JPS5849180B2 - Method for producing concrete members for railway tracks with elastic coating and apparatus for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method and apparatus for manufacturing a concrete member for railway tracks having an elastic coating intended for vibration isolation of railway tracks.

Recent trajectory. In particular, for high-speed railways, slab tracks using precast concrete IJ are used instead of conventional ballast bed tracks for the purpose of improving vehicle running stability, making maintenance free, and short-term construction. It's moving.

For this slab track, a rubber mat is glued to the underside of the slab, and then cement asphalt is injected between the rubber mat and the concrete roadbed to cut vibrations transmitted from the vehicle to the rail fastening device and then to the slab. , methods were used to reduce the vibration and noise levels of structures such as concrete roadbeds, elevated bridge slabs, and elevated columns.

However, when the above-mentioned rubber mat and cement asphalt are injected and filled into the gap between the integrated molded product of the slab and rubber mat and the roadbed, it takes a long time to apply the adhesive, and due to uneven application of the adhesive, the rubber mat and the slab It has drawbacks such as poor adhesion phenomenon during the process.

Conventionally, mixtures of pulverized rubber such as used tires and urethane resin compositions have poor fluidity and can be applied to the surface of concrete after pouring with uniform dimensional accuracy, mechanical properties, and anti-vibration properties. Because it is difficult to bond, laminate, and harden, it is not possible to obtain an elastic layer with a uniform spring constant, stable tensile strength, tear strength, fatigue properties, compression set, etc., which are basic vibration damping properties. Ta.

On the other hand, trackbeds made of conventional ballast are subject to increased deterioration due to the finer particles of the ballast, which in turn induces an increase in shock and vibration caused by trains, creating a vicious cycle.
Orbit maintenance cycles have become significantly shorter.

As a countermeasure to this problem, if elastic buffering material is layered and laid around the circumferential surface of concrete sleepers, the vibration damping effect of the material will reduce trackbed vibration acceleration and significantly reduce the vibration and noise of high-speed railways.

Conventionally, the method of laminating elastic cushioning materials has been to bond and integrate elastic materials, such as Commat, to the bottom and sides of concrete sleepers with adhesive.
The method using a rubber mat has fundamental drawbacks such as poor adhesion due to uneven application of adhesive and peeling phenomenon due to insufficient adhesive strength.

For this reason, there are problems such as the rubber mat peeling off from the concrete sleeper surface over time after being laid, and foreign matter getting mixed in between them, reducing the vibration-proofing and sound-absorbing effect.

In order to eliminate this drawback, the surrounding surface of the concrete sleeper is treated with epoxy resin, and then the concrete sleeper is inserted into the formwork in advance, and urethane resin resin is applied to the gap between the formwork and concrete sleeper, as well as the top surface of the formwork. One possible method is to fill and laminate a mixture of vulcanized rubber products such as rubber and old tires on the circumferential surface of the concrete sleepers by hand packing, injection, etc., but the fluidity of the mixture is poor, and it is difficult to layer the concrete with an even thickness. It was not easy to do so, and it was extremely difficult to produce dogs in large quantities.

The first object of the present invention is to apply a urethane resin composition to the surface of a concrete slab after pouring and apply a vulcanized pulverized rubber material such as an old tire (hereinafter referred to as pulverized rubber material).

) The mixture is layered and hardened on the concrete slab by rolling the surface layer to an even thickness using a rolling machine equipped with at least one hot rolling roller for forming. A vibration-proof track that does not allow the mixture to adhere to the compaction roll during compression, has extremely high surface smoothness and dimensional accuracy, has a uniform spring constant, stable tensile strength, tear strength, working characteristics, compression set, etc. A method for manufacturing a slab is provided.

Next, embodiments of the present invention will be described based on the drawings.

As shown in FIG. 1, the anti-vibration track slab 3 according to the present invention includes a urethane resin composition 17 and a crushed rubber material 6 on the surface of a concrete slab 1 cast in a predetermined shape using an appropriate formwork 14. Mixture 18 (hereinafter abbreviated as urethane mortar).

) is dispersed to laminate the elastic layer 2 to form an elastic layer laminated concrete IJ- (1+2), which is then heated and hardened to obtain a vibration-proof track slab 3.

In this case, as a means for firmly joining the concrete slab 1 and the elastic layer 2, the surface of the poured concrete slab 1 is treated with an epoxy resin 9, as shown in the figure.

The process of manufacturing the above-mentioned vibration-proof track slab 3 is shown in the second section.
As shown in the figure.

That is, urethane prepolymer 4 and curing agent 5 are placed in a stirring tank 10 and mixed to form a urethane resin composition 17.
After producing urethane mortar 18, the urethane resin composition 17 and the rubber pulverized material 6 are mixed in a stirring tank 11 and transferred to a hopper 12 with a rotary feeder.
supply to.

In this case, the blending ratio of the urethane resin composition 17 and the crushed rubber material 6 varies depending on the performance of the main urethane resin composition 17, but usually the rubber pulverized material 6 is added to 100 parts by weight of the urethane resin composition 17. It is used in a range of 5 to 300 parts by weight.

On the other hand, the concrete slab 1 is made by putting cement 7 and aggregate 8 into a concrete mixer 13, mixing them to produce ready-mixed concrete, and then supplying the same ready-mixed concrete to the formwork 14, using a pie breaker etc. , smooth the surface.

Then, epoxy resin 9 is applied to the concrete board 1 using a brush, spray, roller brush, or the like.

The coating amount is used in the range of 50 to 500 g per 1 m7.

Next, apply the urethane mortar 18 to the concrete slab 1.
Quantitatively and continuously spraying a predetermined amount.

Next, using a compaction machine equipped with at least one hot compaction roller for forming, the elastic layer 2 is compacted to an even thickness on the concrete slab 1, and after being laminated, it is heated and hardened to provide vibration isolation. A track slab 3 is manufactured.

The compaction machine has at least one compaction roller, and in order to prevent the spread urethane mortar 18 from adhering to the compaction roll, the inside of the compaction roll is heated with oil, heating wire, steam, etc. The surface temperature of the roller is approximately 40℃.
Maintained above.

Urethane mortar 18 when the roller surface temperature is below 40℃
adheres to the roller, the rolling effect is not exhibited, and the surface of the urethane mortar 18 lacks smoothness, making it difficult to obtain an elastic layer 2 of uniform thickness.

Further, if the surface temperature of the roller is 160° C. or higher, hardening and development of the urethane resin composition 11 is promoted at the contact surface between the urethane mortar 18 and the roll, which shortens the rolling time and impedes workability.

Therefore, the roller surface temperature is preferably 70 to 120°C.

As described above, the elastic laminated concrete IJ-H+2 in which the elastic layer 2 is laminated on the concrete slab 1 is heated and cured together with the formwork using steam or the like to obtain a vibration-proof track slab 3.

In addition to vulcanized materials such as old tires, the crushed rubber used in the present invention includes ordinary rubber products, i.e., rubber materials,
It also includes those composed of fillers, vulcanizing agents, and other compounding agents.

Among these, natural rubber and synthetic rubber are used as the rubber material.

According to the present invention, as described above, a laminate in which the urethane mortar 18, which is a mixture of a pulverized product of vulcanized rubber such as an old tire, and a urethane resin composition, and the concrete slab 1 are integrally formed is uniformly formed at once. Therefore, vibration-proof track slabs can be obtained at low cost.

Example l Concrete (mixture: 418 parts by weight of early strength cement, 582 parts by weight of river sand, 820 parts by weight of pea gravel, 180 parts by weight of water)
After pouring into the formwork, epoxy resin was sprayed onto the surface of the concrete at a rate of 300 g per 1 m.

Next, the urethane resin composition was mixed with crushed old tires (particle size approx.
．． Urethane mortar mixed with the same amount of 5%) by weight was spread on the concrete slab treated with the epoxy resin.

The molding compaction machine is equipped with two heated rollers, and has a structure in which oil heated by a heater is circulated through the rollers to heat the roller surface.

The roller surface temperature of the urethane mortar after the above spraying is 90.
After compaction, the material was heated and cured at ℃.

During the rolling operation using the rolling press, no adhesion of urethane mortar to the roller surface was observed, and the rolling effect with good surface smoothness was exhibited.

Further, the urethane mortar layer after heating and hardening was peeled off from the concrete part and partially cut, and the thickness of the urethane mortar layer was measured using a caliper.

An elastic layer with extremely uniform thickness and dimensional accuracy was obtained with an accuracy of plus 1% minus t% for the target thickness of 25%.

Reference Example 1 After pouring concrete IJ-contact having the same composition as in the example into a formwork, the same epoxy resin treatment as in the example was carried out, and the same urethane mortar as in the example was further spread on the concrete slab.

The urethane mortar after the above scattering was rolled using the same rolling machine as in the example at a roller surface temperature of 35°C.

Urethane mortar adhered to the roller surface, and the urethane mortar surface was partially gouged out.

When rolling was further continued, the rolling part of the roller adhered to the roller, the urethane mortar layer rolled up at the rear of the roller, and the rolling effect was not achieved.

Reference Example 2 After pouring concrete of the same composition as in the example into a formwork, the same epoxy resin treatment as in the example was performed, and the same urethane mortar as in the example was further spread on the concrete slab.

Using the same rolling press as in the example, the roller surface temperature was set to 180°C.
As a result, the urethane mortar after being spread was compacted.

The urethane mortar is hardened and developed at the roller contact area, and once rolled, the fluidity of the urethane mortar surface is inhibited, making it difficult to roll the mortar a second and third time to make it evenly thick.

No adhesion phenomenon was observed on the roller surface during urethane mortar rolling.

After heating and curing, the urethane mortar layer was peeled off from the concrete part and partially cut, and the thickness of the urethane mortar layer was measured using calipers.

The dimensional accuracy was plus 5% and minus 2% with respect to the target thickness of 25%.

A second object of the present invention is to treat the surface of a hardened concrete sleeper inserted and fixed in a formwork, that is, the surface filled with a mixture of urethane resin composite and crushed rubber, with an epoxy resin, and then to apply the mixture to the formwork. After spreading the mixture in a predetermined amount onto the concrete sleepers and pressing it, the mixture is filled and laminated into the gaps between the concrete sleepers and the formwork as well as the top surface of the formwork, and is heated and hardened to form a uniform surface with extremely high surface smoothness and dimensional accuracy. The present invention provides a method for manufacturing an elastic covered concrete sleeper having properties such as spring constant.

The third purpose is to create a device that achieves the second purpose, which can be easily automated, contributes to labor savings, significantly improves work efficiency, and facilitates mass production of the elastic covered concrete sleepers. We are trying to provide manufacturing equipment.

Next, embodiments of the present invention will be described based on the drawings.

As shown in FIG. 3, the elastically coated concrete sleeper 21 according to the present invention is a Funk IJ-to sleeper 19 that has been hardened into a predetermined shape, and the bottom and side surfaces thereof are treated with epoxy resin in advance and then inserted into an appropriate formwork. Fix it.

Next, urethane mortar is spread on the upper surface of the formwork, and then the elastic coating 20 is laminated by pressing with a press or the like to form concrete sleepers 19+20 having an elastic coating that has not hardened yet, and is then heated and hardened to form an elastic coating. Obtain concrete sleeper 21.

The process for manufacturing the elastic covered concrete sleeper 21 is shown in FIG. 4.

That is, the urethane prepolymer 22 and the curing agent 23 are placed in a stirring tank 28 and mixed to form the urethane resin composition 3.
After producing urethane mortar 39, the urethane resin composition 38 and the rubber pulverized material 24 are mixed in a stirring tank 29, and the produced urethane mortar 39 is transferred to a hopper 3 with a rotary feeder.
Supply to 0.

On the other hand, the concrete sleeper 19 is made by putting cement 25 and aggregate 26 into a concrete mixer 31, mixing them to form fresh concrete, and then supplying the same concrete to formwork 32 and using a pie breaker or the like together. and smooth the surface.

The concrete sleepers 19 are then cured by heating and then removed from the mold to produce concrete sleepers 19.

Then, the epoxy resin 21 is applied to the bottom and side surfaces of the concrete sleepers 19 with a brush or spray.

Next, the concrete sleepers 19 coated with epoxy resin 27 are inserted and fixed into the formwork 35, and then the hopper 30 with a rotary feeder is supplied with the urethane mortar 39.
By rotating the rotary feeder, a predetermined amount of urethane mortar 39 is spread onto the upper surface of the formwork 35.

Next, the formwork 35 sprinkled with the urethane mortar 39 is inserted into the press 36 and pressed with a constant pressure to fill and layer the urethane mortar 39 on the bottom and side surfaces of the concrete sleeper, and then hardens with heat to form an elastic coating. Manufacture concrete 1 and sleepers 21.

Based on Figure 4 above, elastic covered concrete sleepers 2
Although the manufacturing method of No. 1 has been briefly described, more specific details are as follows.

An elastically coated concrete sleeper 21 is manufactured using an elastically coated concrete sleeper manufacturing apparatus as shown in FIG.

That is, the urethane prepolymer 22 and the curing agent 23 are delivered from storage tanks 40 and 41 through valves 40' and 4, respectively.
The urethane prepolymer 22 and the curing agent 23 are mixed with each other by a stirring blade 42 connected to the motor M1, and the urethane resin composition is prepared. Object 38 is generated.

And the urethane resin composition 3 produced in this way
8 is weighed and supplied in a predetermined amount from the stirring tank 28 into the stirring tank 29 on the weighing machine 48 via the delivery valve 44.

Next, a predetermined amount of the crushed rubber material 24 is fed into the stirring tank 29 from the storage tank 45 for crushed rubber material via the rotary feeder 46, and the stirring blade 47 connected to the motor M2 is fed into the stirring tank 29 via the rotary feeder 46.
A urethane mortar 39 is produced by mixing.

In this case, the blending ratio of the urethane resin composition 38 and the crushed rubber material 24 varies depending on the performance of the main urethane resin composition 38, but usually the urethane resin composition is 3 g 100
The rubber pulverized material 24 is used in an amount of 5 to 300 parts by weight.

The urethane mortar 39 is fed from the stirring tank 29 to a hopper 30 with a rotary feeder via a rotary feeder 49 or the like.

Since the urethane mortar 39 is a highly adhesive substance, it tends to adhere to the outer surface of the rotary feeder 52 attached to the hopper 30 and the inner wall surface of the hopper 51 when the temperature is relatively low, making quantitative feeding impossible. Therefore, the hopper 51 and the rotary feeder 52 in the hopper with rotary feeder 30 are equipped with a suction 57a which is piped in advance to the hopper 51 and the rotary feeder 52.
, 58a, delivery parts 57b, 58b are internally heated with oil or steam, etc., and the urethane mortar 39
The contact surface temperature is maintained at about 40°C or higher to prevent urethane mortar from adhering.

To explain in detail the mechanism of the hopper with rotary feeder 30, the outer circumferential portion of the rotary feeder is concave, and the urethane mortar 39 is filled into the outer circumferential concave portion of the rotary feeder as the rotary feeder rotates, and falls onto the formwork below. do.

The cross-sectional shape of the outer circumferential recess of the rotary feeder may be any shape, such as a semicircle, a rectangle, a square, or a trapezoid, as long as it does not hinder the supply of urethane mortar.

Note that it is preferable that the recess is divided into a plurality of parts.

The number of divisions is usually preferably in the range of 4 to 12, and if the mortar is divided into 4 or less, the uretai mortar that has entered the recesses will have an irregular shape, causing problems in uniform distribution.

Furthermore, if the mortar is divided into 12 or more parts, it becomes difficult to supply the urethane mortar due to uneven filling of the recesses and an increase in the adhesive area with the rotary feeder surface.

Note that the height of the recess is preferably within the range of 5 to 100%.

Since the amount of spraying on the formwork depends on the volume of the outer periphery of the rotary feeder, the increase or decrease in the amount of spraying can be adjusted by increasing or decreasing the volume of the outer periphery, arranging multiple hoppers 30 with rotary feeders in parallel, or increasing the number of times of spraying. do.

The rotary feeder is rotated by connecting a sprocket 53 connected to a drive motor 50 with a continuously variable transmission and a sprocket 55 fitted to the shaft end of the rotary feeder 52 with a chain 56.

On the other hand, the concrete IJ-to sleeper 19 is constructed by supplying fresh concrete made by mixing cement 25, water and aggregate 26 such as sand and crushed stone to the formwork 32 using a concrete mixer 31 to form a predetermined shape. A shaped concrete sleeper 19 is formed.

At this time, vibration is applied to the formwork 32 during and after supply of the fresh concrete using a pie breaker or the like to flatten the fresh concrete inside and remove air bubbles from the inside to increase the overall density.

Before supplying the urethane mortar 39 to the formwork 35, in order to strengthen the adhesion between the urethane mortar 39 and the concrete sleepers 19, epoxy resin 2T is applied to the surface of the concrete sleepers 19 with a brush or spray.

The amount of coating used is within the range of 50 to 500 g per 1 m'.

In order to obtain a filling gap of a predetermined thickness between the bottom and side surfaces of the hardened concrete sleeper and the formwork, the rail fastening holes 64 of the hardened concrete sleeper are used in advance before filling and laminating the urethane mortar 39. , is fixed to the formwork 35 with fastening bolts 62.

In other words, the concrete sleepers are inserted into the formwork upside down with the bottom facing up.

Next, the formwork 35 supplied with the urethane mortar 39 is inserted between the upper and lower plates of a pressing machine (for example, a press or a jack) and pressurized.

The urethane mortar 39 is pressurized in the gap between the concrete sleepers 19 and the formwork, and in the upper surface of the formwork, so that it flows, is sufficiently filled and laminated, and is integrated.

Note that when filling the urethane mortar 39, a male die that can be inserted into the top of the formwork is placed on the S without directly contacting the upper plate of the press.
Press.

The travel of the male mold is generally preferably within the range of 1 to 200%, and the clearance is preferably within the range of 0.1 to 20%.

Both cold platen and hot platen presses can be used.

The pressure at the time of compression varies depending on the fluidity of the urethane mortar, the shape of the filled part, etc., but is usually o. By applying a pressure of 5ig.
Even if the amount of 4 is large and the fluidity is extremely reduced, it can be easily filled and laminated by increasing the pressing force.

Production can be increased by using a multi-stage press or by expanding the pressing area of the press.

Note that the shape and thickness of the elastic coating of the present invention, the laminated parts, etc. can be arbitrarily adjusted by changing the shape of the mold.

In addition to vulcanized materials such as used tires, the crushed rubber material used in the present invention includes ordinary rubber products, such as rubber materials, fillers, vulcanizing agents, and other compounding agents.

Among these, natural rubber and synthetic rubber are used as the rubber material.

According to the present invention, as described above, by molding a laminate in which the pulverized product of vulcanized rubber such as an old tire, the urethane mortar 39 which is a urethane resin composition, and the concrete sleeper 19 are integrated at once, It has a uniform spring constant, stable tensile strength, tear strength, fatigue properties, and compression set, and is extremely effective in preventing noise and vibration, making the track maintenance-free, and producing large quantities of inexpensive elastic-coated concrete sleepers. can be obtained on a production scale.

Example 2 PC sleepers (Japanese National Railways Standard JRS 0320 1-6D
-13AR2B) elastic coating surface with epoxy resin (St
ruct-Bondl 2 2 3 L (manufactured by Mitsui Toatsu Chemical Co., Ltd.) at 250 g per unit area (lm), and then fixed to a formwork for forming an elastic coating using the rail fastening holes of the sleeper.

The gap between the formwork for the elastic coating mold and the sleeper was adjusted to 20% on both the longitudinal and widthwise sides, and 20% on the top surface.

Then, a urethane resin composite {urethane resin} urethane prepolymer (an 80:20 mixture of polypropylene glycol with an average molecular weight of 1700 and 2,4- and 2.6-1-lylene diisocyanate 1 isomers was mixed with NCO/OH
100 parts by weight of the homogeneous free incyanate group content 5.2% of the reaction product prepared by a known manufacturing method
'15 parts by weight of 1 methylene bis(2-chloroaniline),
10 parts by weight of calcium carbonate, 30 parts by weight of carbon black, 20 parts by weight of dioctyl phthalate, diluent (manufactured by Tokyo Jushi Kogyo KK, trade name Yurex=ll=170)
100 parts by weight of a mixture of 25 parts by weight of ) was added and mixed by stirring. Rubber-like material obtained by crushing used rubber (shape: chip-like, particle size 0.5-2.0%)
) was added and stirred to form a mixture of 35k! 9 was spread and spread on the molding frame using a spreading device, a male mold was inserted, and then both the upper and lower plates were placed in a suppression device having an area of 1 m x 2 m.

Set the travel of the male type to 30%, the clearance of the male and female types to 2%, and lkg/cr at room temperature? Pressure was applied at t.

After 5 minutes of compaction, the pressure was released, and immediately after steam curing at 50° C. for 8 hours, the mold was removed to produce a specified elastically coated concrete sleeper.

The thickness of the elastic coating of the above-mentioned demolded elastic-covered concrete sleeper is measured at two points at the left and right center of the rail fastening hole, at the center point L in the longitudinal direction, and from the bottom of the elastic-covered concrete sleeper in the longitudinal direction and width from the center point as a base point. Both directions are 100
Measurements were made at a total of 7 points (4 symmetrical points) at the height of %.

The measurement method was to insert a needle with a diameter of i% into the vibration damping material layer, and provide an elastic coating until it hit the concrete surface.

After measuring the elastic coating thickness, the elastic coating was forcibly peeled off from the PC sleeper, a predetermined spring constant test specimen was prepared from the seven measurement points, and the spring constant was measured.

Reference Example 3 After applying 300 g of synthetic rubber adhesive (trade name: Cemedine 575, manufactured by Cemedine KK) per unit area (1 m) to the elastic coating surface of the same PC sleeper as in Example 3, a slab mat of a predetermined shape (anti-vibration mat - JNR standard) was applied. JRSO7117-I
B-13BR4B) was attached and left at 25° C. for 7 days, and the same items as in the example were measured at the same location.

Note that the longitudinal and widthwise side surfaces were omitted because there was no slab mat with the same thickness as in the example.

The spring constants shown in this example and reference examples are JISK63.
Measured by 85 (Test method for anti-vibration rubber) (test body size; length x width x thickness - l00% x 100% x 20~25
%, load; upper limit 400 kg, lower limit IOO).

A fourth object of the present invention is to treat the surface of the hardened concrete sleeper inserted and fixed in the formwork, that is, the layered surface filled with a mixture of urethane resin composition and crushed rubber, with an epoxy resin, and then transfer the mixture to a pressure chamber. Transfer,
The mixture is then pressure-fed into the formwork into which the concrete sleepers are inserted, filling the gap between the concrete sleepers and the formwork with the mixture, and then heating and hardening it to create a spring constant with extremely high surface smoothness and dimensional accuracy. The present invention provides a method for manufacturing an elastic coated concrete IJ sleeper having properties such as stable tensile strength, tear strength, fatigue properties, and compression set.

The fifth purpose is to create a manufacturing device that can easily automate, contribute to labor savings, significantly improve work efficiency, and easily mass-produce the above-mentioned elastic-coated concrete sleepers to achieve the fourth purpose. It is not intended to be provided.

Next, embodiments of the present invention will be described based on the drawings.

In the elastically coated concrete sleeper 61 according to the present invention, as shown in FIG. 6, the bottom and side surfaces of a concrete sleeper 65 that has been hardened into a predetermined shape are treated with epoxy resin in advance and then inserted and fixed into a suitable formwork.

Next, the urethane mortar is preliminarily supplied to the pumping chamber using a transfer device connected to the other end of the pumping device, and then pumped to the concrete sleeper insertion form to laminate the elastic coating layer 66, A concrete sleeper 6 5 + 6 6 having an elastic coating that does not harden is formed and then heated and hardened to obtain an elastic covered concrete sleeper 6T.

The process for manufacturing the elastic covered concrete IJ-1 sleeper 67 is shown in FIG. 1.

That is, the urethane prepolymer 69 and the curing agent 70 are placed in a stirring tank 75 and mixed to produce the urethane resin composition 84, and then the urethane resin composition 84 and the crushed rubber material 71 are placed in the stirring tank 76 and mixed. The urethane mortar 85 thus produced is supplied to the pressure feeding device 17.

On the other hand, the concrete sleeper 65 is made by putting cement 72 and aggregate 73 into a concrete mixer 78, mixing them to produce fresh concrete, and then supplying the same concrete to a formwork 79 and using a pie breaker etc. , smooth the surface.

The concrete sleepers 65 are then cured by heating and then demolded to form concrete sleepers 65.

Then, epoxy resin 74 is applied to the bottom and side surfaces of the concrete sleepers 65 by brushing, spraying, or the like.

Next, concrete sleepers 65 coated with epoxy resin 74 were inserted and fixed into formwork 82, and then urethane mortar 85 was inserted into the concrete sleepers using a piston or feed screw from the pressure feeding device 71 that supplied the urethane mortar 85. Urethane mortar 85 is filled and laminated on the bottom and side surfaces of the concrete sleeper by feeding it into a formwork 82 at a constant pressure, and then heated and hardened to produce an elastically coated concrete sleeper 67.

Based on Figure 7 above, elastic covered concrete sleepers 6
Although the method for producing T has been briefly described, more specific details are as follows.

An elastically coated concrete sleeper 67 is manufactured using an elastically coated concrete sleeper manufacturing apparatus as shown in FIG.

That is, the urethane prepolymer 69 and the curing agent 70 are delivered from storage cylinders 86 and 87, respectively, through valves 86' and 87'.
The urethane prepolymer 69 and the curing agent 70 are mixed by a stirring blade 88 connected to a motor M3, and a urethane resin composition is prepared. Generate 84.

A predetermined amount of the urethane resin composition 84 thus produced is then weighed and supplied from the stirring tank 15 into the stirring tank 76 of the weighing machine 94 via the delivery valve 90 .

Next, a predetermined amount of crushed rubber material 71 is supplied from the storage tank 91 of crushed rubber material into the stirring tank T6 via the rotary feeder 92, and the stirring blade 93 connected to the motor M4 is fed into the stirring tank T6.
and mix to produce urethane mortar 85.

In this case, the blending ratio of the urethane resin composition 84 and the crushed rubber material 11 varies depending on the performance of the urethane resin composition 84 as the main component, but usually 5 to 300 parts of the crushed rubber material 11 is added to 84,100 parts by weight of the urethane resin composition. Use within parts by weight.

The urethane mortar 85 is transferred from below the bottom plate 96 of the stirring tank 76 through a transfer device connected in advance to the other end of the pressure feed device 77, and compressed into a cylinder by a rotary feeder 95 built in a hopper 97 of the transfer device. The liquid is supplied to a pressure feeding chamber 105 of a pressure feeding device T7 in which a piston 106 or a feed screw or the like is fitted into the tube 104.

Since the urethane mortar 85 is a highly adhesive substance, it tends to adhere to the outer surface of the rotary feeder 95 of the transfer device connected to the pressure feeding device 77 and the inner wall surface of the hopper 97 when the temperature is low, making quantitative feeding impossible. .

For this reason, the hopper 97 as well as the rotary feeder 95,
Suctions 101a, 102a and delivery 1 are piped to the hopper 97, rotary feeder 95 in advance.
01b and 102b are internally heated with oil or steam to bring the contact surface temperature of the urethane mortar 85 to 7.
Maintain the temperature within the range of 0 to 120°C to prevent urethane mortar from adhering.

If the above temperature is below 70℃, use urethane mortar 8 on the contact surface.
The amount of 5 adhered increases over time, making it difficult to transfer it to the pressure-feeding chamber.

In addition, when the temperature is 120°C or higher, the urethane resin composition in the urethane mortar 85 hardens over time, and the hardened solid urethane mortar adheres to the contact surface, making it impossible to continuously supply a predetermined amount of the urethane mortar 85 to the pressure feeding chamber. becomes impossible.

To explain the mechanism of the rotary feeder 95 in detail, the outer peripheral part of the rotary feeder is concave, and the urethane mortar 85 is filled into the outer peripheral recess of the rotary feeder as the rotary feeder rotates. Fall to 5.

The cross-sectional shape of the outer circumferential recess of the rotary feeder may be any shape, such as a semicircle, a rectangle, a square, or a trapezoid, as long as it does not hinder the supply of urethane mortar.

Note that it is preferable that the recess is divided into a plurality of parts.

The number of divisions is usually preferably in the range of 4 to 12, and if the mortar is divided into 4 or less, the urethane mortar that has entered the recesses will have an irregular shape, causing problems in uniform distribution.

Furthermore, if the mortar is divided into 12 or more parts, it becomes difficult to supply the urethane mortar due to uneven filling of the recesses and an increase in the adhesive area between the mouth and the tally feeder surface.

Note that the height of the recess is preferably within the range of 5 to 100%.

Since the amount transferred to the pressure feeding device 77 depends on the volume of the outer periphery of the rotary feeder, the increase or decrease in the amount transferred is adjusted by increasing or decreasing the volume of the outer periphery recess, a plurality of rotary feeders 95 arranged in parallel, or the like.

The rotary feeder is rotated by connecting a sprocket 99 connected to a drive motor 98 with a continuously variable transmission and a sprocket 100 fitted to the shaft end of the rotary feeder 95 with a chain 103.

On the other hand, the concrete sleeper 65 is made by supplying fresh concrete made by mixing cement 72, water, and aggregate 73 such as sand and crushed stone to the formwork 79 using a concrete mixer 78 to form a concrete sleeper in a predetermined shape. Gi 6
Mold 5.

At this time, vibration is applied to the formwork 79 during and after the fresh concrete is supplied using a pie breaker or the like to level the fresh concrete inside and remove air bubbles from the inside to increase the overall density.

Before supplying the urethane mortar 85 to the formwork 82, epoxy resin 74 is applied to the surface of the concrete sleeper 65 with a brush or spray in order to strengthen the adhesion between the urethane mortar 85 and the concrete sleeper 65.

The amount to be applied is within the range of 50 to 500 g per coat.

In order to obtain a filling gap of a predetermined thickness between the bottom and side surfaces of the hardened concrete and the formwork, use 80% urethane mortar.
5, before filling and laminating the hardened concrete sleepers, they are fixed to the formwork 82 with fastening bolts 109 using the rail fastening holes 110 of the hardened concrete sleepers.

That is, the Conch IJ-1 sleeper is inserted upside down into the formwork with the bottom surface facing upward.

The urethane mortar 85 supplied to the pressure feeding chamber 105 is pressurized by a piston or a feed screw, and passes through a pipe 107 connected to the other end of the compression cylinder 104 to the formwork 8.
2 is filled.

Urethane mortar 85 is continuously supplied to the pressure feeding chamber 105 from the stirring tank 76 by the rotary feeder or feed screw of the transfer device, so that the mold is continuously filled.

It is therefore possible to produce elastically coated concrete sleepers continuously.

When pressure-feeding the urethane mortar 85 to the formwork 82,
The pressure differs depending on the shape of the fluid filling part of the urethane mortar, but normally the urethane mortar 85 can be fluidly filled into the void with a pressure of 0.5 J/crit or more. Even if the amount of pulverized material T1 becomes large and the fluidity is extremely reduced, it can be easily packed and stacked by increasing the pressing force.

When the urethane mortar 85 is fed from the pressure feeding device 77 to the formwork 82, the side and top surfaces of the formwork 82 are adjusted to have a predetermined thickness of elastic coating layer, and then the formwork upper plate 111 provided with the exhaust holes 108 is covered with the urethane mortar 85. It is sealed leaving the mortar supply hole 107.

The material for the formwork may be metal, wood, plastic, etc., as long as it has enough strength to withstand the pressure of the urethane mortar 85.

Although the formwork 82 usually has a single-layer structure, it is also possible to use a two-layer formwork to increase the formwork rotation rate.

In other words, the outer layer of the formwork is made of metal plates with high structural strength.
By using a metal plate with low structural strength for the inner frame, the outer frame is first removed from the mold after being filled with urethane mortar 85, and only the inner frame is used to maintain the shape, which increases the rotation rate of the outer frame and increases productivity. Become.

Note that the shape and thickness of the elastic coating of the present invention, the laminated parts, etc. can be arbitrarily adjusted by changing the shape of the mold.

In addition to vulcanized materials such as old tires, the crushed rubber products used in the present invention include ordinary rubber products, that is, products composed of rubber, fillers, vulcanizing agents, and other compounding agents. .

Among these, natural rubber and synthetic rubber are used as the rubber material.

According to the present invention, as described above, the laminate in which the urethane mortar 85, which is a mixture of pulverized vulcanized rubber such as old tires and urethane resin composite, and the concrete sleeper 65 are formed at once. By doing so, it has a uniform spring constant, stable tensile strength, tear strength, fatigue properties, and compression set, and is extremely effective in preventing noise and vibration, making the track maintenance-free, and making it possible to create an inexpensive elastic coated concrete IJ. The tom sleepers can be obtained on a mass production scale.

[Brief explanation of the drawing]

Fig. 1 is a perspective view showing an example of a vibration-proof track slab according to the present invention, Fig. 2 is a block diagram showing a manufacturing process of a vibration-proof track slab according to the present invention, and Fig. 3 is an elastic coated concrete according to the present invention. FIG. 4 is a block diagram showing the manufacturing process of elastically coated concrete sleepers according to the present invention; FIG. 5 is a schematic explanatory diagram showing an example of the apparatus for manufacturing elastically coated concrete sleepers; FIG. 6 is a perspective view showing an example of a sleeper. Figure 7 is a perspective view showing an example of an elastically coated concrete sleeper according to the present invention, Figure 7 is a block diagram showing a manufacturing process for the elastically coated concrete sleeper according to the present invention, and Figure 8 is an example of an apparatus for manufacturing elastically coated concrete sleepers. A schematic explanatory diagram showing.

Claims (1)

[Claims] 1. The surface of concrete is treated in advance with an epoxy resin, and then a mixture of a urethane resin composition consisting of a urethane prepolymer and a hardening agent, and a crushed product of vulcanized rubber such as an old tire is applied. A method for manufacturing a concrete member for railway tracks having an elastic coating, which comprises laminating and pressing and then heating and hardening the entire material. 2. In the method for manufacturing a concrete member for railway tracks having an elastic coating as set forth in claim 1, the concrete is placed after being poured, and the lamination is performed by spreading the concrete onto the concrete plate using a spreading machine. A method characterized by manufacturing a vibration-proof track slab by rolling the slab to a predetermined thickness using a rolling machine equipped with at least one hot rolling roller for forming. 3. In the method for manufacturing a concrete member for railway tracks having an elastic coating as set forth in claim 1, the concrete is a concrete sleeper after hardening, and the suppression is
After fixing the concrete sleeper in the formwork using the rail fastening holes, the mixture is spread onto the formwork, and the mixture is spread onto the formwork surface in the gap between the concrete sleeper and the formwork. A method characterized by manufacturing an elastically coated concrete sleeper by filling and laminating. 4. In the method for manufacturing a concrete member for railway tracks having an elastic coating as set forth in claim 1, the concrete is after hardening, and the lamination and pressing of the mixture is performed in the formwork by fastening the concrete sleepers to the rails. After fixing using the holes, the mixture is transferred to a pressure-feeding chamber, and then pumped into the formwork for inserting the concrete sleepers, filling the gap between the concrete sleepers and the formwork with the mixture and layering it to create elastic properties. A method characterized in that it produces coated concrete sleepers. 5. Stirring tank for mixing urethane prepolymer and curing agent;
A stirring tank is used to mix a urethane resin composition consisting of a urethane prepolymer and a curing agent mixed in the same stirring tank, and a crushed product of vulcanized rubber such as an old tire. and a suppressing device that fills and laminates the mixture into the gap between the concrete sleepers and the formwork and the top surface of the formwork. An apparatus for manufacturing elastic covered concrete 'J-1-sleepers, characterized by the following: 6. Stirring tank for mixing urethane prepolymer and curing agent;
A stirring tank that mixes the urethane resin composition mixed in the stirring tank and a crushed product of vulcanized rubber such as an old tire, and a transfer device that continuously transfers a predetermined amount of the mixture mixed in the stirring tank. , a pumping mechanism that uses a pumping device supplied with the mixture transferred by the transfer device to pump a predetermined amount of the mixture into a formwork into which already formed concrete sleepers are inserted and fixed, filling and stacking the mixture. A manufacturing device for elastically coated concrete sleepers.