Laminated structure and method for manufacturing the same

Abstract

To provide a laminate structure body which is constituted so as to discharge a liquid on a coating layer or a liquid which has passed through the coating layer.SOLUTION: A manufacturing method of a laminate structure body includes a filling layer, and a coating layer laminated on the filling layer. The manufacturing method includes a circulation passage formation procedure for forming a circulation passage for circulating a liquid on the coating layer or a liquid which has passed through the coating layer so as to penetrate a filling layer formation space in which the filling layer is formed. The manufacturing method also includes a filling layer formation procedure for forming the filling layer in the filling layer formation space by filling the filling layer formation space with a filler.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present disclosure relates to a laminated structure and a method for manufacturing the same.

Background Art

[0002] Patent Document 1 discloses a lightweight embankment method including a step of filling a partitioned space on the ground with a filler to form a filling layer. The filler is, for example, rigid urethane foam, foamed polystyrene blocks, and earth and sand.

[0003] [[ID=十六]]Patent Document 2 similarly discloses a lightweight embankment method including a step of filling a partitioned space on the ground with a filler to form a filling layer. The filler is, for example, hollow blocks and rigid foams. Patent Document 2 further discloses forming a concrete layer or a resin sheet on the filling layer and forming a pavement thereon.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] Lightweight embankment can be applied to land leveling for roads, housing sites, factories, commercial facilities, rooftop greening, and other facilities or equipment. The filling layer is covered with a coating layer (for example, a concrete layer, a resin sheet, an earth and sand layer, a gravel layer) suitable for the application example. It is not preferable that liquid (for example, surface water penetrating from the surface and groundwater leaking from the ground) remains on or within the coating layer (on the filling layer) for a long period of time.

[0006] This disclosure provides a laminated structure configured to discharge liquid on or through a coating layer, and a method for manufacturing the same. [Means for solving the problem]

[0007] A manufacturing method according to one aspect of the present disclosure is a method for manufacturing a laminated structure comprising a packed layer and a coating layer laminated on the packed layer. The manufacturing method includes a flow channel forming step of forming a flow channel for a liquid on the laminated layer or a liquid that has passed through the laminated layer so as to penetrate a packed layer forming space in which the packed layer is formed. The manufacturing method further includes a packed layer forming step of forming a packed layer in the packed layer forming space by filling the packed layer forming space with a filler.

[0008] A laminated structure according to another aspect of the present disclosure comprises a packed layer and a coating layer laminated on the packed layer. The packed layer includes a passage through the packed layer for the flow of a liquid on the layered layer or a liquid that has passed through the layered layer. [Effects of the Invention]

[0009] 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. [Brief explanation of the drawing]

[0010] [Figure 1] A cross-sectional view showing a laminated structure according to one embodiment of the present disclosure. [Figure 2] A cross-sectional view showing a laminated structure according to another embodiment of the present disclosure. [Figure 3] A cross-sectional view showing a laminated structure according to yet another embodiment of the present disclosure. [Figure 4] A flowchart illustrating a manufacturing process for a laminated structure according to one embodiment of this disclosure. [Figure 5] A cross-sectional view illustrating a laminated structure after flow channel formation but before packing layer formation. [Modes for carrying out the invention]

[0011] 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.

[0012] The laminated structure 10 comprises 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, 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 on-site by filling the space with urethane and allowing the urethane to foam and harden within 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 3 The foamed polyurethane weighs about 1 / 80th the weight of concrete. The filling layer 11 may be formed by stacking factory-molded polystyrene foam blocks (e.g., 1.0m x 0.5m x 2.0m) without gaps in the space (EPS method). Lightweight concrete may be made lighter by mixing air bubbles into the concrete (FCB method). Lightweight soil may be made lighter by mixing foamed beads into the soil (foamed bead mixed soil method).

[0013] The laminated structure 10 further comprises a covering layer 12 laminated on the filling layer 11. The covering 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 has a thickness of, for example, 150 mm if its purpose is to distribute the weight of vehicles on the pavement.

[0014] 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 of crushed stone. The pavement 16 may be formed of asphalt. The pavement 16 is permeable to surface water. Surface water that seeps through 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.

[0015] The packed layer 11 includes a flow passage 20 for circulating the liquid on the coating layer 12.

[0016] 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.

[0017] 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 the coating layer 12 and the filling layer 11.

[0018] Thus, the flow passage 20 discharges the liquid on the coating layer 12 to the outside. If the liquid is not discharged, the liquid will stay on the coating layer 12 for a long time. The retention of the liquid on the coating layer may have an adverse effect on the paving on the coating layer. Specifically, the liquid may saturate in the roadbed 14, causing a decrease in the strength of the roadbed 14, and as a result, cracks in the paving 16 may occur. Also, when the coating layer 12 has cracks undesirably, the liquid on the coating layer 12 penetrates the coating layer 12 and reaches the filling layer 11. When the filling layer 11 contains a liquid-impermeable (water-impermeable) material such as foamed urethane, for example, the liquid that reaches the filling layer 11 stays between the coating layer 12 and the filling layer 11 for a long time. When the filling layer 11 contains a liquid-permeable (water-permeable) material such as lightweight earth and sand, the liquid that reaches the filling layer 11 may penetrate the filling layer 11, causing an increase in the weight and a decrease in the strength of the filling layer 11 (soil mass). The flow passage 20 prevents the occurrence of the above technical problems by discharging the liquid on the coating layer 12 to the outside.

[0019] The filling layer 11 may include a plurality of flow passages 20 arranged at appropriate intervals. The intervals between the plurality of flow passages 20 may be determined according to the amount of liquid flowing onto the coating layer 12.

[0020] The flow passage 20 may be a pipe made of resin, metal, ceramics, or other appropriate materials. The flow passage 20 may also be a pipe coated with a buffer material. The buffer material, for example, alleviates damage to the pipe due to the pressure during compaction work. The buffer material is, for example, urethane or other resins. The flow passage 20 may be a pipe coated with a waterproof material. The waterproof material, for example, prevents water leakage due to damage undesirably formed in the pipe. The waterproof material is, for example, urethane or other resins. The flow passage 20 may be a pipe coated with a heat-insulating material. The heat-insulating material, for example, protects the pipe from heat generated by urethane foaming in the R-PUR method. The heat-insulating material is, for example, urethane or other resins.

[0021] Instead of a pipe, the flow passage 20 may be a hole formed in the filling layer 11.

[0022] The flow passage 20 may include reinforcing materials of a fixed or irregular shape. The reinforcing materials prevent the flow passage 20 from collapsing due to the pressure exerted on it by the filling layer 11. The reinforcing materials may be, for example, crushed stone or recycled roof tiles.

[0023] The packed bed 11 may include, in addition to the flow passage 20, pipes for electricity, gas, sewage, or water.

[0024] 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 bed 11. The intermediate section 23 is connected between the first end 21 and the second end 22 and is located within the packed bed 11. In other words, 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.

[0025] 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.

[0026] 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.

[0027] 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 an 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. The split pipe 52 may also be positioned on the upper surface of the coating layer 12.

[0028] 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.

[0029] Figure 4 shows an example of the manufacturing process for a laminated structure. Here, we illustrate the process for manufacturing a laminated structure 10 using the R-PUR method. The workers in each of the following steps may be the same or different.

[0030] 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 wall 32 and the slope 33, by forming the side wall 32 on the ground 31.

[0031] Next, the worker forms a flow passage 20 so as to penetrate the packed layer forming 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.

[0032] The worker forms a filling layer 11 within the filling layer forming space 60 by filling the space 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 top surface of the hardened urethane. Before filling the urethane, the worker may take measures to prevent urethane from flowing into the flow passage 20. For example, the first end 21 of the flow passage 20 may be closed with a lid.

[0033] The worker forms a covering 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 covering layer 12.

[0034] The worker forms a surface layer 13 on the covering layer 12 (step S5). For example, the worker forms a subgrade 14 by placing crushed stone on the covering layer 12. Next, the worker forms a base course 15 by placing crushed stone on the subgrade 14. Subsequently, the worker forms a pavement 16 by placing asphalt on the base course 15.

[0035] In the process shown in Figure 4, the filling layer 11 is formed after the flow passage 20 is formed. Conversely, the flow passage 20 may be formed after the filling layer 11 is formed. For example, the worker pours urethane into the filling layer forming space 60 to form the filling layer 11 within the filling layer forming space 60. Next, the worker forms the flow passage 20 by creating holes in the filling layer 11.

[0036] 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 combined as needed. [Explanation of Symbols]

[0037] 10 Laminated Structure 11 Filled bed 12 Covering layer 13 Surface layer 14 Roadbed 15. Roadbed 16. Pavement 20,40,50 Distribution path 21 First end 22 Second end 23 Middle section 31 Ground 32 Side wall 33 Slope 34 External space 60 Filled bed formation space

Claims

1. 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).

2. A non-permeable packing 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).

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