Rubber mat for caissons and method for manufacturing the same

Abstract

To provide a caisson rubber mat which can secure a connection strength and prevent corrosion by regulating an embedded position and an embedded posture of a female screw member, and a method for manufacturing the same .SOLUTION: A caisson rubber mat 1 fixed to a bottom face portion b of a steel caisson A comprises: a female screw member 10 having a female screw portion 11 embedded in an intermediate portion in a thickness t direction of the rubber mat 1 and connected to the steel caisson A; and a resistance member 20 attached to the female screw member 10 and embedded to increase an area in a pull-out direction. The female screw member 10 and the resistance member 20 are embedded in the intermediate portion in the thickness t direction of the rubber mat 1 so as to regulate an embedded position and an embedded posture by means of a male screw member screwed into the female screw member 10 and temporarily fixing the female screw member 10 and the resistance member 20 in the rubber mat 1.SELECTED DRAWING: Figure 5

Description

Technical Field

[0006] , , , , , ,

[0001] The present invention relates to a rubber mat for caissons and a method for manufacturing the same.

Background Art

[0002] One method of constructing a dike body such as a breakwater, a quay wall, or a revetment is to use a caisson. The caisson is installed on a rubble mound provided on the ground such as the seabed, and a rubber mat is interposed to increase the frictional force between the caisson and the rubble mound and improve stability.

[0003] The rubber mat is attached during the manufacture of the caisson, and it is necessary to ensure the attachment strength between the rubber mat and the caisson. For this reason, in a concrete caisson, a large number of anchors are attached to the rubber mat and embedded and fixed in the cast concrete. In a steel caisson, the rubber mat and the steel shell are connected with bolts or the like.

[0004] As such a rubber mat for caissons, for example, there is one disclosed in Patent Document 1. A through hole is formed in the rubber mat, and a counterbore portion is formed on the bottom side of the through hole. A bolt is inserted from the counterbore portion so as to protrude from the upper surface of the rubber mat, and a nut is tightened on the bolt penetrating the bottom surface portion of the steel shell to attach the rubber mat.

[0005] In addition, in order to enable construction from the surface side of the rubber mat, a socket nut is previously embedded and fixed at the attachment position of the rubber mat with an adhesive or the like, and a bolt is screwed into the socket nut embedded in the surface of the rubber mat from the steel shell side to attach it to the bottom surface portion of the steel shell.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

[0007] However, when inserting bolts through the counterbore on the underside of the rubber mat, the bolt heads are exposed in the counterbore, which could lead to damage from direct contact with the protruding stones of the rubble mound, or damage to the tightened steel shell due to the bolt being pushed upwards. Furthermore, the bolt being pushed upwards could cause it to break, leading to a chain reaction of corrosion down to the steel shell. Furthermore, when connecting to a steel shell by screwing bolts into cap nuts that have been pre-embedded and fixed to the surface of the rubber mat, there is a risk of insufficient embedding strength of the cap nuts, difficulty in maintaining a vertical embedded position for fixing the cap nuts, and other problems such as not being able to tighten the bolts vertically to the steel shell.

[0008] This invention has been made in view of the problems of the prior art, and aims to provide a rubber mat for caissons and a method for manufacturing the same, which can ensure connection strength and prevent corrosion by regulating the embedded position and embedded orientation of the female screw member. [Means for solving the problem]

[0009] To solve the above problems, the rubber mat for caissons according to the first aspect of the present invention is: A rubber mat for caissons that is fixed to the bottom surface of the caisson, A female screw member having a female screw portion embedded in the middle of the thickness direction of the rubber mat and connected to the caisson, The female threaded member is attached to and embedded in the female threaded member, and includes a resistance member that increases the area in the pulling direction, The resistive member is fixed to the upper and lower intermediate portion of the female screw member. It is being done, It is characterized by the following:

[0013] This invention 2 The method for manufacturing rubber mats for caissons from this perspective is: When manufacturing rubber mats for caissons, A first step involves fixing a resistance member to increase pull-out resistance to one end or middle of the upper or lower part of a female screw member embedded in the rubber mat, A second step involves assembling the assembly by screwing a temporary fastening male screw member into the female screw member, A third step involves placing the assembly assembled in the second step into the rubber mat material inside the mold with the male screw member facing upwards, and temporarily fixing the assembly by pressing down on the upper surface of the male screw member to restrict its embedding position and orientation in the rubber mat material inside the mold. The fourth step involves press-vulcanizing the rubber mat material inside the mold to embed and fix the female screw member and the resistance member, and then removing the male screw member used for temporary fastening. It is characterized by the following: The aforementioned male threaded member is preferably a countersunk bolt. [Effects of the Invention]

[0014] The present invention provides a rubber mat for caissons and a method for manufacturing the same that can ensure connection strength and prevent corrosion by regulating the buried position and buried orientation of the female screw member. [Brief explanation of the drawing]

[0015] [Figure 1] The present invention relates to a female thread member and a resistance member according to one embodiment, where (a) is a plan view and (b) is a front view. [Figure 2] The present invention relates to a male screw member according to one embodiment, where (a) is a plan view and (b) is a front view. [Figure 3] The present invention relates to one embodiment of a method for manufacturing a rubber mat for caissons, wherein (a) is an explanatory diagram of the first step, (b) is an explanatory diagram of the second step, (c) is an explanatory diagram of the third step, and (d) is an explanatory diagram of the fourth step. [Figure 4] The present invention relates to a rubber mat for a caisson according to one embodiment, where (a) is a front view and (b) is a side view. [Figure 5]This is an enlarged cross-sectional view showing a portion of the steel caisson attached to one embodiment of the present invention. [Modes for carrying out the invention]

[0016] Hereinafter, one embodiment of the rubber mat for caissons and its manufacturing method according to the present invention will be described in detail with reference to the drawings. The rubber mat 1 for caissons is attached to the bottom surface b of the steel shell a of a steel caisson A by connecting and fixing it with bolts c, for example, as shown in a magnified view of a portion of Figure 5. The caissons to which it can be attached are not limited to steel caissons A, but may also be concrete caissons, hybrid caissons, flap gates, etc. However, as will be described later, it is particularly suitable for steel caissons A by regulating the buried position and buried orientation of the female threaded member 10 that is connected and fixed with bolts c, and the following explanation will use steel caissons A as an example.

[0017] The caisson rubber mat 1 is a caisson rubber mat (hereinafter simply referred to as "rubber mat") 1 fixed to the bottom surface b of a steel caisson (caisson) A, and comprises a female screw member 10 having a female screw portion 11 embedded in the middle of the thickness t direction of the rubber mat 1 and connected to the steel caisson A, and a resistance member 20 attached to and embedded in the female screw member 10, which increases the area in the pull-out direction (see Figures 5 and 3(d)). The female screw member 10 and the resistance member 20 are embedded in the rubber mat 1 with their embedding position and embedding orientation restricted by a male screw member 30 that is screwed into the female screw member 10 and temporarily fastens the female screw member 10 and the resistance member 20 within the rubber mat 1 (see Figures 2 and 3(c)). The embedded position of the female thread member 10 and the resistance member 20 here is, as shown in Figure 5, in a direction perpendicular to the front and back surfaces of the rubber mat 1 (a vertical direction along the thickness t direction), and is such that the rubber mat 1 can be in close contact with the bottom surface b of the steel caisson A and the steel shell a and rubber mat 1 can be fixed together with vertical bolts c and the female thread member 10. In other words, the center line of the thread of the female thread portion 11 is perpendicular (usually vertical) to the rubber mat 1. The embedded position is in the middle of the thickness t direction of the rubber mat 1.

[0018] As shown in FIG. 1, for example, the female screw member 10 is formed in a hollow hexagonal shape (nut shape), and a female screw portion 11 is formed in the hollow portion. The height H of the female screw portion 11 is set to a height that can ensure the strength required for tightening with the steel shell a (see FIG. 5). Note that the female screw member 10 may not be limited to a hollow hexagonal shape and may be a cylindrical shape, or may be a hollow body with another cross-sectional shape, but the height H of the female screw portion 11 should be set to ensure the strength required for tightening.

[0019] As shown in FIG. 1, the resistance member 20 is formed in a disc shape that is larger than the area of the female screw member 10 in a plan view (see FIG. 1(a)), and is formed so that the area in the pulling direction (the thickness t direction of the rubber mat 1 (see FIGS. 3 and 5)) becomes larger when embedded in the rubber mat 1. The area of the resistance member 20 in a plan view becomes the shear surface area that generates the pulling resistance in the pulling direction when embedded in the rubber mat 1, and the mounting strength (pulling strength) of the rubber mat 1 is determined by this shear surface area. A through hole 21 that can penetrate the female screw member 10 is formed in the center of the resistance member 20 in order to position the female screw member 10 at the middle portion in the height H direction. The through hole 21 formed in the resistance member 20 may have any shape that can penetrate the female screw member 10, such as a hexagonal shape or a circular shape.

[0020] As shown in FIG. 1(b), for example, the resistance member 20 is attached and integrally fixed by welding or the like to the middle portion in the height H direction of the female screw member 10. This process is the first process in the manufacture of the rubber mat 1 (see FIG. 3(a)). Furthermore, the resistance member 20 is not limited to the middle of the female thread member 10 in the height H direction, but may also be attached to the upper or lower end by welding or other means and fixed integrally. When the resistance member 20 is attached to the lower end, it is not necessary to pass the bolt c through, and it may not have a through hole 21 in the center. In addition, the resistance member 20 may be of any shape other than circular as long as a shear surface area (projected area on a plane) is secured, and may be of a shape such as a cross shape made by combining plate materials. The material may be metal or synthetic resin, and the connection with the female thread member 10 may be not limited to welding, but may be adhesive or mechanical connection and fixing.

[0021] By using these two components, the female thread member 10 and the resistance member 20, as shown in Figure 5, it is possible to secure the height H of the female thread portion 11 necessary for tightening the rubber mat 1 with bolt c, and to secure the shear surface area provided by the resistance member 20, while also achieving weight reduction compared to a rubber mat 1 with an inner layer of steel plate covering the entire surface. In other words, if the resistance member 20 is composed of only the resistance member 20, the plate thickness must be such that the height H of the female thread portion 11 is necessary to secure the tightening strength, which leads to an increase in weight. On the other hand, if the resistance member 20 is thin, it is not possible to secure the height H of the female thread portion 11, resulting in insufficient tightening strength.

[0022] The rubber mat 1 is assembled by integrally assembling the female threaded member 10 and the resistance member 20 (see Figure 3(a)), and then embedded in the rubber mat material before vulcanization, with its embedding position and embedding orientation restricted. For this reason, as shown in Figures 2 and 3(b), a male threaded member 30 is used. The male threaded member 30 is, for example, a countersunk bolt with a hexagonal socket.

[0023] The male threaded member 30 is used as a jig to position the embedded positions of the female threaded member 10 and the resistance member 20 midway along the thickness t direction of the rubber mat 1, and to ensure that the embedded position is perpendicular (vertical) to the center line of the female threaded portion 11 relative to the front and back surfaces of the rubber mat 1. The male threaded member 30 is screwed into the female threaded portion 11. This process is the second step in the manufacturing of the rubber mat 1 (see Figures 3(b) and (c)). By screwing into the male threaded member 30, the distance from the top surface of the male threaded member 30 is adjusted, the embedded position is set, and the intrusion of rubber into the female threaded portion 11 is prevented.

[0024] Furthermore, the female thread member 10 and the resistance member 20 assembled on the male thread member 30 are positioned in the rubber mat material within the molding die (not shown) of the rubber mat 1, and the upper surface of the male thread member 30 is horizontally pressed down with a flat pressing plate 40, thereby making the male thread member 30 perpendicular to the pressing plate 40 and restricting its embedded position to vertical. This process is the third step in the manufacturing of the rubber mat 1 (see Figure 3(c)).

[0025] The rubber mat 1, in which the female thread member 10 and the resistance member 20 are embedded with the male thread member 30 to restrict their embedded position and orientation, is then press-vulcanized in the molding die, and the male thread member 30 is removed to complete the rubber mat 1. This process is the fourth step in the manufacturing of the rubber mat 1 (see Figure 3(d)).

[0026] The male threaded member 30 is a countersunk bolt with a hexagonal socket, so that even when embedded in the rubber mat 1, it does not require a tool to be applied to the outside like a nut, and can be removed from the female threaded portion 11 via the hexagonal socket. Furthermore, by removing the countersunk bolt (male threaded member 30), a conical guide recess 2 is formed from the upper end surface of the female threaded member 10 to the surface of the rubber mat 1, with the diameter increasing towards the surface (see Figure 3(d)). This conical guide recess 2 guides the bolt c that secures the steel shell a into the female threaded portion 11 of the female threaded member 10, making the tightening work with the bolt c easier (see Figure 5). Furthermore, the male threaded member 30 is not limited to a countersunk bolt; it may be a bolt of any other shape, as long as it can be screwed into the female threaded member 10 to prevent rubber from entering and can be removed after press vulcanization.

[0027] The rubber mat 1 is, for example, 1000mm x 2000mm x 30mm in size, and a molding die (not shown) corresponding to these dimensions is prepared. In the rubber mat material of the molding die, a resistance member 20, which is integrated with a female screw member 10, is screwed into a male screw member 30 and positioned in the middle of the thickness t direction. The embedding position is adjusted by a retaining plate 40, and eight of these are embedded at approximately equal intervals on the horizontal plane (see Figures 3(c) and 4). The rubber mat material inside the molding die is press-vulcanized to embed and fix the resistance member 20, which is integrated with the female screw member 10, and remove the male screw member 30 (see Figure 3(d)). The rubber mat material is made from powdered rubber compounded for rubber mats, similar to the conventional rubber mat 1. For example, it may be made by crushing used rubber products such as tires and mixing them with a crosslinking agent, or by mixing this with new rubber powder before vulcanization.

[0028] The rubber mat 1 is laid, for example, on a yard, and the steel caisson A is constructed on the rubber mat 1. With the rubber mat 1 in contact with the bottom surface b of the steel shell a, the steel caisson A is attached by screwing bolts c into the female threaded member 10, sandwiching the steel shell a (see Figure 5). Note that rubber mat 1 should be installed during construction or before it is placed on the rubble mound.

[0029] With this type of rubber mat 1, the embedded position and orientation of the female threaded member 10 can be restricted, allowing the bolt c to be screwed perpendicularly into the female threaded member 10. The resistance member 20 increases the pull-out resistance, ensuring the connection strength between the rubber mat 1 and the steel caisson A. By embedding the female threaded member 10 and the resistance member 20 within the rubber mat 1 without exposing them, corrosion can be prevented (see Figure 5). Furthermore, since the female thread member 10 and the resistance member 20 are embedded within the rubber mat 1, there is no risk of them being directly hit and damaged by the protrusions of the rubble mound, nor is there any risk of the bolt c being pushed up, and there is no risk of damage to the steel shell a (see Figure 5).

[0030] When manufacturing the rubber mat 1, a male threaded member 30 is used, and the female threaded member 10 and resistance member 20, which are integrally assembled to the male threaded member 30, are screwed in to adjust their positions. After positioning them in the rubber mat material, the male threaded member 30 is pressed down with a retaining plate 40 and press-vulcanized. This allows the female threaded member 10 and resistance member 20 to be easily embedded in the rubber mat 1, controlling their embedding position and orientation, thus facilitating the manufacture of the rubber mat 1. As a result, the bolt c can be screwed perpendicularly into the female threaded member 10, the pull-out resistance force is increased by the resistance member 20, ensuring the connection strength between the rubber mat 1 and the steel caisson A, and corrosion can be prevented by embedding the female threaded member 10 and resistance member 20 in the rubber mat 1 without exposing them (see Figure 5).

[0031] As described in detail above along with the embodiments, the rubber mat 1 for caissons of the present invention is a rubber mat 1 for caissons that is fixed to the bottom surface b of a steel caisson A, and comprises a female screw member 10 having a female screw portion 11 that is embedded in the middle of the rubber mat 1 in the thickness direction t and connected to the steel caisson A, and a resistance member 20 that is attached to the female screw member 10 and embedded to increase the area in the pull-out direction, and the female screw member 10 and the resistance member 20 are embedded in the rubber mat 1 by a male screw member 30 that is screwed into the female screw member 10 and temporarily fastens the female screw member 10 and the resistance member 20 in the rubber mat 1, thereby restricting the embedding position and embedding orientation in the middle of the rubber mat 1 in the thickness direction t. With this configuration, the embedding position and orientation of the female threaded member 10 can be temporarily fixed and restricted by the male threaded member 30, allowing the bolts c for attaching the rubber mat 1 to the steel caisson A to be screwed perpendicularly into the female threaded member 10. The resistance member 20 increases the pull-out resistance, ensuring the connection strength between the rubber mat 1 and the steel caisson A. Furthermore, the female threaded member 10 and the resistance member 20 can be embedded in the rubber mat 1 without being exposed, thus preventing corrosion. Furthermore, since the female thread member 10 and the resistance member 20 are embedded within the rubber mat 1, there is no risk of damage from direct contact with the protrusions of the rubble mound, nor is there a risk of the bolt c being pushed up, and there is no risk of damage to the steel shell a.

[0032] The rubber mat 1 for the caisson has a resistance member 20 fixed to the upper and lower middle portion or one end of the female screw member 10. With this configuration, the pull-out resistance can be increased by the resistance member 20, and the weight can be reduced compared to a rubber mat 1 with an inner layer of steel plate covering the entire surface, while maintaining a sufficient shear surface area. Furthermore, the height H of the female thread portion 11 of the female thread member 10, which is integrated with the resistance member 20, can be set to the height H necessary to ensure tightening strength, regardless of the plate thickness of the resistance member 20. As a result, both pull-out resistance and tightening strength can be ensured with a thin resistance member 20 and a female thread member 10 with a sufficient height for the female thread portion 11.

[0033] The rubber mat 1 for the caisson is designed so that the resistance member 20 at the lower end of the female screw member 10 does not have a through hole 21 through which the male screw member 30 passes. With this configuration, the structure of the resistive member 20 can be simplified, and when assembling it with the female screw member 10, it is only necessary to place the female screw member 10 on the resistive member 20, making alignment and other processes easier. In addition, it is possible to prevent rubber material from entering the female screw portion 11 of the female screw member 10 from below.

[0034] The rubber mat 1 for the caisson has a male threaded member 30 which is a countersunk bolt, and a conical guide recess 2 is formed in the rubber mat 1. With this configuration, the female thread member 10 is temporarily fastened with the countersunk bolt, which is the male thread member 30, forming a conical guide recess 2 above the female thread portion 11. This guide recess 2 makes it easier to align and connect the bolts c when attaching the rubber mat 1 to a steel caisson A or the like.

[0035] The caisson rubber mat 1 and its manufacturing method include the following steps when manufacturing the caisson rubber mat 1: a first step of fixing a resistance member 20 to increase pull-out resistance to a female screw member 10 to be embedded in the rubber mat 1 at one end or in the middle of the upper or lower part; a second step of screwing a temporary fixing male screw member 30 into the female screw member 10 to assemble it; a third step of pressing the upper surface of the temporary fixing male screw member 30 assembled in the second step to restrict the embedding position and embedding orientation in the rubber material in the mold and temporarily fixing the female screw member 10 and the resistance member 20; and a fourth step of pressing vulcanize the rubber mat material in the mold to embed and fix the female screw member 10 and the resistance member 20, and then removing the temporary fixing male screw member 30. With this configuration, the connection strength can be ensured by regulating the buried position and orientation of the female thread member 10 and the resistance member 20 with the male thread member 30, and a rubber mat for caissons can be manufactured that prevents corrosion of the buried female thread member 10 and the resistance member 20.

[0036] The present invention is not limited to the embodiments described above, and each constituent element can be appropriately modified without altering the gist of the invention. [Explanation of symbols]

[0037] 1. Rubber mat for caissons (rubber mat) 2 Guide recess 10 Female threaded member 11 Female thread Department 20 Resistive component 21 Through hole 30 Male threaded member (Countersunk bolt) 40 Pressing plate A. Steel caisson (caisson) a steel shell b Bottom part c bolt Height of the female thread section t Thickness of the rubber mat

Claims

1. A rubber mat for caissons that is fixed to the bottom surface of the caisson, A female screw member having a female screw portion embedded in the middle of the thickness direction of the rubber mat and connected to the caisson, The female threaded member is attached to and embedded in the female threaded member, and includes a resistance member that increases the area in the pulling direction, The resistive member is fixed to the upper and lower intermediate portion of the female screw member. A rubber mat for caissons characterized by the following features.

2. When manufacturing rubber mats for caissons, A first step involves fixing a resistance member to increase pull-out resistance to one end or the middle of the female screw member embedded in the rubber mat, A second step involves assembling the assembly by screwing a temporary fastening male screw member into the female screw member, A third step involves placing the assembly assembled in the second step into the rubber mat material inside the mold with the male screw member facing upwards, and temporarily fixing the assembly by pressing down on the upper surface of the male screw member to restrict its embedding position and orientation in the rubber mat material inside the mold. The fourth step involves press-vulcanizing the rubber mat material inside the mold to embed and fix the female screw member and the resistance member, and then removing the male screw member used for temporary fastening. A method for manufacturing rubber mats for caissons, characterized by the following features.

3. The aforementioned male threaded member is a countersunk bolt. The method for manufacturing a rubber mat for caissons according to feature 2.

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