JP2003056290A - Laminate and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate which is a member suitable for constituting a part that is provided in a portion of a tunnel wall such as a segment wall body and can be excavated and which enables completion of excavation by a shield machine in a short time and moreover lessens a burden on the shield machine. SOLUTION: A plurality of sheet-like composite materials 1a prepared by reinforcing a plastic foam with inorganic fibers are laminated in a state of being curved at a prescribed curvature, while an adhesive layer 1b (or FRP layer) is interlaid between the materials 1a so as to adhere them to each other.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminate used for forming a part of a wall of a tunnel in a shield construction method for constructing a tunnel using a shield machine, for example, and a manufacturing method thereof.

[0002]

2. Description of the Related Art At present, when constructing a tunnel for roads or railways or a tunnel for constructing a sewer pipe, a shield method is generally adopted. The shield method is a method of excavating a tunnel hole while propelling a shield machine equipped with an excavating blade at the tip in the ground.

In the shield construction method, while excavating the ground by the shield machine, the tunnel wall is constructed by sequentially assembling the segments behind the shield machine along the inner wall surface around the excavation portion. The segment has a size, for example, that divides the circumference in the tunnel into a plurality of parts (for example, 6 parts), and is sequentially added in the circumferential direction and the shield tunnel extension direction. Examples of the segment include a reinforced concrete segment, a steel segment made only of a steel plate, and a steel shell segment in which concrete is filled in the steel shell.

In the shield construction method, a shield machine is assembled on a road and excavated downward to construct a vertical tunnel. When the vertical tunnel reaches a predetermined depth, the shield machine is turned to the horizontal direction. Excavate the tunnel. Further, a vertical / horizontal continuous shield method has also been adopted in which the shield is turned to excavate a vertical tunnel or a horizontal tunnel when the position reaches a position advanced by a predetermined distance from the start position of the horizontal tunnel.

By the way, in the shield construction method, when a vertical tunnel or a horizontal tunnel is constructed and then excavation in a direction different from the tunnel (for example, a lateral direction or a longitudinal direction) is started, first, the tunnel constructed earlier is constructed. It is necessary to excavate the wall body (segment wall body) of. However, if the segment is made of steel, excavation of the wall cannot be done with a shield machine. Also, when using a shield machine to excavate walls when using reinforced concrete segments, the reinforcing bar will be entangled with the shield machine's cutting blade, significantly reducing the excavation speed, and in the worst case, the shield machine may fail. There is. For this reason, in the past, the work of breaking the tunnel wall body (fusing, chipping, etc.) has been performed manually, but the work performed manually requires a lot of work and a considerably long construction period.

As a method of eliminating such a point, a method of providing a part which can be excavated by a shield machine in a part (excavation start part) of the segment wall body is considered.
When adopting this method, the excavable part of the segment is
New material concrete using rope-shaped (rebar-shaped) reinforcing bar (new material) obtained by impregnating resin with carbon fiber or glass fiber (disclosed in, for example, JP-A-5-302490 and JP-2709245). It may be configured with.

[0007]

By the way, when a part of the segment wall body is made of the above-mentioned new material concrete, it is possible to excavate by the shield machine, but concrete has a large excavation resistance, so that it takes much time to excavate. Requires. Further, during the excavation process, the rope-shaped reinforcing bar cut may be clogged with the screw (for excavation removal) of the shield machine, and the shield machine may stop or malfunction.

The present invention has been made to solve such a problem, and is a member suitable for constituting an excavable portion provided in a part of a tunnel wall such as a segment wall body,
An object of the present invention is to provide a laminate capable of completing excavation by a shield machine in a short time and lessening the burden on the shield machine, and a method for producing a laminate suitable for producing such a laminate. And

[0009]

The laminated body of the present invention is a laminated body used for forming a part of a wall body such as a tunnel wall, and is a plate-like body in which a plastic foam is reinforced with inorganic fibers. A plurality of composite materials are laminated in a curved state with a predetermined curvature (for example, a curvature that matches the shield segment), and an adhesive layer or FRP layer is laminated between the plate-shaped composite materials. Characterized by

The laminated body of the present invention is applied to construct a shield tunnel wall body having an outer diameter of, for example, about φ1800 mm to φ4200 mm.

In the laminate of the present invention, the material of the adhesive layer laminated between the plate-shaped composite materials may be an epoxy resin adhesive, a urethane resin adhesive or an acrylic resin adhesive. .

As the FRP layer, a resin such as polyester resin or epoxy resin reinforced with a reinforcing material such as mat or cloth can be used. Examples of the mat or cloth include those obtained by processing glass fiber, carbon fiber or aramid fiber.
When a mat is used as the reinforcing material, for example, a method of stacking the FRP layers by using two mats of the mesh 370 may be adopted.

As a more specific example of the laminate of the present invention,
An outer layer made of a plurality of plate-shaped composite materials, and an inner layer made of a plurality of plate-shaped composite materials, between the outer layer and the inner layer, an intermediate layer made of foam or an intermediate layer of honeycomb structure. A structure having a sandwiched between can be mentioned.

The plate-shaped composite material forming the laminate of the present invention is preferably a composite material in which a plastic foam (urethane foam) made of a hard urethane resin is reinforced with long glass fibers.

According to the laminated body of the present invention, since it is composed of the composite material in which the plastic foam is reinforced with the inorganic fiber, for example, when it is used for the excavable portion of the shield segment, compared with the case where concrete is used. As a result, the excavation speed is increased and the excavation process can be shortened.

Here, in the laminated body of the present invention, for example, in the composite material as shown in FIG. 5, that is, in the urethane foam, the long glass fibers are unidirectionally in a monofilament state, that is, the long glass fibers are unidirectionally one by one. Since the composite material filled in the dispersed state is used, even when excavated by the shield machine, the problem that the cut glass long fibers are clogged with the screw or the like does not occur.

Further, since the plate-shaped composite material in which such urethane foam is reinforced with long glass fibers is excellent in bending strength and compressive strength, the earth pressure acting on the shield tunnel is obtained by forming a laminated body.・ Can withstand water pressure sufficiently. Moreover, urethane foam is relatively inexpensive,
Since long glass fiber is also inexpensive, the excavable portion can be manufactured at a lower cost than the new material concrete described above. Further, since the urethane foam is lighter than concrete, it is possible to reduce the weight of the shield segment.

The laminated body of the present invention can be applied not only to the shield segment but also to various wall bodies for constructing a circular cavity such as a circular shaft or a circular pipe.

The manufacturing method of the present invention is a method for manufacturing a laminate having the above-mentioned characteristics, wherein the plate-shaped composite material is controlled in the center of the plate-shaped composite material at both ends thereof with the restriction members. It is characterized by including the step of bending the plate-shaped composite material by pressing the portion.

According to the manufacturing method of the present invention, the plate-shaped composite material is bent by pressing the central portion of the plate-shaped composite material in a state where both ends of the plate-shaped composite material are regulated. Bending with uniform curvature can be performed. Also, without using a mold or the like that strictly defines the bending curvature of the entire composite material,
The plate-shaped composite material can be processed by a simple bending device.

[0021]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings.

First, a shield segment to which the laminated body of the present invention is applied will be described.

The segment constitutes a wall of a tunnel constructed by a shield construction method using a shield machine. For example, as shown in FIG.
The segment ring 210 can be configured by assembling 1 ... 211 in a ring shape.

When constructing the wall body of the shield tunnel 200 using such a segment 211, first, a shield machine (not shown) having an excavating blade at its tip is horizontally (or vertically) placed in the ground. Propulsion, and when the space for one ring of the segment ring 210 is formed behind this shield machine, the propulsion of the shield machine is stopped,
The segments 211 are assembled in a ring shape along the inner wall surface of the rear space of the shield machine. Next, in the same manner, install the shield machine on the segment ring 210 1
By sequentially repeating the process of propelling only the ring and assembling the segments 211 ... 211 in a ring shape, for example, a lateral shield tunnel 200 as shown in FIG. 6 can be constructed.

The segment to which the laminate of the present invention is applied is
It is a special segment 201 used when constructing an upward vertical tunnel 220 in a horizontal shield tunnel 200 as shown in FIG. This special segment 201 is a member that constitutes a part of the segment ring 210 described above (FIG. 7), and as shown in FIGS. 8 to 10, two segment bodies 202 and 202 and a shield machine can be used for excavation. The excavable part (the laminated body 1 of the present embodiment) is provided.

Next, an embodiment of the laminated body of the present invention will be described with reference to FIG.

First, the laminated body 1 of this embodiment is formed by laminating a plurality of (for example, 10) plate-shaped composite materials 1a .. These plate-shaped composite materials 1
.. 1a are adhered to each other by an adhesive layer 1b (for example, an epoxy adhesive) laminated between the layers.

The laminated body 1 is processed to have a diameter larger by a predetermined amount than the excavation diameter of the shield machine. Further, the curvature (radius of curvature) of the outer peripheral surface and the inner peripheral surface of the laminated body 1 approximately match the curvature (curvature radius) of the outer peripheral surface and the inner peripheral surface of the segment main body 202, respectively.

The plate-shaped composite material 1a constituting the laminated body 1 is
As shown in FIG. 5, it is a composite material in which urethane resin foam (hard urethane resin) is reinforced with long glass fibers. Examples of such a composite material 1a include Eslon Neo-Lumber FFU (manufactured by Sekisui Chemical Co., Ltd.). The thickness (plate thickness) of the composite material 1a as shown in FIG. 5 is about 10 mm at the maximum.

In the embodiment of FIG. 1, the adhesive layer 1b is laminated between the plate-shaped composite materials 1a, 1a, but instead of this, the FRP layer is laminated between the plate-shaped composite materials 1a. Then, the plate-shaped composite materials 1a may be bonded to each other. When the FRP layers are laminated in this manner, the plate-shaped composite materials 1a can be firmly adhered to each other and the overall strength of the laminated body 1 can be increased.

FIG. 2 is a partial vertical cross-sectional view of another embodiment of the laminated body of the present invention.

The laminate 11 of FIG. 2 has an outer layer 12 and an inner layer 14.
And an intermediate layer 1 between these outer layer 12 and inner layer 14.
The feature is that 3 is laminated. As in the embodiment of FIG. 1, the outer layer 12 and the inner layer 14 are formed by laminating a plurality of curved plate-shaped composite materials 1a (5 sheets) and an adhesive agent between the respective plate-shaped composite materials 1a. It has a structure in which the layers 1b are laminated.

The intermediate layer 13 is, for example, a simple foam of a resin such as PE-PS, acrylic, PVC or urethane, and the inner surface of the plate-shaped composite material 1a constituting the innermost layer of the outer layer 12,
The outer surface of the plate-shaped composite material 1a forming the outermost layer of the inner layer 14 is adhered to each other via an epoxy adhesive.

If the sandwich structure as shown in FIG. 2 is adopted, it is possible to increase the plate thickness of the entire laminated body 11 while suppressing an increase in the total weight of the laminated body 11.

In the structure shown in FIG. 2, the intermediate layer 13 made of a simple foam may be replaced with a resin intermediate layer 23 having a honeycomb structure as shown in FIG.

Next, a method of manufacturing the laminated body 1 of FIG. 1 will be described with reference to FIG.

First, as shown in FIG. 4 (A), the laminated body manufacturing apparatus is arranged between the regulating members 101, 101 for regulating both ends of the plate-shaped composite material 1a, and the regulating members 101, 101. And a pressing member 103 that presses the central portion of the plate-shaped composite material 1a. The molding surface 102a of the receiving mold 102 is a curved surface (arc surface) that substantially matches the curvature (curvature radius) of the outer peripheral surface of the segment body 202.

The concrete manufacturing procedure is as follows.
In the state of being positioned with respect to 01, as shown in FIG. 4A, the central portion of the plate-shaped composite material 1a is pressed by the pressing member 103 to be curved in an arc shape. At this time, the deformation of the plate-shaped composite material 1a is restricted by the molding surface 102a of the receiving mold 102, and the curvature (curvature radius) of the outermost plate-shaped composite material 1a is the curvature (curvature) of the outer peripheral surface of the segment body 202. Radius).

Next, an epoxy adhesive is laminated on the inner surface of the outermost plate-shaped composite material 1a to form an adhesive layer 1b (FIG. 4 (B)). The laminated thickness of the adhesive layer 1b is, eg, about 1-2 mm.

After the lamination of the adhesive layer 1b is completed, FIG.
As shown in (C), the plate-shaped composite material 1a serving as the second layer (second layer counted from the outside of the laminate 1) was heated on the inner surface of the outermost plate-shaped composite material 1a. They are arranged in a state, and in this state, the central portion of the plate-shaped composite material 1a of the second layer is pressed and curved. At this time, a pressing force is applied so that the outermost plate-shaped composite material 1a and the second-layer plate-shaped composite material 1a are adhered to each other by the adhesive layer 1b.

Next, when the adhesive layer 1b is almost cured (when the second layer of plate-shaped composite material 1a can maintain a curved state), the second layer of plate-shaped composite material 1a is formed. An epoxy adhesive is laminated on the inner surface of the to form the adhesive layer 1b (FIG. 4 (D)). After that, the same procedure, that is, “bending process of plate-shaped composite material” → “adhesive lamination” → “bending process of plate-shaped composite material” is sequentially repeated to obtain FIG.
The laminated body 1 having the structure shown in can be obtained.

Next, examples of use of the laminated body of FIG. 1 will be described with reference to FIGS.
A description will be given with reference to 0.

First, the segment main body 202 of the special segment 201 to which the laminated body 1 of FIG. 1 is attached is made of only a steel plate. A semi-circular cutout 202a is formed in the segment main body 202, and a circular hole 201a is formed at the center position of the two segment main bodies 202, 202 in a connected state.
The inner diameter of the circular hole 201a is processed to be smaller than the outer diameter of the laminated body 1 by a predetermined amount.

FIG. 11 shows a structure in which the laminated body 1 is connected to the segment body 202 in the special segment 201 described above.

In this connection structure, connection plates (steel plates) 2 and 2 are sandwiched between the end portions of the laminate 1. The inner and outer two connecting plates 2 and 2 are bolts.
It is fixed to the laminated body 1 with a nut 3. A through hole 2a is formed at the tip of each connecting plate 2 for allowing the connecting bolt 5a to pass therethrough. Inner and outer connecting plates 2,
Of the two, a back nut 5b is fixed to the through hole 2a of the outer connecting plate 2 by welding or the like. The connecting plates 2 are arranged at a predetermined pitch along the peripheral edge of the end of the laminate 1.

On the other hand, the notch 20 of the segment body 202
In the vicinity of 2a, two fixed plates 4 and 4 are attached to the laminated body 1
Are provided in a positional relationship corresponding to the connecting plates 2 and 2 of the laminated body 1, and the connecting plate 2 of the laminated body 1 is attached to each fixed plate 4 in a state where the peripheral portion of the laminated body 1 is aligned with the peripheral portion of the cutout 202a. It comes to abut. Each fixing plate 4 is formed with a through hole 4a through which the connecting bolt 5a is inserted. Each fixing plate 4 is firmly fixed to the segment body 202 by welding.

In the connection structure shown in FIG. 11, the connection plate 2 of the laminated body 1 is aligned with the fixed plate 4 of the segment body 202, and the two fixed plates 4,
With the spacer (steel) 6 sandwiched between 4 and 4, the connecting bolt 5a is passed through the through holes 2a, 4a of the plates 4 and 4 and the through hole 6a of the spacer 6, and the bolt tip is screwed into the back nut 5b. Thus, the laminated body 1 and the segment body 202 can be connected to each other.

In the connection structure of FIG. 11, the inner and outer two connecting plates 2 and 2 and the two fixing plates 4 and 4 are provided, but the number of these connecting plates 2 and fixing plates 4 ( The number in the stacking direction of the stacked body 1)) is not particularly limited and may be appropriately selected in consideration of the earth pressure, water pressure, etc. acting on the special segment 201.

In the above embodiment, the segment main body 202 uses the segment ring 210 in the same manner as described in FIG. 6 when constructing the shield tunnel.
Can be assembled as a member forming a part of the.

For the installation of the laminated body 1, for example, one of the two segment main bodies 202, 202 incorporating the laminated body 1 is installed in the space behind the shield machine in the above-described manner, and then the shield machine is used to make the segment. When the ring 210 is propelled by one ring, the laminated body 1 is connected to the segment main body 202 installed earlier, and then the other segment main body 202 is installed in the rear space of the shield machine and This can be performed by connecting the segment body 202 and the laminated body 1.
In addition, you may employ | adopt the method of conveying to the back of a shield machine in the state which the laminated body 1 was integrated in both or either of the two segment main bodies 202.

In the above embodiments, the shape of the laminated body 1 is circular, but the shape is not particularly limited, and may be a rectangular laminated body 21 as shown in FIG. 12, for example.

In the above embodiment, an example in which the laminated body of the present invention is applied to the shield segment (tunnel wall) is shown, but the present invention is not limited to this, and for example, a circular shaft or a circular pipe culvert. It can also be applied to various wall bodies that form a circular cavity.

[0053]

As described above, the laminate of the present invention has a structure in which a plurality of plate-like composite materials obtained by reinforcing plastic foam with inorganic fibers are laminated, and therefore, for example, a shield is used. When used in the excavable part of a segment,
It becomes possible to increase the excavation speed by the shield machine. By the way, when a plastic foam made of a hard urethane resin is used, the excavation speed is about 10 times faster than that of concrete, and the excavation process can be significantly shortened.

Since the plastic foam made of hard urethane resin is lighter than concrete,
There is also an advantage that the weight saving of the segment can be achieved.

According to the manufacturing method of the present invention, the plate-shaped composite material forming the laminate having the above-mentioned characteristics can be curved in a state where the curvature of bending is uniform, so that the laminate excellent in shape and dimension can be obtained. You can get the body.

[Brief description of drawings]

FIG. 1 is a partial vertical cross-sectional view of an embodiment of a laminated body of the present invention.

FIG. 2 is a partial vertical cross-sectional view of another embodiment of the laminated body of the present invention.

FIG. 3 is a perspective view schematically showing an example of an intermediate layer constituting the laminated body of FIG.

FIG. 4 is an explanatory view of a method for manufacturing the laminated body of FIG.

FIG. 5 is a diagram schematically showing a cross-sectional structure of a composite material forming the laminate of the present invention.

FIG. 6 is a perspective view schematically showing an example of a shield tunnel in which a wall body is constituted by segments.

7 is a side view showing a configuration of a shield ring used in the shield tunnel of FIG.

8 is a view on arrow X in FIG. 7. FIG.

9 is a perspective view schematically showing the structure of a special segment used in the shield tunnel of FIG.

FIG. 10 is an exploded perspective view schematically showing the structure of the special segment.

FIG. 11 is a cross-sectional view showing an example of a connecting structure between the laminated body of FIG. 1 and a segment body.

FIG. 12 is a perspective view showing another embodiment of the laminated body of the present invention in a use state.

[Explanation of symbols]

1 stack 1a Plate-shaped composite material 1b adhesive layer 11 laminate 12 outer layer 13 Middle class 14 Inner layer 101 Control member 102 receiving type 103 pressing member 201 segment 202 segment body 210 segment ring 211 segments 210 Shield tunnel (sideways) 220 vertical tunnel

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Hirohide Nakagawa             2-2 Kamitobagamichocho, Minami-ku, Kyoto             Gaku Kogyo Co., Ltd. F-term (reference) 2D055 BA01 BB01 BB10 EB10 KB12                       KB13

Claims (4)

[Claims] 1. A laminate used for forming a part of a wall body such as a tunnel wall, in which a plate-shaped composite material in which a plastic foam is reinforced with inorganic fibers is curved to a predetermined curvature. The laminated body is characterized in that a plurality of sheets are laminated and the adhesive layer or the FRP layer is laminated between the respective plate-shaped composite materials. 2. An outer layer composed of a plurality of plate-shaped composite materials,
2. An inner layer made of a plurality of plate-shaped composite materials, and an intermediate layer made of foam or an intermediate layer having a honeycomb structure is provided between the outer layer and the inner layer. The laminate described. 3. The laminated body according to claim 1, wherein the plate-shaped composite material is a composite material in which a plastic foam made of a hard urethane resin is reinforced with long glass fibers. 4. The method for manufacturing a laminated body according to claim 1, wherein both ends of the plate-shaped composite material are regulated by regulation members, and the center of the plate-shaped composite material is controlled. A method for manufacturing a laminate, comprising a step of bending a plate-shaped composite material by pressing a portion.