 1 wherein the thermoset composite material further comprises a fibrous glass material.
7. The railroad crosstie of claim 6 wherein the thermoset composite material comprises about 10% to about 25% by weight of the fibrous glass material.
8. A composite railroad crosstie, comprising:
about 30% to about 50% by weight of vulcanized recycled rubber particles;
about 12% to about 20% by weight of a polyurea binding agent added to the vulcanized rubber particles;
about 5% to about 15% by weight of a granulated silica material;
about 15% to about 20% by weight of urea melamine powder filler and,
wherein the vulcanized recycled rubber, the polyurea binding agent, the granulated silica and urea melamine, is subjected to a compression molding force of about 300 psi to about 1,000 psi and heat at one or temperatures of about 230° F. to about 270° F. for a resident time period forming the thermoset composite railroad crosstie.
9. The railroad crosstie of claim 8 wherein the thermoset composite material comprises about 10% by wt to about 25% by wt of a fibrous glass material.
10. A method of assembling a railroad crosstie, comprising:
developing a thermoset composite material by mixing of blend of vulcanized recycled rubber particles, a polyurea binding agent, a granulated silica material and a urea melamine filler in powder form;
introducing the blend into a compression mold;
subjecting the blend to a compressive molding force and heat for a resident time;
allowing the blend to cool and harden after the resident time has elapsed; and,
removing the hardened blend from the mold.
11. The method of claim 10 wherein the blend further comprises a fibrous glass material.
12. The method of claim 10 wherein the blend further comprises an unbundled glass fiber material.