Thermoset composite material and structural component and method of making the same from engineered recycled rubber powder

Abstract

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.

What is claimed is: 
     
         1 . A thermoset composite material comprising:
 vulcanized recycled rubber particles; and,   a polyurea binding agent.   
     
     
         2 . The thermoset composite material of  claim 1  further comprising a granulated silica filler material. 
     
     
         3 . The thermoset composite material of  claim 1  further comprising a fibrous filler material. 
     
     
         4 . The thermoset composite material of  claim 1  further comprising a fibrous filler material and a granulated silica material. 
     
     
         5 . The thermoset composite material of  claim 1  wherein the composite material of  claim 1  is subjected to compression molding at one or more temperatures ranging from about 200° F. to about 350° F. 
     
     
         6 . The thermoset composite material of  claim 1  wherein the composite material comprises about 30% to about 50% by weight of the vulcanized recycled rubber particles. 
     
     
         7 . The thermoset composite material of  claim 6  wherein the composite material comprises about 3% to about 15% by weight of the polyurea binding agent. 
     
     
         8 . A thermoset composite material for a composite structural component, comprising:
 about 30% to about 50% by weight of vulcanized recycled rubber particles;   about 3% to about 15% by weight of a polyurea binding agent;   a granulated silica material; and,   a fibrous filler material,   
     
     
         9 . The thermoset composite material of  claim 8  wherein the composite material of  claim 1  is subjected to compression molding at one or more temperatures ranging from about 200° F. to about 350° F. to form the composite structural component. 
     
     
         10 . The thermoset composite material of  claim 9  wherein the structural component is a railroad tie. 
     
     
         11 . A composite structural component, comprising:
 a blend of vulcanized recycled rubber particles and a polyurea binding agent having been subjected to a compressive molding force at one or more temperatures ranging from about 200° F. to about 350° F.   
     
     
         12 . The composite structural component of  claim 11  wherein the blend comprises a about 30% to about 50% by weight of the vulcanized recycled rubber particles, and about 3% to about 15% by weight of the polyurea binding agent. 
     
     
         13 . The composite structural component of  claim 11  wherein the blend further comprises a granulated silica material. 
     
     
         14 . The composite structural component of  claim 12  wherein the blend further comprises a fibrous filler material. 
     
     
         15 . The composite structural component of  claim 12  wherein the blend further comprises a granulated silica material and a fibrous filler material. 
     
     
         16 . The composite structural component of  claim 15  wherein the homogenous blend is subjected to compression molding at one or more temperatures ranging from about 200° F. to about 350° F. to form the composite structural component. 
     
     
         17 . A method of fabricating a composite structural component, comprising:
 mixing vulcanized recycled rubber particles with a polyurea binding agent to form a mixture;   placing the mixture into a mold having a desired geometric configuration associated with the composite structural component; and,   applying a compressive molding force to the mixture in the mold at one or more temperatures ranging from about 200° F. to about 350° F. to form the composite structural component.   
     
     
         18 . The method of  claim 17  further comprising mixing a granulated silica material with the vulcanized recycled rubber particles and the polyurea binding agent. 
     
     
         19 . The method of  claim 17  further comprising mixing a fibrous filler material with the vulcanized recycled rubber particles and the polyurea binding agent. 
     
     
         20 . The method of  claim 17  further comprising mixing a granulated silica material and a fibrous filler material with the vulcanized recycled rubber particles and the thermoset polyurea binding agent.