GB2529034A

GB2529034A - A wear plate

Info

Publication number: GB2529034A
Application number: GB1509939.3A
Authority: GB
Inventors: Simon Eves
Original assignee: Pipex Structural Composites Ltd
Current assignee: Pipex Structural Composites Ltd
Priority date: 2014-06-08
Filing date: 2015-06-08
Publication date: 2016-02-10
Also published as: GB2529380B; GB2529380A; GB201410146D0; GB2528768A; GB201509942D0; GB201509939D0

Abstract

There is provided a method of manufacturing a mould for a wear-resistant plate, comprising the steps of: a) providing a master plate; b) applying particulate material onto a surface of the plate; and c) taking a mould of the master plate. A high grade moulding silicone is mixed, de-gassed and poured onto the plate and allowed to cure. Once cured, the silicone mould is then peeled off and placed into a composite mould which is used to give the silicone strength. A railway platform level access structure may comprise one or more plates. In some embodiments, for example, the plate is a wear surface forming part of a modular frame. The wear plates may be removable so it can be replaced/repaired and be resistant to wear from footfall. The present invention also provides a resin-infused, wear-resistant gritted plate, the grit being formed integrally with the resin-infused material of the plate. A railway platform level access hump structure is generally indicated 150. To create a hump with required dimensions three different types of module 125A, 125B, 125C are used. At either end of the hump stainless steel nosing 155 is provided. The top plate (20, Fig 1) is formed by moulding of an FRP material; in which the moulding process includes the step of adding in grit to the mould so that it becomes an integral part of the plate rather than.

Description

A WEAR PLATE

The present invention relates generally to a plate and particularly to a wear plate which is intended for long-life in highly abrasive environments, such as when used as a S flooring plate.

According to an aspect of the present invention there is provided a method of manufacturing a mould for a wear-resistant plate, comprising the steps of: a) providing a master plate; b) applying particulate material onto a surface of the plate; and c) taking a mould of the master plate.

Prior to step b) the plate may be abraded. In some embodiments adhesive is applied to the plate after abrading; then particulate material is sprinkled over the adhesive.

After curing of the adhesive excess particulate material may be removed to provide the finished master plate prior to a mould being taken.

A further aspect provides a method of forming wear-resistant plates, comprising the steps of: i) providing a master plate; ii) applying particulate material onto the plate surface; iii) forming a mould with a textured surface using the plate; and iv) using the mould to form wear plates.

The wear plates may be formed by adding particulate material to the textured surface and then introducing material into the mould.

In aspect and embodiments of the present invention the master plate and/or wear S plates may be formed from a composite material, such as an FRP material.

Fibre-reinforced plastic (FRP) (also fibre-reinforced polymer) is a composite material made of a polymer matrix reinforced with fibres. The fibres may be, for example, inorganic fibres (with glass fibre being most common), carbon, aramid, or basalt The polymer may be, for example, an epoxy, vinylester or polyester thermosetting plastic.

or a phenol formaldehyde resin. Resins are usually thermosetting types, but thermoplastic resins can also be used for infusion.

The FRP material may, for example, be a phenolic FRP material. Phenolic-based resins are ideal for high temperature applications where parts must meet fire safety, smoke emission, combustion and toxicity requirements. They have excellent flame retardence, heat and chemical resistance, and electrical non-conductivity characteristics; they offer low density, good thermal insulation, outstanding durability and ease of formability to complex contours.

FRP products require minimal maintenance, and our lightweight FRP materials may be ideal where access is difficult The minimal conductive properties of FRP also eliminate the need for electrical grounding, and fire-resistant properties have a significant benefit In aspects and embodiments of the present invention the master plate and/or wear plates may be formed by resin infusion.

Resin (or vacuum) infusion: in the field of composites, resin infusion is a process where S the voids in an evacuated stack of porous material are filled with a liquid resin. When the resin solidifies, the solid resin matrix binds the assembly of materials into a unified rigid composite. A key part of the process is the evacuation, or removal, of the air from the porous material prior to admitting the resin. The air needs to be removed from the porous material to allow the resin to take its place.

The particulate material may, for example, be grit (such as particles of stone and/or sand).

In some embodiments one or more tactiles, studs or the like are introduced into the mould.

At least part of the master plate mould may be formed from silicon.

The particulate size used to form the master plate may be larger than the particulate size to be used when forming wear plates therefrom.

The resin used to form the wear plates may include a dye to add colour to, or to change the colour of, the plate.

A further aspect provided a method of manufacturing a mould for a wear-resistant plate, comprising the steps of: a) providing a master plate; b) applying one or more studs onto a surface of the plate; and c) taking a mould of the master plate.

A further aspect provides a method of forming wear-resistant plates, comprising the steps of: i) providing a master plate; ii) applying one or more studs onto the plate surface; iii) forming a mould a surface having one or more stud recesses using the plate; and iv) using the mould to form wear plates by introducing studs into the stud recesses and then introducing composite material into the mould.

The present invention also provides a method of forming a wear-resistant plate, comprising the steps of: i) providing a mould; ii) applying particulate material into the mould onto a surface which will become an upper surface of the plate; and iii) introducing material into the mould to form the plate.

One method of wear plate fabrication in accordance with the present invention is as follows.

Wear Plate Plug

S

A fibre reinforced plastic (FRP) plate is prepared for bonding by the use of a double action sander.

A thin layer of adhesive is applied and grit is sprinkled over adhesive, which is then left to cure. Once cured, the lose grit is removed and you have a standard' FR? gritted plate ready for the next process.

Silicone Mould Fabrication A thermoplastic boundary is attached to the fabricated plug plate as stated above. A high grade moulding silicone is mixed, de-gassed and poured onto the plate and allowed to cure. Once cured, the silicone mould is then peeled off and placed into a composite mould which is used to give the silicone strength.

Wear Plate Fabrication The silicone mould is prepared for layup; it is cleaned; a mould sealer chemical is applied and a mould release chemical is applied. Once dry, a thin layer of grit is applied within a thermoplastic boundary. When an even amount is applied the glass layup can now be added. The layers of glass depend on how thick the plate needs to be.

Once the glass is applied, the resin infusion consumables are applied and a vacuum is attached. A leak test is now carried out to ensure the vacuum is absolute. The mould is then placed into an oven and heated to 40°C.

S

Once the mould has reached the required temperature, phenolic resin is injected into the mould at 40°C until all the glass has been wetted out'. This confirms the infusion is complete.

Once complete. the injection machine is turned off and cleaned; the oven temperature is ramped up to cure the resin off.

When the resin has cured, the plate is removed from the mould, placed on a computer numerical controlled (CNC) machine, and cut to the correct size. The process is then repeated to create another plate.

Further method steps may include painting or tactile installation.

The present invention also provides a wear plate formed according to a method as described herein.

The plates may be regularly or irregularly shaped depending on the required purpose.

The plates may be generally quadrilateral in shape, for example square or rectangular.

The present invention also provides a railway platform level access structure comprising one or more plates as described herein. In some embodiments, for example, the plates is a wear surface forming part of a modular frame. The wear plates may be removable so it can be replaced/repaired and be resistant to wear from S footfall.

The present invention also provides a resin-infused, wear-resistant gritted plate, the grit being formed integrally with the resin-infused material of the plate.

Different aspects and embodiments of the invention may be used separately or together.

Further particular and preferred aspects of the present invention are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with the features of the independent claims as appropriate, and in combination other than those explicitly set out in the claims.

The present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which: Figure I is a perspective view of a wear plate manufactured according to the present invention forming part of a modular framework; Figure 2 is a plan view of a railway platform level access structure based on a modular framework system of the type shown in Figure I; Figure 3 is a side view of the structure of Figure 2; Figures 4A to 4E illustrate the formation of a wear plate mould in accordance with the present invention; Figure 5 shows a method of forming a wear plate in accordance with the present invention; Figures 6A to 6D show plan, sectional, magnified and perspective views of a mould formed according to a further embodiment; and Figures 7A to 7E show plan, side, sectional, magnified and perspective views of a wear plate formed from a mould of the type shown in Figure 6.

The example embodiments are described in sufficient detail to enable those of ordinary skill in the art to embody and implement the systems and processes herein described. It is important to understand that embodiments can be provided in many alternate forms and should not be construed as limited to the examples set forth herein.

Accordingly, while embodiment can be modified in various ways and take on various alternative forms, specific embodiments thereof are shown in the drawings and described in detail below as examples. There is no intent to limit to the particular forms disclosed. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Elements of the example embodiments are consistently denoted by the same reference numerals throughout the drawings and detailed description where appropriate.

S Unless otherwise defined, all terms (including technical and scientific terms) used herein are to be interpreted as is customary in the art It will be further understood that terms in common usage should also be interpreted as is customary in the relevant art and not in an idealised or overly formal sense unless expressly so defined herein.

Referring now to the drawings, wherein like reference numbers are used to designate like elements throughout the various views, several embodiments of the present invention are further described. The figures are not necessary drawn to scale, and in some instances the drawings may have been exaggerated or simplified for illustrative purposes only. One of ordinary skill in the art will appreciate the many possible applications and variations of the present invention based on the following examples of possible embodiments of the present invention.

Referring first to Figure I there is shown a generally rectangular frame generally indicated 10 intended to be used in conjunction with one or more further such frames to form a modular framework.

The frame 10 is shown in the figure with a top panel 20 removed. In use the top panel is fitted on to the frame IC and together the unit can be assembled with other such units 25 as shown in the figure.

The top panel 20 is a removable wear plate which is securable to the top deck IS using fixings (for example bolts, screws or studs) which pass through pre-drilled holes 21 and are received by fixings holes 8.

S The panel 20 is removable and therefore repairable and/or replaceable in use.

The top panel includes a gritted top surface 22 and is resistant to wear in use, for example, as a flooring member which may receive a large amount of pedestrian footfall.

The top panel also includes markings (in this embodiment, coloured lines 23) and a studded zone 24.

Referring now to Figures 2 and 3 there is shown a railway platform level access hump structure generally indicated ISO. To create a hump with required dimensions three different types of module 125A, 125B, 125C are used. At either end of the hump stainless steel nosing 155 is provided.

The top plate 20 of Figure I is formed by moulding of an FRP material; in which the moulding process includes the step of adding in grit to the mould so that it becomes an integral part of the plate rather than, for example, being applied in a post-moulding process.

In this embodiment the plate is formed from a mould which is produced from a plate master copy.

Figure 4 illustrates steps involved in forming a master plate copy.

In Figure 4 a plain plate I formed from FR.P is provided (Figure 4A).

An upper surface 2 of the plate is prepared to receive particulate material, in this S embodiment by sanding followed by application of adhesive 3 (Figure 4B).

Particulate material 4 is then sprinkled onto the surface 2 (Figure 4C).

A mould 5 is then taken of the plate (Figure 4D.

The mould will therefore include a cavity with a surface 6 (which will form the upper surface of wear plates) which is textured, due to the particulate material (Figure 4E).

As shown in Figure 5, subsequently the mould 5 is used as an insert as part of moulding apparatus to form wear plates.

In the wear plate formation process grit 7 is sprinkled onto the textured surface 6 (which will form the "upper" wear surface). The grit 7 is of a lower grade than the particulate material 4.

Glass fibre mats 8 are then layered onto the mould and a silicon bag 9 is used to seal the mould before a vacuum is applied and FRP material in injected.

In an alternative embodiment an insert 105 including recess ISO for studs is used.

Studs can thereby be added into the mould and composite material is formed around them so that the studs are embedded into the plate material (part of the studs being in the composite material to anchor them, and part extending above the material so as to be exposed).

S In Figures 6A to 6D a top plate mould 205 is shown. The mould 205 includes a plurality of stud recesses 250.

Figures 7A to 7E show a plate 220 formed from the mould 205. Metal (for example aluminium) studs/tactiles 260 are placed in the recesses 250 before material is introduced into the mould. In this embodiment the plate 220 is formed with a peripheral lip 265 which allows grit to be introduced, either as part of the moulding process or as a post-moulding operation. In a further embodiment the studs are formed as embossments on the plate and are not separate structures but rather are moulded from the composite material.

Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiments shown and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention.

Claims

CLAIMSI. A method of manufacturing a mould for a wear-resistant plate, comprising the steps of: a) providing a master plate; b) applying particulate material onto a surface of the plate; and c) taking a mould of the master plate.
2. A method as claimed in claim I, in which prior to step b) the plate is abraded.
3. A method as claimed in claim I, in which prior to step b) adhesive is applied to the plate surface.
4. A method of forming wear-resistant plates, comprising the steps of: i) providing a master plate; ii) applying particulate material onto the plate surface; iii) forming a mould with a textured surface using the plate; and iv) using the mould to form wear plates.
5. A method as claimed in claim 4, in which the wear plates are formed by adding particulate material to the textured surface and then introducing material into the mould.
6. A method as claimed in any preceding claim, in which the master plate and/or wear plates are formed from an FRP material.
7. A method as claimed in claim 6, in which the material is a phenolic FRP material.
8. A method as claimed in any preceding claim, in which the master plate and/or wear plates are formed by resin infusion.
9. A method as claimed in any preceding claim, in which the particulate material is grit.
10. A method as claimed in any preceding claim, in which one or more tactiles, studs or the like are introduced into the mould.
II. A method as claimed in any preceding claim, in which at least part of the master plate mould is formed from silicon.
12. A method as claimed in any preceding claim, in which the particulate size used to form the master plate is larger than the particulate size to be used when forming wear plates therefrom.
13. A method as claimed in any preceding claim, in which the resin used to form the wear plates includes a dye.
14. A method of manufacturing a mould for a wear-resistant plate, comprising the steps of: a) providing a master plate; b) applying one or more studs onto a surface of the plate; and c) taking a mould of the master plate.
IS. A method of forming wear-resistant plates, comprising the steps of: i) providing a master plate; ii) applying one or more studs onto the plate surface; iii) forming a mould a surface having one or more stud recesses using the plate; and iv) using the mould to form wear plates by introducing studs into the stud recesses and then introducing composite material into the mould.
16. A method of forming a wear-resistant plate, comprising the steps of: i) providing a mould; ii) applying particulate material into the mould onto a surface which will become an upper surface of the plate; and iii) introducing material into the mould to form the plate.
17. A method substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings.
18. A wear plate formed according to a method as claimed in any preceding claim.
19. A railway platform level access structure comprising one or more plates as claimed in claim IS.
20. A resin-infused, wear-resistant gritted plate, the grit being formed integrally with the resin-infused material of the plate.
21. A wear plate substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings.