Technical Field
[0001]
The present invention relates to a filler layer-forming bag
for a slab track and, in particular, a bag and a filler layer
10 formation unit for forming a filler layer in a gap between a
projection formed project ingly on a concrete road bed and a concave
part defined in a track slab. The present invention further
relates to a filler layer formation method for a slab track using
the bag.
15
Background Art
[0002]
Conventionally, slab tracks as railway track are known to
replace ballasted tracks for saving labor. In a slab track,
20 concrete track slabs are fixed to a concrete road bed of, for
example, an elevated structure, an underground structure, or a
bridge constructed of, for example, concrete, with a filler layer
placed therebetween, which is made of cement asphalt mortar (also
referred to as CA mortar, hereinafter), obtained by mixing cement,
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asphalt emulsifier, and fine aggregate, and track rails are
arranged on the track slabs (see Patent Documents 1 and 2, for
example) . In such a slab track, a plurality of track slabs are
disposed in a line in the direction in which the track rails are
5 placed.
[0003]
In a slab track, as illustrated in Fig. 11, a track slab
3 is provided on the upper surface of a concrete road bed 1 with
a filler layer 2 placed therebetween and, further, a pair of track
10 rails 4 are arranged on the upper surface of the track slab 3.
The track slab 3 has concave parts 6 defined at both longitudinal
ends thereof and the concave parts 6 of the track slab 3 are aligned
with projections 7 having a shape of a round column provided on
the concrete road bed 1 at certain intervals. Filler layers 9
15 made of, for example, synthetic resin or CA mortar are formed in
gaps 8 between the concave parts 6 engaged with the projections
7 to protect the projections 7 from loads applied on the track
slab 3 longitudinally (in the direction in which the rails are
placed) and laterally (in the direction perpendicular to the
20 direction in which the rails are placed) when a train runs.
[0004]
Further, as a method of forming a filler layer in a gap
between a projection and a concave part, a projection supporting
method is known, by which a bag made of nonwoven fabric with an
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open top is fixedly fitted into the gap and then filled with filler
material supplied from the opening of the bag and the filler
material is allowed to cure (Patent Document 2).
5 Prior Art References
Patent Documents
[0005]
Patent Document 1: Japanese Laid-Open Patent Application
Publication No. 2010-203178.
10 Patent Document 2: Japanese Laid-Open Patent Application
Publication No. H7-158001.
Patent Document 3: Japanese Laid-Open Patent Application
Publication No. 2016-223239.
Patent Document 4: Japanese Laid-Open Patent Application
15 Publication No. 2015-045185.
Summary of the Invention
Problems to be Solved by the Invention
[0006]
20 According to the conventional method recited in Patent
Document 2, when fitting the bag into the gap, the worker needs
to manually shape the bag and attach the bag to the outer
circumferential surface of the projection and the inner
circumferential surface of the concave part, using adhesive, to
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prevent any opening in the boundaries between the bag and the outer
circumferential surface of the projection and between the bag and
the inner circumferential surface of the concave part. If the
bag is filled with filler material and the filler material is
5 allowed to cure while an opening exists, the filler layer is not
formed properly and may result in a decrease in strength. Further,
the manual operation requires a substantial time and skill, which
is problematic.
[0007]
10 Further, a presence of an object alien to the filler material
or of a material different from the nonwoven fabric and obstructing
attachment at the time of filling the bag with the filler material
may lead to a breakage around the edges of the filler layer or
a decrease in strength.
15 [0008]
Patent Documents 3 and 4 disclose a structure of a bag that
includes a core to enable the bag to stand to allow efficient
insertion and setting of the bag in the gap defined by the outer
circumferential surface of the projection and the inner
20 circumferential surface of the concave part of the track slab.
The core is sewn on the bag in such a way as to extend through
the filler layer and, when made of a material different from the
filler material, the core may cause a breakage around the edges,
which leads to a marked deterioration of the durability of the
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filler layer. Further, even when the core is molded using the
same kind of material as the filler layer, the mold release agent
required for releasing the core from the mold after molding remains
on the core surface and may lead to a breakage around the edges.
5 In either case, providing a core in the filler material compromises
homogeneity of the filler layer and may markedly impair the
essential function of the filler layer, which is to
semi-permanently protect the projection formed on the concrete
road bed.
10 [0009]
An object of the present invention is to provide a filler
layer-forming bag and a filler layer formation unit that enable
improvement in workability in forming a filler layer in a gap
between a projection of a concrete road bed and a concave part
15 of a track slab in execution of slab track works and enable
formation of a filler layer excellent in durability and to provide
a filler layer formation method using the filler layer-forming
bag.
20 Means for Solving the Problems
[0010]
A filler layer-forming bag according to the present
invention is
a filler layer-forming bag to be used, for a slab track that
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includes a concrete road bed, a track slab, a filler layer placed
between the concrete road bed and the track slab, and a track rail
arranged on the track slab, in order to form a filler layer in
a gap between a concave part that is semicircular in plan view
5 and defined at either end of the track slab in a direction in which
the rail is placed and a projection having a shape of a round column
or a semicircular column, formed projectingly on the concrete road
bed, the bag including:
a bag body formed approximately in an identical form to a
10 space forming the gap; and
extensible adjustment belts disposed on both
circumferential ends of the bag body,
wherein a sum of a circumferential length of an inner
circumferential surface of the bag body and lengths of the
15 extensible adjustment belts when not yet stretched is smaller than
a circumferential length of an outer circumferential surface of
the projection that comes into contact with the bag body and the
extensible adjustment belts.
[0011]
20 This eliminates the troublesome manual work when inserting
the bag body into the gap and, since the bag body is guite firmly
attached to the outer circumferential surface of the projection
by the shrinking force of the extensible adjustment belts, the
bag body is easily allowed to stand in the gap without using a
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core. This improves workability in disposing the filler
layer-forming bag in the gap. Further, since the bag body is
allowed to stand without using a core made of an alien material
to the filler material, homogeneity of the filler material is
5 maintained and a filler layer excellent in durability can be
formed.
[0012]
Further, in a filler layer-forming bag according to the
present invention, the extensible adjustment belts connect
10 circumferential ends of two or more of the bag bodies in a ring.
This allows the bag bodies to be firmly attached around the
projection by the shrinking force of the extensible adjustment
belts.
[0013]
15 In a filler layer-forming bag according to the present
invention, the extensible adjustment belts connect both
circumferential ends of the bag body in a ring.
That is, the bag body is firmly attached around the
projection by the shrinking force of the extensible adjustment
20 belts even at a start point or an end point of a slab track.
[0014]
Further, in a filler layer-forming bag according to the
present invention, the bag body includes a filler material port
through which to fill the bag body with filler material.
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A filler material port thus provided for the bag body
facilitates the filling of the bag body with filler material since
a supply hose connected to a filler material supply machine can
be connected to the filler material port.
5 [0015]
Further, in a filler layer-forming bag according to the
present invention, the bag body includes at least one filler
material port at a circumferential end of the bag body.
A filler material port thus provided at a circumferential
10 end of the bag body facilitates the filling of the bag body with
filler material, which is preferable.
[0016]
In a filler layer-forming bag according to the present
invention, an opening is defined in an upper part of the bag body,
15 the opening serving as the filler material port.
Even when no filler material port is provided, an opening
thus defined allows the bag body to be filled with filler material.
[0017]
A filler layer-forming bag according to the present
20 invention includes a foamed member or an air tube disposed at a
bottom of the filler layer-forming bag.
This reduces the amount of the filler material used.
[0018]
In a filler layer-forming bag according to the present
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invention, the extensible adjustment belts are disposed near both
vertical ends of the bag body.
This prevents the shrinking force from applying only on the
vertically central part of the bag body and allows the bag body
5 to be firmly attached around the projection in a balanced manner.
[0019]
In a filler layer-forming bag according to the present
invention, at least one of the extensible adjustment belts,
disposed near a bottom end of the bag body, is disposed at a height
10 at which the foamed member is positioned.
That is, when a foamed member is disposed, it is preferable
to dispose the extensible adjustment belt at a height at which
the foamed member is positioned since the foamed member is
positioned at the lower end of the bag body.
15 [0020]
In a filler layer-forming bag according to the present
invention, the bag body is formed of nonwoven fabric.
A bag body thus formed of nonwoven fabric allows the filler
material filling the bag body to ooze out and cure, causing the
20 inner circumferential surface of the bag body adhere to the outer
circumferential surface of the projection.
[0021]
In a filler layer-forming bag according to the present
invention, the bag body has a semi-cylindrical form.
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By connecting such tv/o semi-cylindrical bag bodies by
extensible adjustment belts, the bag bodies are firmly attached
around the projection with an appropriate shrinking force.
Further, even at a start point or an end point of a slab track,
5 where the projection is semi-cylindrical, the bag body can be
firmly attached around the projection by the extensible adjustment
belts.
[0022]
In a filler layer-forming bag according to the present
10 invention, the extensible adjustment belts are formed of rubber
or synthetic resin.
That is, the extensible adjustment belts are preferably
formed of rubber or synthetic resin because the extensible
adjustment belts need to display an appropriate extensibility.
15 [0023]
A filler layer formation unit according to the present
invention includes a filler material supply machine that supplies
filler material to the filler layer-forming bag according to the
present invention.
20 That is, the filler material is supplied to the filler
layer-forming bag preferably by using such a filler material
supply machine.
[0024]
In a filler layer formation unit according to the present
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invention, the filler material supply machine includes
supply means for measuring and supplying a base ingredient
and a hardener that constitute the filler material, and
mixing means for mixing the base ingredient and the hardener
5 supplied by the supply means.
The filler material is thus produced preferably by measuring
and mixing a base ingredient and a hardener.
[0025]
A filler layer formation method according to the present
10 invention is
a filler layer formation method, for a slab track that
includes a concrete road bed, a track slab, a filler layer placed
between the concrete road bed and the track slab, and a track rail
arranged on the track slab, of forming a filler layer in a gap
15 between a concave part that is semicircular in plan view and
defined at either end of the track slab in a direction in which
the rail is placed and a projection having a shape of a round column
or a semicircular column, formed projectingly on the concrete road
bed, the method including:
20 a disposing step of disposing the filler layer-forming bag
according to the present invention in the gap;
a filling step of filling the bag body with filler material
through a filler material port; and
a curing step of curing the filler material and forming the
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filler layer.
[0026]
This method improves workability in disposing the filler
layer-forming bag in the gap since the bag body is easily allowed
5 to stand in the gap without using a core.
[0027]
A filler layer formation method according to the present
invention
further comprises before the disposing step
10 a tube setting step of setting an air tube at a bottom
of the gap and
a space forming step of forming a space by inflating
the air tube by filling the air tube with a fluid, and
comprises after the curing step
15 a removing step of removing the air tube.
This method allows a filler layer to be formed around the
projection while reducing the amount of the filler material used,
without using a foamed body.
[0028]
20 In a filler layer formation method according to the present
invention, the filling step further includes measuring and mixing
a base ingredient and a hardener.
That is, the filler material is produced preferably by
measuring and mixing a base ingredient and a hardener.
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Advantageous Effects of the Invention
[0029]
According to the present invention there are provided a
5 filler layer-forming bag ; a filler layer formation unit that
enable improvement in workability in forming a filler layer in
a gap between a projection of a concrete road bed and a concave
part of a track slab in execution of slab track works and enable
formation of a filler layer excellent in durability ; and a filler
10 layer formation method using the filler layer-forming bag.
Brief Description of the Drawings
[0030]
Fig. 1 is a perspective view, partially in cross section,
15 of a structure of a slab track with a filler layer-forming bag
according to an embodiment.
Fig. 2 is a perspective view from above of a filler
layer-forming bag according to the embodiment.
Fig. 3 is a perspective view illustrating a situation when
20 a filler layer-forming bag according to the embodiment is to be
disposed in a gap.
Fig. 4 is a diagram schematically illustrating a filler
material supply machine according to the embodiment.
Fig. 5 is a perspective view from above of a filler
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layer-forming bag according to another embodiment.
Fig. 6 is a perspective view from above of a filler
layer-forming bag according to another embodiment.
Fig. 7 is a perspective view illustrating a situation when
5 a filler layer-forming bag according to another embodiment is to
be disposed in a gap.
Fig. 8 is a perspective view illustrating a situation when
a filler layer-forming bag according to another embodiment is
disposed in a gap.
10 Fig. 9 is a perspective view illustrating a situation when
a filler layer-forming bag according to another embodiment is
disposed in a gap.
Fig. 10 is a diagram schematically illustrating another
filler material supply machine according to the embodiment.
15 Fig. 11 is a perspective view, partially in cross section,
of a structure of a slab track.
Mode for Carrying Out the Invention
[0031]
20 An embodiment of the present invention will be described
below with reference to the drawings. First, with reference to
Fig. 1, an overview will be given of a slab track for which a filler
layer-forming bag according to the present invention is used. The
basic structure of the slab track is similar to the one described
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in the background art section (see Fig. 11). Therefore, like
members are denoted by like reference signs in the description
below.
[0032]
5 A slab track 5 includes a track slab 3 fixed to a concrete
road bed 1 with a filler layer 2 made in CA mortar provided
therebetween and a pair of track rails 4 arranged on the track
slab 3 by using fasteners (not illustrated).
[0033]
10 The track slab 3 is, for example, a precast concrete slab
having a length of about 5,000 mm, a width of 2,000 to 2,300 mm
and a thickness of about 200 mm. The thickness (height) of the
filler layer 2 is about 40 to 60 mm. The slab track 5 has a
plurality of track slabs 3 disposed in a line in the direction
15 in which the track rails 4 are placed (rail placement direction).
[0034]
The track slab 3 has concave parts 6 defined at both ends
thereof in the rail placement direction and is aligned with the
projections 7 having a shape of a round column provided on the
20 concrete road bed 1 at certain intervals. The inner diameter of
each concave part 6 is greater than the outer diameter of each
projection 7 and the track slab 3 is aligned in such a way that
an approximately cylindrical gap 8 exists between each projection
7 and the corresponding concave parts 6.
SF-3391
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[0035]
For example, the inner diameter of each concave part 6 is
about 600 mm and the outer diameter of each projection 7 is about
500 mm. In this case, each projection 7 and the corresponding
5 concave parts 6 are concentrically engaged with each other, an
approximately cylindrical gap 8 of 4 0 to 60 mm existing
therebetween (see Fig. 3).
[0036]
A filler layer 9 made of, for example, synthetic resin or
10 CA mortar is formed in the gap 8 in such a way as to leave a space
on the concrete road bed 1 (at the bottom) that serves as a drainage
channel (not illustrated) for, for example, rain water.
[0037]
An embodiment of a filler layer-forming bag 10 according
15 to the present invention will be described next with reference
to the drawings. As illustrated in Fig. 2, a filler layer-forming
bag 10 according to an embodiment includes a bag body 20, an
extensible adjustment belt 23, and a port member 24. Fig. 2
illustrates an example in which two bag bodies 20 are connected
20 by extensible adjustment belts 23 in a ring.
[0038]
Each bag body 20 is herein made of nonwoven fabric sewn in
an approximately identical form to the spatial form of the gap
8 and includes two enclosed spaces vertically arranged inside.
SF-3391
17
That is, a filler material-enclosing compartment 20X, which is
filled with a filler material to be described later, is formed
in the upper part of the bag body 20 and a member-enclosing
compartment 20Y, in which a foamed member (not illustrated) such
5 as sponge or expanded polystyrene is disposed, is formed in the
lower part of the bag body 20. The sides at the circumferential
ends of the member-enclosing compartment 20Y are open and an
elongated foamed member that fits the spatial form of the
member-enclosing compartment 20Y can be inserted from these
10 openings. Herein, the foamed member has a bar form of about 20
to 60 mm square in cross section. The filler material-enclosing
compartment 2OX is formed in such a way as to have a height greater
than that of the member-enclosing compartment 20Y and three to
six times as great as that of the member-enclosing compartment
15 20Y. Note that disposing a foamed member in the lower part of
the bag body 20 reduces the amount of the filler material used.
[0039]
The filler material may be any material that cures after
the filling but preferably be a material containing synthetic
20 resin in view of filling property and curing property. Examples
of filler materials containing synthetic resin include a
polyurethane resin-based filler material of a two-liquid curing
type of which the base ingredient is polyol and the hardener is
polyisocyanate, an epoxy resin-based filler material of a
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two-liquid curing type of which the base ingredient is epoxy resin
and the hardener is amine or polyamine, a vinyl ester resin-based
filler material of a two-liquid curing type of which the base
ingredient is vinyl ester resin and the hardener is a peroxide
5 or a radical generator, a polyester acrylate resin-based filler
material of a two-liquid curing type of which the base ingredient
is polyester acrylate resin and the hardener is a peroxide or a
radical generator, and a silicone resin-based filler material of
moisture curing type. A filler material of a two-liquid curing
10 type is preferable among others and a polyurethane resin-based
filler material of a two-liquid curing type is more preferable
in terms of curing property and workability in execution.
[0040]
Further, the filler material preferably contains extender
15 pigment (for example, silica or calcium carbonate) or aggregate
(for example, silica sand) in terms of mechanical strength,
durability, and cost of the filler layer. For example, the filler
material may contain 10 to 60% by weight of extender pigment (for
example, silica or calcium carbonate) or 20 to 80% by weight of
20 aggregate (for example, silica sand). When a filler material of
a two-liquid curing type is used, the extender pigment and the
aggregate may be contained in either the base ingredient or the
hardener, but preferably in the base ingredient because a filler
layer having homogeneous physical properties can thus be easily
SF-3391
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obtained.
[0041]
A bag body 20 is a semi-cylindrical bag that includes six
surfaces including a top surface 20A and a bottom surface 20B,
5 which are semi-cylindrical, an inner circumferential surface 20E
and an outer circumferential surface 20F, which are curved, and
two end surfaces 20Cf which are rectangular and formed at the
circumferential ends of the bag body 20.
[0042]
10 Both the inner circumferential surface 20E and the outer
circumferential surface 20F of the bag body are in the form of
circumferential surface of a semicylinder and, when the filler
layer-forming bag 10 is disposed in the gap 8, the inner
circumferential surface 20E comes into contact with the outer
15 circumferential surface of the projection 7 and the outer
circumferential surface 20F comes into contact with the inner
circumferential surface of the concave part 6. The inner
circumferential surface 20E and the outer circumferential surface
20F are rectangular when the bag body 20 is expanded. Similarly,
20 the bag body 20 is a flat rectangular parallelepiped when the
filler layer-forming bag 10 is not yet disposed in the gap 8.
[0043]
The bag body 20 is formed by sewing together the edges of
the top surface 20A, the bottom surface 20B, the end surfaces 20C,
SF-3391
20
the inner circumferential surface 20E, and the outer
circumferential surface 20F, each made of nonwoven fabric.
[0044]
The nonwoven fabric used for the bag body 20 may be, for
5 example, one having a mass per unit area of 20 to 500 g/m2 but
not limited to those within this range. The extensible adjustment
belts 23 are made of an extensible material and disposed near both
vertical ends at both circumferential ends of each bag body 20.
More specifically, one or two extensible adjustment belts 23 are
10 provided both at an upper part and a lower part of each end surface
20C on the side of the inner circumferential surface 20E to connect
two bag bodies 20. The extensible adjustment belts 23 have, for
example, a length of 6 cm when not stretched (relaxed) , a length
of 10 cm when stretched, and a width of 3 cm, approximately, and
15 are sewn on the side of the inner circumferential surface 20E at
positions about 1 to 5 cm beneath the top surface 20A and positions
about 1 to 5 cm above the bottom surface 20B. Further, the
extensible adjustment belts 23 at the lower positions are disposed
at a height at which the foamed member is disposed. Note that,
20 when the filler layer-forming bag 10 is not yet disposed in the
gap 8, the distance between an end surface 20C of one bag body
20 and an end surface 20C of the other bag body 20 between which
an extensible adjustment belt 23 is disposed is equal to the length
of the extensible adjustment belt 23 when not stretched , that
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21
is, about 6 cm. Further, the sum of the circumferential lengths
of the inner circumferential surfaces of the bag bodies 20 and
the lengths of the extensible adjustment belts 23 when not
stretched is smaller than the circumferential length of the outer
5 circumferential surface of the projection 7 that comes into
contact with the bag bodies 20 and the extensible adjustment belts
23. Therefore, when the filler layer-forming bag 10 is disposed
in the gap 8, the bag bodies 20 are firmly attached to the
circumference of the projection 7 by the shrinking force of the
10 extensible adjustment belts 23.
[0045]
Note that the number, positions, and sizes of the extensible
adjustment belts 23 according to the present invention are not
limited to this and may be altered as appropriate. The extensible
15 material for the extensible adjustment belts 23 may be, for example,
rubber or synthetic resin. Rubber may be, for example, synthetic
rubber or natural rubber and synthetic resin may be, for example,
thermoplastic resin. Concrete examples of synthetic rubbers
include silicone rubber, styrene-butadiene rubber, butyl rubber,
20 ethylene-propylene-diene rubber, fluorocarbon rubber, acrylic
rubber, polyurethane rubber, and vinyl chloride rubber.
[0046]
The port members 2 4 are cylindrical members through which
filler material is supplied to fill the filler material-enclosing
SF-3391
22
compartment 20X and are provided at both ends of the top surface
20A near the end surfaces 20C, with the filler material ports 25
facing above. Note that a port member 24 and a filler material
ports 25 may have disposed only at one end of the top surface 20A.
5 [0047]
The steps of disposing the filler layer-forming bag 10 in
the gap 8 defined between a projection 7 and the corresponding
concave parts 6 of track slabs 3 will be described next. First,
a worker prepares two bag bodies 20, expanded and rectangular,
10 and two square bar-shaped foamed members on the slab track 5 or
near the slab track 5. The end surfaces 20C of the two bag bodies
20 are respectively connected by means of the extensible
adjustment belts 23 to form a ring.
[0048]
15 Next, the foamed members are installed in the bag bodies
20, the foamed members respectively inserted to the
member-enclosing compartments 20Y of the bag bodies 20 (foamed
member installation step). Next, the bag bodies 20 are pulled
away, the inner circumferential surfaces 20E separated from each
20 other to bring the two bag bodies 20 connected by the extensible
adjustment belts 23 into an approximately cylindrical form as
illustrated in Fig. 2 (cylinder forming step).
[0049]
Next, the filler layer-forming bag 10 in this state is
SF-3391
23
aligned over the gap 8 as illustrated in Fig. 3, lowered as it
is, and inserted along the outer circumferential surface of the
projection 7 of the slab track 5 to be disposed in the gap 8
(disposing step) . Note that in this state the bag bodies 20 are
5 quite firmly attached to the outer circumferential surface of the
projection 7 by the shrinking force of the extensible adjustment
belts 23. This allows the bag bodies 20 to stand in the gap 8,
saving troublesome manual works of shaping the bag bodies 20 or
attaching the bag bodies 20 to the projection 7 with adhesive.
10 [0050]
After the filler layer-forming bag 10 is disposed in the
gap 8, filler material is supplied under pressure to the filler
material-enclosing compartment 20X of each bag body 20 through
the port member 24, by connecting a supply hose (not illustrated)
15 connected to a filler material supply machine, which will be
described below, to the filler material port 25 (filling step).
[0051]
Fig. 4 is a diagram schematically illustrating a filler
material supply machine 32 . The filler material supply machine
20 32 has a 2-liquid mixing function of compounding and mixing two
ingredients, Ingredient A and Ingredient B, and includes supply
means that includes a first reservoir 33, a first supply pump 34,
a first tank 36, a first transfer pump 38, a first flowmeter 40,
a second reservoir 43, a second supply pump 44, a second tank 46,
SF-3391
24
a second transfer pump 48, and a second flowmeter 50 and mixing
means including a mixer 52 and an opening/closing means 54.
Further, when the filler material supply machine 32 is to be
cleaned, the supply means and the mixing means can be cleaned by
5 connecting cleaning means (not illustrated). This allows proper
maintenance of the filler material supply machine.
[0052]
According to the present embodiment, Ingredient A is a base
ingredient and Ingredient B is a hardener. For Ingredient A and
10 Ingredient B, either CUS-UB10 Ingredient A (polyurethane
resin-based base ingredient) and CDS-UB Ingredient B {hardener
for polyurethane resin) or CUS-UB2 0 Ingredient A (polyurethane
resin-based base ingredient) and CUS-DB Ingredient B (hardener
for polyurethane resin) (brand names) , sold by the applicant, are
15 preferably used. For the first transfer pump 38 and the second
transfer pump 48, pumps such as diaphragm pumps or smooth flow
pumps, for example, are preferably used. Among smooth flow pumps,
products of TACMINA Corporation are preferably used in particular.
Further, a static mixer is preferably used for the mixer 52 . Among
20 static mixers, products of Noritake Co., Ltd are preferably used
in particular.
[0053]
In the filler material supply machine 32, as illustrated
in Fig. 4, first, Ingredient A stored in the first reservoir 33
SF-3391
25
is supplied to the first tank 36 by the first supply pump 34.
Ingredient A supplied to the first tank 36 is then transferred
in the pipe by the first transfer pump 38. Ingredient A in the
pipe is measured by the first flowmeter 40 to see whether a
5 predetermined compounding ratio (ratio of the weight of Ingredient
A to the total weight of Ingredient A and Ingredient B supplied
to the mixer 52) is achieved.
[0054]
When Ingredient A is supplied in the proper compounding
10 ratio, Ingredient A is supplied unhindered to the mixer 52. When
Ingredient A is not supplied in the proper compounding ratio,
Ingredient A is transferred in a loop of the first tank 36, the
first transfer pump 38, and the first flowmeter 40 and, when the
proper compounding ratio is achieved, Ingredient A is supplied
15 to the mixer 52.
[0055]
Similarly, Ingredient B stored in the second reservoir 43
is first supplied to the second tank 46 by the second supply pump
44, then transferred in the pipe by the second transfer pump 48,
20 and measured by the second flowmeter 50 to check against a
predetermined compounding ratio (ratio of the weight of Ingredient
B to the total weight of Ingredient A and Ingredient B supplied
to the mixer 52).
[0056]
SF-3391
26
When Ingredient B is supplied in the proper compounding
ratio, Ingredient B is supplied unhindered to the mixer 52. When
Ingredient B is not supplied in the proper compounding ratio,
Ingredient B is transferred in a loop of the second tank 46, the
5 second transfer pump 48, and the second flowmeter 50 and, when
the proper compounding ratio is achieved, Ingredient B is supplied
to the mixer 52.
[0057]
After mixing (stirring) Ingredient A and Ingredient B, the
10 mixer 52 operates the opening/closing means 54 to open the fluid
path and discharges the filler material, which is the mixture,
to the port member 24 through a pipe and a supply hose (not
illustrated). The mixing ratio between Ingredient A and
Ingredient B may be adjusted as appropriate in a manner depending
15 on the kind of the filler material used. For example, when a
two-liguid curing type polyurethane resin-based filler material
is used, the mixing ratio of Ingredient A and Ingredient B is such
that the ratio (NCO/OH index) of the number of isocyanate groups
(NCO) contained in Ingredient B (hardener) to the total number
20 of hydroxyl groups (OH) contained in Ingredient A (base
ingredient) is ordinarily in the range of 0.5 to 2.0, preferably,
0.9 to 1.2, more preferably 1.0 to 1.15 for obtaining a filler
layer with stable properties.
[0058]
SF-3391
27
Note that, when the filler material-enclosing compartment
20X of each bag body 20 is filled under pressure, the other filler
material port 25 is fastened before the filler material supplied
under pressure overflows from the other filler material port 25
5 (or in advance) . Note also that in a place called cant, where
the whole concrete road bed 1 is inclined either to the right or
to the left relative to the direction of travel on the slab track
5, the filler material is supplied under pressure from the filler
material port 25 on the lower position while the filler material
10 port 25 on the higher position is sealed by nonwoven fabric
attached with adhesive or by other means.
[0059]
When filler material is further supplied under pressure,
each bag body 20 is expanded by the weight and the pressure of
15 the filler material and is attached even more firmly to the inner
circumferential surface of the corresponding concave part 6 and
the outer circumferential surface of the projection 7 . The filler
material filling the filler material-enclosing compartment 20X
oozes out from the inner circumferential surface 20E and the outer
20 circumferential surface 20F, made of nonwoven fabric, and the bag
body 20 adheres to the inner circumferential surface of the concave
part 6 and the outer circumferential surface of the projection
7. This allows the bag body 20 to adhere fast to the inner
circumferential surface of the concave part 6 and the outer
SF-3391
28
circumferential surface of the projection 7 without adhesive.
When the filler material cures in this state, a filler layer 9
that is homogeneous and excellent in durability is formed in the
gap 8 (curing step).
5 [0060]
The filler layer-forming bag 10 according to the embodiment
saves troublesome manual works for inserting the bag bodies 20
into the gap 8 and allows the bag bodies 20 to stand in the gap
8 easily without using cores (see Patent Documents 3 and 4) since
10 the bag bodies 20 are quite firmly attached to the outer
circumferential surface of the projection 7 by the shrinking force
of the extensible adjustment belts 23. This improves the
workability in disposing the filler layer-forming bag 10 in the
gap 8. Further, since the bag bodies 20 are allowed to stand
15 without using cores, which are members alien to the filler material,
homogeneity of the filler material is maintained and a filler layer
9 excellent in durability is formed.
[0061]
Note that, although an example of a filler layer-forming
20 bag 10 with a port member 24 has been described in the
above-described embodiment, a filler layer-forming bag 110
without a port member 24 as illustrated in Fig. 5 may be used.
In such a case, to supply filler material under pressure, the ends
of the top surface 20A near both end surfaces 20C are opened to
SF-3391
29
be used instead of the filler material ports 25. Further, a part
or all of the top surface 20A may be opened to use the opening
instead of the filler material ports 25.
[0062]
5 Further, in the above-described embodiment, the filler
layer-forming bag 10 may be without a member-enclosing compartment
20Y. In such a case, for example, each bag body 220 of the filler
layer-forming bag 210 includes a filler material-enclosing
compartment 20X alone as illustrated in Fig. 6. An air tube 22Z
10 is disposed beneath the bag body 220 instead of a foamed member.
[0063]
When disposing the filler layer-forming bag 210 in the gap
8, the worker first prepares two bag bodies 220, expanded and
rectangular, and air tubes 22Z on the slab track 5 or near the
15 slab track 5. Next, as illustrated in Fig. 7, the air tubes 22Z
are set at the bottom of the gap 8 (tube setting step), the air
tubes 22Z are connected to the fluid supply machine (not
illustrated) , the air tubes 22Z are filled with a fluid such as
air or liquid and are inflated to form a space beneath the position
20 that the filler layer-forming bag 210 occupies when the filler
layer-forming bag 210 is disposed (space forming step). Next,
the bag bodies 220 are pulled away, the inner circumferential
surfaces 20E separated away from each other (cylinder forming
step) , and the bag bodies 220 are disposed above the space of the
SF-3391
30
gap 8 (disposing step). Next, a supply hose (not illustrated)
connected to the filler material supply machine 32 is connected
to the filler material port 25 to supply filler material under
pressure to the filler material-enclosing compartment 20X of each
5 bag body 220 through the port member 24 (filling step).
[0064]
After the filler material cures to form a filler layer
(curing step) , the air tubes 22Z are then removed (removing step) .
By this method, a filler layer can be formed around the projection
10 7 without using a foamed body while reducing the amount of the
filler material used. Note that the air tubes 22Z need not be
separate from the bag bodies 220 and may be integrated therewith.
In other words, the air tubes 22Z may be disposed on the bottom
surfaces 20B of the bag bodies 220.
15 [0065]
Further, although an example in which two bag bodies 20 are
connected by extensible adjustment belts 23 in a ring is described
in the above-described embodiment (see Fig. 2), the filler
layer-forming bag 10 does not necessarily include two bag bodies
20 20. For example, at the start point or the end point of the slab
track 5, no track slab 3 is disposed on the start side or the end
side of the projection 7, exposing a half of the projection 7.
In such a case, as illustrated in Fig. 8, when the projection 7
on the start point or the end point is in the shape of a round
SF-3391
31
column, the end surfaces 20C are connected by the extensible
adjustment belts 23 in the circumferential direction of the bag
body 20 and the extensible adjustment belts 23 are firmly attached
to the outer circumferential surface of the projection 7 where
5 the gap 8 is not defined. Further, as illustrated in Fig. 9, when
the projection 7 is in the shape of a semicircular column, the
end surfaces 20C are connected by the extensible adjustment belts
23 in the circumferential direction of the bag body 20 also in
this case.
10 [0066]
Further, in the above-described embodiment, when bag bodies
2 0 are connected in a ring, there may be one or more bag bodies
20 and the number of the bag bodies 20 is not necessarily limited
to two. In other words, three or more bag bodies 20 may be
15 connected in a ring. Bag bodies 20 in such a case have a shorter
circumferential length than when they are semi-cylindrical.
[0067]
Further, in the above-described embodiment, specific
numerical values such as sizes indicate examples and the objects
20 are not limited by such numerical values. Further, in the
above-described embodiment, the filler material supply machine
to be used in the filling step is not necessarily limited to the
one illustrated in Fig. 4. For example, a filler material supply
machine 62 as illustrated in Fig. 10 may be used. The filler
SF-3391
32
material supply machine 62 illustrated in Fig. 10 includes a first
reservoir 64, a first pump 66, a second reservoir 68, a second
pump 70, a third reservoir 71, a mixer 72, a load cell 74, and
a third pump 76.
5 [0068]
In this filler material supply machine 62, Ingredient A
stored in the first reservoir 64 is supplied to the third reservoir
71 by the first pump 66 and Ingredient B stored in the second
reservoir 68 is supplied to the third reservoir 71 by the second
10 pump 70. Ingredient A and Ingredient B in the third reservoir
71 are measured by the load cell 74 as appropriate and when the
total weight of Ingredient A and Ingredient B reaches a
predetermined weight, Ingredient A and Ingredient B are mixed by
the mixer 72 to produce the filler material.
15 [0069]
In the filling step, the filler material produced from
Ingredient A and Ingredient B mixed by the mixer 72 is supplied
under pressure by the third pump 76 to the filler
material-enclosing compartment 20X of the bag body 20 through a
20 supply hose (not illustrated) and the port member 24.
Reference Signs List
[0070]
1 concrete road bed
SF-3391
33
2 filler layer
3 track slab
4 track rail
5 slab track
5 6 concave part
7 projection
8 gap
9 filler layer
10 filler layer-forming bag
10 2 0 bag body
20A top surface
20B bottom surface
20C end surface
20E inner circumferential surface
15 20F outer circumferential surface
20X filler material-enclosing compartment
2 0Y member-enclosing compartment
22Z air tube
23 extensible adjustment belt
20 2 4 port member
25 filler material port
32 filler material supply machine
33 first reservoir
34 first supply pump
SF-3391
34
36 first tank
38 first transfer pump
40 first flowmeter
43 second reservoir
5 4 4 second supply pump
46 second tank
48 second transfer pump
50 second flowmeter
52 mixer
10 54 opening/closing means
62 filler material supply machine
64 first reservoir
66 first pump
68 second reservoir
15 7 0 second pump
71 third reservoir
72 mixer
74 load cell
7 6 third pump
20 110 filler layer-forming bag
210 filler layer-forming bag
220 bag body

WHAT IS CLAIMED IS:
1. A filler layer-forming bag to be used, for a slab track
that includes a concrete road bed, a track slab, a filler layer
placed between the concrete road bed and the track slab, and a
5 track rail arranged on the track slab, in order to form a filler
layer in a gap between a concave part that is semicircular in plan
view and defined at either end of the track slab in a direction
in which the rail is placed and a projection having a shape of
a round column or a semicircular column, formed projectingly on
10 the concrete road bed, the bag comprising:
a bag body formed approximately in an identical form to a
space forming the gap; and
extensible adjustment belts disposed on both
circumferential ends of the bag body,
15 wherein a sum of a circumferential length of an inner
circumferential surface of the bag body and lengths of the
extensible adjustment belts when not yet stretched is smaller than
a circumferential length of an outer circumferential surface of
the projection that comes into contact with the bag body and the
20 extensible adjustment belts.
2. The filler layer-forming bag according to claim 1,
wherein the extensible adjustment belts connect circumferential
ends of two or more of the bag bodies in a ring.
SF-3391
36
3. The filler layer-forming bag according to claim 1,
wherein the extensible adjustment belts connect both
circumferential ends of the bag body in a ring.
5
4. The filler layer-forming bag according to any one of
claims 1 to 3, wherein the bag body comprises a filler material
port through which to fill the bag body with filler material.
10 5. The filler layer-forming bag according to claim 4,
wherein the bag body comprises at least one filler material port
at a circumferential end of the bag body.
6. The filler layer-forming bag according to claim 4 or
15 5, wherein an opening is defined in an upper part of the bag body,
the opening serving as the filler material port.
7. The filler layer-forming bag according to any one of
claims 1 to 6, further comprising a foamed member or an air tube
20 disposed at a bottom side of the filler layer-forming bag.
8 . The filler layer-forming bag according to any one of
claims 1 to 7, wherein the extensible adjustment belts are disposed
near both vertical ends of the bag body.
SF-3391
37
9. The filler layer-forming bag according to claim 8,
wherein at least one of the extensible adjustment belts, disposed
near a bottom end of the bag body, is disposed at a height at which
5 a foamed member is positioned.
10. The filler layer-forming bag according to any one of
claims 1 to 9, wherein the bag body is formed of nonwoven fabric.
10 11. The filler layer-forming bag according to any one of
claims 1 to 10, wherein the bag body has a semi-cylindrical form.
12. The filler layer-forming bag according to any one of
claims 1 to 11, wherein the extensible adjustment belts are formed
15 of rubber or synthetic resin.
13. A filler layer formation unit comprising a filler
material supply machine that supplies filler material to the
filler layer-forming bag according to any one of claims 1 to 12.
20
14. The filler layer formation unit according to claim
13, wherein the filler material supply machine comprises
supply means for measuring and supplying a base ingredient
and a hardener that constitute the filler material, and
SF-3391
38
mixing means for mixing the base ingredient and the
hardener supplied by the supply means.
15. A filler layer formation method, for a slab track that
5 includes a concrete road bed, a track slab, a filler layer placed
between the concrete road bed and the track slab, and a track rail
arranged on the track slab, of forming a filler layer in a gap
between a concave part that is semicircular in plan view and
defined at either end of the track slab in a direction in which
10 the rail is placed and a projection having a shape of a round column
or a semicircular column, formed projectingly on the concrete road
bed, the method comprising:
a disposing step of disposing the filler layer-forming bag
according to any one of claims 1 to 12 in the gap;
15 a filling step of filling the bag body with filler material
through a filler material port; and
a curing step of curing the filler material and forming the
filler layer.
20 16. The filler layer formation method according to claim
15,
further comprising before the disposing step
a tube setting step of setting an air tube at a bottom
of the gap and
SF-3391
# 39
a space forming step of forming a space by inflating
the air tube by filling the air tube with a fluid, and
comprising after the curing step
a removing step of removing the air tube.
5
17. The filler layer formation method according to claim
15 or 16, wherein the filling step further comprises measuring
and mixing a base ingredient and a hardener.