Polywood, Inc., of Edison, NJ, used recycled plastic to make railway sleepers, I-beams, and decking. It is worth pointing out that there is no fiber structure reinforcing material in the raw material, but the self-reinforcing effect formed in the interior of the profile when extruding the mixed plastic is used to improve the product performance.
In the 1980s, a doctoral student at the Rutgers University in the United States discovered that when a mixture of PS (polystyrene) and PE (polyethylene) is extruded in a suitable ratio, incompatibility, the matrix resin (PS) can be molded to enhance the matrix resin ( The continuous structural blends of PE) have a surprising compressive strength. The raw materials used are high melt strength PS of 20% to 35% and HDPE (High Density Polyethylene) recycled on the roadside. Rutgers University received a patent on the extrusion technology of incompatible polymer blends. A company that later became Plastic Lumers tried to cooperate with Rutgers University but failed. Until the late 1990s, local entrepreneur James Kerstein heard about this technology and sold his former business (plastic stent injection molding plant) to others to buy used equipment for production of plastic and wood materials. Rutgers University Technology The only patent license for the entire patent period (2011), the preparation of PE/PS composites for railway sleepers has proven to be a qualified product. Kerstein's new company, Polywood, has been granted a patent for railroad sleepers for PE/PS composites without fillers and is currently applying for other applications. Kerstein's research and development work has been supported by recycled HDPE suppliers and has received New Jersey technology. The Association’s $250,000 interest-free loan is used for research and development and promotion applications.
Polywood's existing PE/PS composite device with a production capacity of 15.9 kt/a. The PE/PS sleeper is different from the wooden sleeper (sleeper) in the sense that the new sleeper is installed on the gravel roadbed and the train that passes the sleeper The sleepers will be pressed into the gravel to form pit fixing sleepers, while the plastic sleepers are not easy to form pits. For this reason, Polywood has embossed the side and bottom of the sleeper so that the sleepers can “grab†the gravel. Surprisingly, the mechanical properties of plastic sleepers increased over time. Polywood's sleeper compression modulus was 18.2 MPa, rose to 21.7 MPa after simulated aging, and the initial value of sleepers was 22.4 MPa. Drop to 70MPa.
Polywood's first two online equipment for compounding extruded HDPE and PS sleepers was Davis-Standard's extruder in the United States and was equipped with a system for transfer to different molds. It later added two Belgian A, R, and T companies. The in-line conveyor belt in the injection molding (intrusion) production line, filling the mold speed of 181 ~ 227kg/h, and then rotate input to the water cooling tank. Polywood's two newest production lines are not extrusion equipment, but continuous compounding and extrusion profiles. Each line can extrude 8 rail sleepers per hour. The sizing sleeves are cooled by -1°C water and glycerol fluids, and quickly cooled. Curing profile surface, so that the sleeper has a good rigidity, extruded profiles through two 9.1 meters long spray cooling tank, the gap between the air 1.5 meters, then the profile re-embossed embossed, cut off immediately immersed in the sink cooling for 2 hours .
Polywood company has two specifications products, one kind of PS content is high, the rigidity is good, because its fiber content is high, another HDPE content is high, the rigidity is slightly lower, uses in making the industrial pallet and the planking. The HDPE parent resin has a lower melting temperature than the PS. Therefore, when the extrusion temperature is controlled at a temperature higher than the glass transition temperature of the PS, but the melting temperature is not reached, the HDPE melts and the PS is drawn into intertwined fibers (average diameter is about 15 μm, length to diameter ratio Greater than 8:1).
Polywood's plastic sleepers were tried by 6 institutes. In 2000, the Chicago Transportation Authority (CTA) had successfully used pre-buried elevated tracks. The CTA installed a total of 16 to 24 kilometers of track.
In the 1980s, a doctoral student at the Rutgers University in the United States discovered that when a mixture of PS (polystyrene) and PE (polyethylene) is extruded in a suitable ratio, incompatibility, the matrix resin (PS) can be molded to enhance the matrix resin ( The continuous structural blends of PE) have a surprising compressive strength. The raw materials used are high melt strength PS of 20% to 35% and HDPE (High Density Polyethylene) recycled on the roadside. Rutgers University received a patent on the extrusion technology of incompatible polymer blends. A company that later became Plastic Lumers tried to cooperate with Rutgers University but failed. Until the late 1990s, local entrepreneur James Kerstein heard about this technology and sold his former business (plastic stent injection molding plant) to others to buy used equipment for production of plastic and wood materials. Rutgers University Technology The only patent license for the entire patent period (2011), the preparation of PE/PS composites for railway sleepers has proven to be a qualified product. Kerstein's new company, Polywood, has been granted a patent for railroad sleepers for PE/PS composites without fillers and is currently applying for other applications. Kerstein's research and development work has been supported by recycled HDPE suppliers and has received New Jersey technology. The Association’s $250,000 interest-free loan is used for research and development and promotion applications.
Polywood's existing PE/PS composite device with a production capacity of 15.9 kt/a. The PE/PS sleeper is different from the wooden sleeper (sleeper) in the sense that the new sleeper is installed on the gravel roadbed and the train that passes the sleeper The sleepers will be pressed into the gravel to form pit fixing sleepers, while the plastic sleepers are not easy to form pits. For this reason, Polywood has embossed the side and bottom of the sleeper so that the sleepers can “grab†the gravel. Surprisingly, the mechanical properties of plastic sleepers increased over time. Polywood's sleeper compression modulus was 18.2 MPa, rose to 21.7 MPa after simulated aging, and the initial value of sleepers was 22.4 MPa. Drop to 70MPa.
Polywood's first two online equipment for compounding extruded HDPE and PS sleepers was Davis-Standard's extruder in the United States and was equipped with a system for transfer to different molds. It later added two Belgian A, R, and T companies. The in-line conveyor belt in the injection molding (intrusion) production line, filling the mold speed of 181 ~ 227kg/h, and then rotate input to the water cooling tank. Polywood's two newest production lines are not extrusion equipment, but continuous compounding and extrusion profiles. Each line can extrude 8 rail sleepers per hour. The sizing sleeves are cooled by -1°C water and glycerol fluids, and quickly cooled. Curing profile surface, so that the sleeper has a good rigidity, extruded profiles through two 9.1 meters long spray cooling tank, the gap between the air 1.5 meters, then the profile re-embossed embossed, cut off immediately immersed in the sink cooling for 2 hours .
Polywood company has two specifications products, one kind of PS content is high, the rigidity is good, because its fiber content is high, another HDPE content is high, the rigidity is slightly lower, uses in making the industrial pallet and the planking. The HDPE parent resin has a lower melting temperature than the PS. Therefore, when the extrusion temperature is controlled at a temperature higher than the glass transition temperature of the PS, but the melting temperature is not reached, the HDPE melts and the PS is drawn into intertwined fibers (average diameter is about 15 μm, length to diameter ratio Greater than 8:1).
Polywood's plastic sleepers were tried by 6 institutes. In 2000, the Chicago Transportation Authority (CTA) had successfully used pre-buried elevated tracks. The CTA installed a total of 16 to 24 kilometers of track.
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