JP7845823B2 - Laminated structure and method for manufacturing the same - Google Patents

Description

This disclosure relates to a laminated structure and a method for manufacturing the same.

Patent Document 1 discloses a lightweight embankment construction method that includes a step of filling a partitioned space on the ground with a filling material to form a filled layer. The filling material is, for example, rigid polyurethane foam, expanded polystyrene blocks, and soil.

Patent Document 2 similarly discloses a lightweight embankment construction method that includes the step of filling a partitioned space on the ground with a filler material to form a filled layer. The filler material is, for example, a hollow block and a rigid foam. Patent Document 2 further discloses forming a concrete layer or a resin sheet on the filled layer, and then forming pavement on top of that.

Japanese Patent Publication No. 2001-220747 Japanese Patent Publication No. 2012-149404

Lightweight embankments can be applied to land preparation for roads, residential areas, factories, commercial facilities, rooftop gardens, and other facilities or equipment. The filling layer is covered with a suitable covering layer (e.g., concrete layer, resin sheet, soil layer, gravel layer) depending on the application. It is undesirable for liquids (e.g., surface water seeping in from the surface and groundwater leaking from the ground) to remain on or within the covering layer (on the filling layer) for extended periods.

This disclosure provides a laminated structure configured to discharge liquid on or through a coating layer, and a method for manufacturing the same.

A manufacturing method according to one aspect of this disclosure is a method for manufacturing a laminated structure comprising a packed layer and a coating layer laminated on the packed layer. This manufacturing method includes a flow channel formation step of forming a flow channel for a liquid on the laminated layer or a liquid that has passed through the laminated layer, such that the flow channel penetrates the packed layer forming space where the packed layer is formed. This manufacturing method further includes a packed layer formation step of forming a packed layer within the packed layer forming space by filling the packed layer forming space with a filler material.

A laminated structure according to another aspect of this disclosure comprises a packed layer and a coating layer laminated on the packed layer. The packed layer includes a passage that penetrates the packed layer for the flow of a liquid on the laminated layer or a liquid that has passed through the laminated layer.

The above-described method for manufacturing a laminated structure can provide a laminated structure configured to discharge liquid on the coating layer or liquid that has passed through the coating layer (e.g., water) via a flow passage.

A cross-sectional view showing a laminated structure according to one embodiment of the present disclosure. A cross-sectional view showing a laminated structure according to another embodiment of the present disclosure. A cross-sectional view showing a laminated structure according to yet another embodiment of the present disclosure. A flowchart illustrating a manufacturing process for a laminated structure according to one embodiment of this disclosure. A cross-sectional view illustrating a laminated structure after flow channel formation but before packing layer formation.

As shown in Figure 1, the laminated structure 10 may be formed on the ground 31 for the purpose of widening a road. However, the laminated structure 10 may be used not only for roads, but also for land leveling for residential areas, factories, commercial facilities, rooftop gardens, and other facilities or equipment.

The laminated structure 10 includes a filling layer 11 placed on the ground 31. The filling layer 11 is located in a space partitioned by a side wall 32 built on the ground 31 and a slope 33 of the ground 31. The filling layer 11 includes, for example, a foamed resin, lightweight concrete, lightweight soil, or a combination thereof. The foamed resin is, for example, foamed urethane, expanded polystyrene, or other resins. The filling layer 11 can be formed by filling the space with urethane on site and allowing the urethane to foam and harden in the space (R-PUR method). The foaming ratio of the foamed urethane is, for example, 10 to 40 times. The density of the foamed urethane is preferably 36 ± 4 kg/ ^m³ . The foamed urethane has a weight of about 1/80th that of concrete. The filling layer 11 may also be formed by stacking factory-molded expanded polystyrene blocks (for example, 1.0 m × 0.5 m × 2.0 m) without gaps in the space (EPS method). Lightweight concrete may be made lighter by, for example, mixing air bubbles into the concrete (FCB method). Lightweight soil may be made lighter by, for example, mixing expanded foam beads into the soil (expanded foam bead soil method).

The laminated structure 10 further comprises a coating layer 12 laminated on the filling layer 11. The coating layer 12 is, for example, a concrete layer, a resin sheet, a soil layer, a gravel layer, a crushed stone layer, or a combination thereof. The concrete layer, if intended to distribute the weight of vehicles on the pavement, may have a thickness of, for example, 150 mm.

The laminated structure 10 may further include a surface layer 13 laminated on the covering layer 12. The surface layer 13 can take various forms depending on the intended use of the laminated structure 10. In this embodiment, the surface layer 13 includes, for example, a subgrade 14, a base course 15, and pavement 16. The subgrade 14 and base course 15 may be formed from crushed stone. The pavement 16 may be formed from asphalt. The pavement 16 allows surface water to pass through. Surface water infiltrating the pavement 16 passes through the base course 15 and subgrade 14 and reaches the covering layer 12. Groundwater leaking from the ground also passes through the base course 15 and subgrade 14 and reaches the covering layer 12.

The packed layer 11 includes a flow passage 20 for circulating the liquid on the coating layer 12.

The flow passage 20 penetrates the filling layer 11. For example, if the coating layer 12 has undesirable cracks, liquids on the coating layer 12 (e.g., surface water and groundwater) reach the filling layer 11 through the cracks. Alternatively, for example, if the coating layer 12 is a concrete layer with relatively good liquid permeability, liquids on the coating layer 12 pass through the concrete layer to reach the filling layer 11. These liquids are discharged to the outside through the flow passage 20 that penetrates the filling layer 11.

The flow passage 20 may further penetrate the coating layer 12. For example, if the coating layer 12 is a concrete layer with relatively good liquid barrier properties, the liquid on the coating layer 12 will remain on the coating layer 12. This retained liquid is discharged to the outside through the flow passage 20 that penetrates both the coating layer 12 and the filling layer 11.

In this way, the flow channel 20 discharges the liquid on the coating layer 12 to the outside. If the liquid is not discharged, it will remain on the coating layer 12 for a long period of time. The retention of liquid on the coating layer can adversely affect the pavement on the coating layer. Specifically, the liquid may saturate the subgrade 14, causing a decrease in the strength of the subgrade 14, and as a result, causing cracks in the pavement 16. Also, if the coating layer 12 has unwanted cracks, the liquid on the coating layer 12 will permeate the coating layer 12 and reach the filling layer 11. If the filling layer 11 contains an impermeable (non-water-permeable) material such as foamed urethane, the liquid that reaches the filling layer 11 will remain between the coating layer 12 and the filling layer 11 for a long period of time. If the filling layer 11 contains a permeable (water-permeable) material such as lightweight soil, the liquid that reaches the filling layer 11 may permeate the filling layer 11, causing an increase in the weight and a decrease in the strength of the filling layer 11 (embankment). The flow passage 20 prevents the occurrence of the above-mentioned technical problems by discharging the liquid on the coating layer 12 to the outside.

The packed bed 11 may include a plurality of flow channels 20 arranged at appropriate intervals. The spacing of the flow channels 20 may be determined according to the amount of liquid flowing onto the coating layer 12.

The flow passage 20 may be a pipe made of resin, metal, ceramics, or other suitable material. The flow passage 20 may also be a pipe coated with a buffer material. The buffer material mitigates damage to the pipe due to pressure during compaction work, for example. The buffer material is, for example, urethane or other resin. The flow passage 20 may also be a pipe coated with a waterproofing material. The waterproofing material prevents water leakage due to undesirable damage to the pipe, for example. The waterproofing material is, for example, urethane or other resin. The flow passage 20 may also be a pipe coated with an insulating material. The insulating material protects the pipe from heat generated by urethane foaming in the R-PUR method, for example. The insulating material is, for example, urethane or other resin.

The flow passage 20 may be a hole formed in the packed bed 11 instead of a pipe.

The flow passage 20 may contain reinforcing materials of a fixed or irregular shape. The reinforcing materials prevent the flow passage 20 from collapsing due to the pressure exerted by the filling layer 11. The reinforcing materials may be, for example, crushed stone or recycled roof tiles.

The packed bed 11 may include, in addition to the flow passage 20, pipes for electricity, gas, sewage, or water supply.

As shown in Figure 1, the flow passage 20 includes a first end 21, a second end 22, and an intermediate section 23. The first end 21 is located on the upper surface of the coating layer 12. The second end 22 is located in the external space 34, which is situated to the side of the packed layer 11. The intermediate section 23 is connected between the first end 21 and the second end 22 and is located within the packed layer 11. That is, the flow passage 20 extends continuously from the upper surface of the coating layer 12 to the external space 34. Liquid on the coating layer 12 passes through the flow passage 20 and is discharged into the external space 34.

As shown in Figure 2, the flow passage 40 may include a horizontally extending split pipe 42 and a plurality of vertically extending pipes 43 connected to the split pipe 42. The split pipe 42 is positioned on the upper surface of the packed bed 11 with its opening facing upward to receive liquid from above. Each pipe 43 has a first end 44 and a second end 45. The first end 44 is connected to the split pipe 42 to receive liquid from the split pipe 42. The second end 45 is positioned within the ground 31. That is, the flow passage 40 extends continuously from the upper surface of the packed bed 11 to the ground 31.

In this embodiment, the covering layer 12 is a crushed stone layer (e.g., subgrade). The covering layer 12 receives liquid (e.g., surface water) from the surface layer 13 and allows the liquid to pass through. The liquid that has passed through the covering layer 12 is discharged to the ground 31 through the flow passage 40. The split pipe 42 may be placed on the upper surface of the covering layer 12.

As shown in Figure 3, the flow passage 50 may include a horizontally extending split pipe 52, a plurality of vertically extending pipes 53 connected to the split pipe 52, and a horizontally extending pipe 54 connected to the plurality of pipes 53. The split pipe 52 is positioned on the upper surface of the packed bed 11 with its opening facing upward to receive liquid from above. Each pipe 53 allows liquid to flow from the split pipe 52 to the pipe 54. The pipe 54 is positioned inside the packed bed 11. The pipe 54 has a first end 55 and a second end 56. The first end 55 and the second end 56 are each positioned in the external space 34 located to the side of the packed bed 11. That is, the flow passage 50 extends continuously from the upper surface of the packed bed 11 to the external space 34. The liquid passes through the flow passage 50 and is discharged into the external space 34. Note that the split pipe 52 may be positioned on the upper surface of the coating layer 12.

As shown in Figures 2 and 3, the laminated structure 10 may be formed on the ground 31 as an internal structure of the embankment. The laminated structure 10 is located in a space partitioned by two side walls 32.

Figure 4 shows an example of the manufacturing process for a laminated structure. Here, the process for manufacturing the laminated structure 10 using the R-PUR method is illustrated. The workers in each of the following steps may be the same or different.

First, the worker demarcates the filling layer formation space 60 in which the filling layer 11 will be formed (step S1). For example, as shown in Figure 5, the worker defines the filling layer formation space 60, which is demarcated by the side walls 32 and the slope 33, by forming side walls 32 on the ground 31.

Next, the worker forms a flow passage 20 so as to penetrate the packed layer formation space 60 (step S2). The flow passage 20 is, for example, a pipe. The first end 21 of the flow passage 20 is positioned at a height level 61 corresponding to the upper surface of the coating layer 12. The second end 22 of the flow passage 20 is positioned within the external space 34.

The worker forms a filling layer 11 within the filling layer forming space 60 by filling it with a filler (step S3). Specifically, the worker pours urethane into the filling layer forming space 60. The filled urethane foams and hardens within the filling layer forming space 60. The worker forms the filling layer 11 by appropriately adjusting the height of the upper surface of the hardened urethane. The worker may take measures to prevent urethane from flowing into the flow passage 20 before filling the urethane. For example, the first end 21 of the flow passage 20 may be closed with a lid.

The worker forms a coating layer 12 on the filling layer 11 (step S4). For example, the worker pours concrete onto the filling layer 11 up to a height level 61. The poured concrete hardens on the filling layer 11 to form the coating layer 12.

The worker forms the surface layer 13 on the covering layer 12 (step S5). For example, the worker forms the subgrade 14 by placing crushed stone on the covering layer 12. Next, the worker forms the base course 15 by placing crushed stone on the subgrade 14. Subsequently, the worker forms the pavement 16 by placing asphalt on the base course 15.

In the process shown in Figure 4, the filling layer 11 is formed after the flow channel 20 is formed. Conversely, the flow channel 20 may be formed after the filling layer 11 is formed. For example, the worker pours urethane into the filling layer formation space 60 to form the filling layer 11 within the filling layer formation space 60. Next, the worker forms the flow channel 20 by creating holes in the filling layer 11.

Although one embodiment of the present disclosure has been described above, the present disclosure is not limited to the above embodiment, and various modifications are possible without departing from the spirit of the invention. In particular, the multiple embodiments and modifications described herein can be arbitrarily combined as needed.

10 Laminated structure 11 Filling layer 12 Covering layer 13 Surface layer 14 Subgrade 15 Base course 16 Pavement 20, 40, 50 Flow channel 21 First end 22 Second end 23 Intermediate section 31 Ground 32 Side wall 33 Slope 34 External space 60 Filling layer formation space

Claims (2)

A method for manufacturing a laminated structure comprising a non-permeable packing layer and a coating layer laminated on the packing layer,
A flow channel formation procedure comprising forming a pipe for flowing the liquid on the coating layer or the liquid that has passed through the coating layer so as to penetrate the packed layer forming space where the packed layer is formed,
A filling layer forming procedure includes foaming and curing urethane within the filling layer forming space to form the filling layer such that the pipe is covered with the urethane ,
Manufacturing method for laminated structures (excluding those in which hollow blocks are placed on a foundation in the ground). A non-permeable filling layer,
A coating layer laminated on the aforementioned filling layer,
Equipped with,
The aforementioned packed layer is
A pipe that penetrates the filling layer and allows the liquid on the coating layer or the liquid that has passed through the coating layer to flow through,
The pipe includes,
Laminated structures (excluding those in which hollow blocks are placed on a foundation in the ground).